Tie Layer Resin Composition for Multilayer Film Adhesion
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Solution Overview
Problem
Current tie layer formulations in multilayer films lack sufficient adhesion strength and toughness, leading to compatibility issues between different polymer layers, particularly with polyethylene and polyamide or ethylene vinyl alcohol layers, which restricts the reduction of film thickness and increases material costs.
Innovation Solution
Development of a resin composition comprising an ethylene-based polymer with a MWCDI value greater than 0.9 and a specific melt index ratio, combined with maleic anhydride grafted polyethylene, to enhance adhesion and toughness, allowing for reduced thickness of multilayer structures and potential cost savings by minimizing the use of engineering polymers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional tie layer formulations are used, then adhesion between polymer layers is achieved, but adhesion strength and toughness are insufficient
Solution Approach 1:
The patent applies parameter changes by carefully controlling the molecular weight distribution (MWCDI > 0.9) and melt index ratio (110/12 ≥ 7.0 - 1.2 x log(12)) of the ethylene-based polymer, along with the maleic anhydride grafting level (0.5-5 wt%), to optimize both adhesion strength and toughness of the tie layer
Solution Approach 2:
The patent uses composite materials by combining ethylene-based polymer with maleic anhydride grafted polyethylene, creating a composite resin composition that leverages the complementary properties of both components to achieve superior adhesion and toughness
2Reliability
If tie layer with sufficient adhesion and toughness is used, then compatibility between polyethylene and polyamide/EVOH layers is improved, but film thickness cannot be reduced
Solution Approach 1:
The patent uses parameter changes in the resin composition (MWCDI, melt index ratio, grafting level) to achieve such high adhesion and toughness that the tie layer can be made thinner while maintaining or improving overall layer compatibility and performance
3Reliability
If engineering polymers are used in multilayer structures, then required performance is achieved, but material costs increase
Solution Approach 1:
The patent applies parameter changes to create a cost-effective resin composition using primarily ethylene-based polymer with controlled molecular weight distribution and maleic anhydride grafting, providing engineering polymer-level performance at lower material cost
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 resin composition significantly improves adhesion and toughness, enabling the reduction of overall thickness in multilayer structures and reducing the amount of engineering polymers required, while maintaining or enhancing puncture strength and dart impact resistance.
Implementation Method 1
a maleic anhydride grafted polyethylene comprising a maleic anhydride grafted high density polyethylene, a maleic anhydride grafted linear low density polyethylene, or a maleic anhydride grafted polyethylene elastomer
Data Source
Figure 1~2
Figure 3~4
AI summary
The present disclosure provides resins that can be used as a tie layer in a multilayer structure and to multilayer structures comprising one or more tie layers formed from such resins. In one aspect, a resin for use as a tie layer in a multilayer structure comprises a first composition, wherein the first composition comprises at least one ethylene-based polymer and wherein the first composition comprises a MWCDI value greater than 0.9, and a melt index ratio (I10/I2) that meets the following equation: I10/I2 ? 7.0 - 1.2 x log (I2), wherein the first composition comprises 1 to 99 weight percent of the resin; and a maleic anhydride grafted polyethylene comprising a maleic anhydride grafted high density polyethylene, a maleic anhydride grafted linear low density polyethylene, a maleic anhydride grafted polyethylene elastomer, or a combination thereof, wherein the maleic anhydride grafted polyethylene comprises 1 to 99 weight percent of the resin.