Polyolefin Gas Barrier Layered Body for Recyclable Packaging
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Solution Overview
Problem
Conventional polyolefin-based resin packaging materials face challenges in achieving favorable barrier properties and hot-water treatment resistance, making mono-material formation difficult for recyclability and recycling purposes.
Innovation Solution
A gas barrier layered body comprising a polyolefin-based substrate layer, a first polyvinyl alcohol-based resin layer, a Si or Al-containing thin film layer, and a second polyvinyl alcohol-based resin layer, which enhances gas barrier properties and maintains barrier performance even after high-temperature sterilization treatments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If polyolefin-based resin is used as substrate layer, then recyclability and mono-material formation are improved, but gas barrier properties and hot-water treatment resistance deteriorate
Solution Approach 1:
The patent uses a composite layered structure combining polyolefin substrate layer with polyvinyl alcohol barrier layers and inorganic thin film layers. This composite structure allows the polyolefin to provide recyclability while the additional layers provide the necessary gas barrier properties that polyolefin alone cannot achieve.
Solution Approach 2:
The packaging material is divided into functional segments: polyolefin substrate layer for recyclability, polyvinyl alcohol layers for adhesion and barrier enhancement, and inorganic thin film layers for gas barrier properties. Each layer performs its specific function while maintaining overall system recyclability.
2Ease of manufacture
If polyolefin-based resin is used as substrate layer, then ease of manufacture and cost are improved, but resistance to hot-water treatment and sterilization deteriorates
Solution Approach 1:
The polyolefin substrate is combined with polyvinyl alcohol layers that have high hot-water treatment resistance. The composite structure allows the polyolefin to provide ease of manufacture while the polyvinyl alcohol layers provide resistance to hot-water treatment and sterilization.
Solution Approach 2:
The polyvinyl alcohol layers are applied beforehand to protect the polyolefin substrate during subsequent hot-water treatment and sterilization processes. These layers act as a protective barrier that prevents degradation of the polyolefin under harsh thermal conditions.
3Reliability
If multiple heterogeneous materials are combined for high performance, then gas barrier properties are improved, but recyclability and mono-material formation deteriorate
Solution Approach 1:
The patent changes the material parameter strategy by using a polyolefin base (recyclable) and adding thin functional layers with specific properties. The key is that the polyvinyl alcohol layers can be designed to delaminate or be processed together with the polyolefin, enabling mono-material recycling while maintaining gas barrier properties through the layered structure.
Solution Approach 2:
Instead of making the entire structure from heterogeneous materials, the patent applies localized functional layers (polyvinyl alcohol and inorganic thin films) only where needed for gas barrier performance, while the bulk remains polyolefin for recyclability. This local quality approach maintains recyclability while achieving high performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides excellent gas barrier properties and recyclability, allowing for mono-material formation of packaging materials, where the polyolefin-based resin can be used for both the substrate and sealant layers, facilitating easier recycling and reducing material costs.
Implementation Method 1
a gas barrier layered body in which a plastic film substrate and an inorganic compound layer formed of silicon oxide, aluminum oxide, magnesium oxide, or the like are combined has been widely used in packaging of articles requiring blocking of water vapor or various gases such as oxygen
Implementation Method 2
a logarithmic decrement at 100° C. of a surface of the first polyvinyl alcohol-based resin layer on a side that is in contact with the Si or Al-containing thin film layer as measured by a rigid-body pendulum type physical property testing instrument is 0.20 or less
Data Source
AI summary
The present disclosure relates to a gas barrier layered body including: a substrate layer containing a polyolefin-based resin; a first polyvinyl alcohol-based resin layer; a Si or Al-containing thin film layer; and a second polyvinyl alcohol-based resin layer, in the stated order, in which a logarithmic decrement at 100° C. of the first polyvinyl alcohol-based resin layer as measured by a rigid-body pendulum type physical property testing instrument is 0.20 or less and a logarithmic decrement at 125° C. is 0.30 or less, and an indentation hardness of the second polyvinyl alcohol-based resin layer as determined by a nanoindenter is 0.5 to 1.0 GPa.