Thin Gas Barrier Laminate for Hot-Humid Oxygen Resistance
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Solution Overview
Problem
Existing gas barrier laminates fail to provide adequate protection against gas permeation under high temperature and high humidity conditions, particularly above 40°C and 90% RH, and there is a need for thinner films with improved barrier properties to address global warming and environmental concerns.
Innovation Solution
A gas barrier laminate comprising a plastic base material with a metal-containing layer and a polycarboxylic acid-based gas barrier layer, where the layers are in direct contact, and the laminate undergoes a specific filtration process to ensure homogeneity and effective gas barrier performance, achieving an oxygen transmission rate of 300 ml/(m2·day·MPa) or less under harsh conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thicker films are employed to increase gas barrier performance in high temperature and high humidity environments, then gas barrier performance is improved, but film thickness increases leading to reduced bag-making processability and increased weight
Solution Approach 1:
The invention changes the chemical composition parameters of the laminate by incorporating a metal-containing layer (with specific metal content of 0.1-70% by mass) and a polycarboxylic acid-based gas barrier layer, allowing thinner films to achieve superior gas barrier performance under high temperature and high humidity conditions without compromising processability
Solution Approach 2:
The invention uses a composite structure consisting of a plastic base material, a metal-containing layer, and a polycarboxylic acid-based gas barrier layer. This multi-layer composite achieves enhanced gas barrier properties through the synergistic effect of metal compounds and polycarboxylic acid, enabling thin film design with excellent barrier performance
2Reliability
If thicker films are employed to increase gas barrier performance, then gas barrier performance is improved, but weight of film products increases
Solution Approach 1:
The invention modifies the material composition by introducing metal-containing layers and polycarboxylic acid-based barrier layers, which provide superior gas barrier properties at lower thicknesses, thereby reducing the overall weight of the packaging film while maintaining or improving barrier performance
Solution Approach 2:
The composite laminate structure with metal-containing layer and polycarboxylic acid layer creates a highly efficient gas barrier system in a thin configuration, significantly reducing the weight of packaging materials compared to conventional thicker single-layer films
3Reliability
If conventional gas barrier laminates are used, then gas barrier properties are adequate at room temperature, but gas barrier performance deteriorates under high temperature and high humidity conditions
Solution Approach 1:
The invention changes the chemical composition by using polycarboxylic acid and metal compound combinations that form stable barrier structures resistant to degradation under high temperature and high humidity, preventing oxidative deterioration of packaged contents
Solution Approach 2:
The composite structure of metal-containing layer and polycarboxylic acid layer creates a synergistic effect where the metal compounds (such as magnesium, calcium, zinc) react with polycarboxylic acid to form stable complex structures that maintain gas barrier properties even under harsh high temperature and high humidity conditions
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 laminate exhibits excellent gas barrier properties even in high temperature and high humidity environments, inhibiting oxidative deterioration while maintaining a thickness of 100 μm or less, enhancing processability, reducing weight, and lowering production costs.
Implementation Method 1
a gas barrier layer (II) containing a polycarboxylic acid... the metal-containing layer and gas barrier layer are laminated so that the layers are in direct contact with each other
Data Source
AI summary
A gas barrier laminate with a total thickness of 100 μm or less, including a plastic base material (I) and a gas barrier layer (II) laminated on said plastic base material, wherein (1) plastic base material (I) includes a metal-containing layer including at least one metal and a metal compound and a resin component, (2) the total content of metal and metal compound in said metal-containing layer is 0.1 to 70% by mass, (3) gas barrier layer (II) contains polycarboxylic acid, (4) metal-containing layer and gas barrier layer are laminated so that they are in direct contact with each other, and (5) gas barrier laminate is treated at a temperature of 95° C. for 30 minutes. (5) the gas barrier laminate has an oxygen transmission rate of 300 ml/(m2·day·MPa) or less under a temperature of 40° C. and a humidity of 90% RH after hot water treatment for 30 minutes at 95° C.