Volatile Corrosion Inhibitor Package With Nested Barriers
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Solution Overview
Problem
Volatile corrosion inhibitor products enclosed in gas-permeable barriers alone tend to lose effectiveness over time due to vapor pressure equilibration and have limited release rates, which are further hindered by the surface area of the substrate, leading to inadequate corrosion protection for electronic components.
Innovation Solution
A package design incorporating a gas-impermeable outer enclosure and a gas-permeable, solid particle-impermeable inner barrier to maintain elevated vapor pressure and enhance the emission surface area of volatile corrosion inhibitors, using materials like metallized films and Tyvek® for the barriers and open cell foam substrates with high volatile corrosion inhibitor concentrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a gas-permeable barrier is used to enclose volatile corrosion inhibitor products, then vapor phase corrosion inhibitors can be released to protect electronic components, but the products lose effectiveness over time due to vapor pressure equilibration and have limited release rates
Solution Approach 1:
The patent employs a nested barrier structure where an inner gas-permeable, solid particle-impermeable barrier is placed inside an outer gas-impermeable barrier. The VCI substrate is enclosed within the inner barrier, which itself is enclosed within the outer barrier. This nested configuration allows the inner barrier to release VCIs while the outer barrier prevents vapor escape, maintaining elevated vapor pressure and extending the duration of corrosion protection effectiveness.
Solution Approach 2:
The patent applies different barrier properties to different regions of the packaging system. The inner barrier is designed to be gas-permeable to allow VCI vapor release, while the outer barrier is gas-impermeable to retain vapors. This local differentiation of barrier qualities enables simultaneous VCI release and vapor pressure maintenance, resolving the contradiction between release rate and duration of effectiveness.
2Productivity
If the surface area of the substrate is limited, then the product structure remains simple, but the release rate of vapor phase corrosion inhibitors is hindered
Solution Approach 1:
The patent transitions from a two-dimensional surface-based VCI release model to a three-dimensional volume-based system. By enclosing the VCI substrate within a gas-impermeable outer barrier, the system creates a confined vapor space where VCIs can accumulate and be released through the gas-permeable inner barrier. This dimensional change allows the entire substrate volume to contribute to VCI release, effectively increasing the release rate without requiring increased substrate surface area.
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 package design maintains a high concentration of vapor phase corrosion inhibitors, ensuring effective corrosion protection for extended periods and accelerating the release of inhibitors when needed, thereby preventing corrosion damage to electronic components.
Implementation Method 1
The volatile corrosion inhibitor (VCI) materials emit vapor phase corrosion inhibitors over time, even at ambient conditions
Implementation Method 2
the corrosion inhibitor products are preferably enclosed within a gas-permeable, solid particle-impermeable barrier
Data Source
AI summary
A package for enclosing volatile corrosion inhibiting materials includes a first enclosure barrier being fabricated from one or more gas-impermeable materials and defining a first enclosed space. The package further includes a substrate having one or more volatile corrosion inhibitor materials disposed thereon, with the substrate being disposed within the first enclosed space. In some embodiments, a second enclosure barrier being fabricated from a gas-permeable, solid particle-impermeable material is disposed in the first enclosed space, and defines a second enclosed space inside of the first enclosed space. In such embodiments, the substrate is preferably disposed within the second enclosed space.