Tie Layer Composition for Multilayer Film Adhesion

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Solution Overview

Problem

Current tie layer compositions for multilayer films, used in applications like automotive and outdoor furniture, lack improved thermal and mechanical properties, leading to brittleness and poor adhesion, especially under higher temperature processing conditions and varying geometries.

Innovation Solution

A tie layer composition comprising polycarbonate, impact modifier, aromatic vinyl copolymer, and polyester carbonate or polycarbonate-polysiloxane, which provides enhanced thermal stability, high modulus, and improved adhesion to both superstrate and substrate, reducing surface defects and enhancing impact and flow balance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If conventional tie layer compositions are used, then adhesion between multilayer film and substrate is provided, but thermal stability and mechanical properties deteriorate under higher temperature processing conditions

Engineering Contradiction:

Improvethermal stabilityVSAvoidmechanical properties

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent employs a composite material system consisting of polycarbonate blended with polyester carbonate and polycarbonate-polysiloxane copolymer. This composite formulation achieves superior thermal stability while maintaining mechanical integrity under processing conditions, resolving the contradiction between temperature resistance and reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention modifies the chemical composition parameters of the tie layer by incorporating specific ratios of polycarbonate (30-50 wt%), polyester carbonate (15-35 wt%), and polycarbonate-polysiloxane (0-10 wt%). These parameter changes enable the material to maintain both thermal stability and mechanical properties simultaneously.

Inventive Principle:

Principle #35Parameter changes

2Strength

If low modulus tie layer materials are used, then flexibility is provided, but brittleness increases and adhesion deteriorates over time

Engineering Contradiction:

ImprovemodulusVSAvoidaging resistance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent creates a composite material where polycarbonate provides high modulus and structural integrity, while the blended polyester carbonate and polycarbonate-polysiloxane components prevent brittleness and maintain adhesion during aging. This composite approach resolves the contradiction between strength and reliability.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention applies different functional properties to different components within the tie layer: polycarbonate provides high modulus and dimensional stability, while the polyester carbonate and polycarbonate-polysiloxane components provide flexibility and aging resistance. This local quality differentiation resolves the contradiction between strength and reliability.

Inventive Principle:

Principle #3Local quality

3Temperature

If tie layer composition is optimized for thermal stability, then processing temperature resistance improves, but adhesion to superstrate and substrate deteriorates

Engineering Contradiction:

Improveprocessing temperature resistanceVSAvoidadhesion

Core Design Contradiction:

TemperatureVSForce

Solution Approach 1:

The patent develops a composite material where polycarbonate provides thermal stability for processing temperature resistance, while the polyester carbonate and polycarbonate-polysiloxane components maintain adhesion properties. The synergistic interaction among these components resolves the contradiction between temperature resistance and adhesion.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The invention optimizes the compositional parameters by maintaining polycarbonate content at 30-50 wt% for thermal stability while incorporating 15-35 wt% polyester carbonate and 0-10 wt% polycarbonate-polysiloxane to preserve adhesion. These parameter adjustments simultaneously achieve processing temperature resistance and adhesion.

Inventive Principle:

Principle #35Parameter changes

4Strength

If impact resistance is enhanced, then mechanical durability improves, but flow balance and surface defect rate worsen

Engineering Contradiction:

Improveimpact resistanceVSAvoidsurface defect rate

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The patent employs a composite material formulation where the polycarbonate-polyester carbonate-polycarbonate-polysiloxane blend provides impact resistance while maintaining flow balance. The synergistic interaction among components ensures both mechanical durability and manufacturing precision, resolving the contradiction between strength and surface quality.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8324318B2Tie layer compositions

Publication Date: 2012.12.04 SHPP GLOBAL TECH BV

AI summary

A thermoplastic composition including a combination of a polycarbonate, an impact modifier, an aromatic vinyl copolymer, and a polyester carbonate and/or a polycarbonate polysiloxane copolymer having excellent thermal and mechanical properties as well as good adhesion to both a polymer superstrate and certain types substrates is disclosed. Also disclosed are articles and multilayer films including the tie layer composition.