method

Abstract

A method of forming a water, oil, and / or gas resistant and / or impermeable product is disclosed, the method comprising the steps of (a) coating the product with a composition, the composition comprising a protein and / or shellac, the protein being a plant-derived protein, an animal-derived protein, a fungal-derived protein, or any combination thereof, and (b) heating the coated product.

Description

Detailed Description of the Invention

[0001] [Introduction] This invention relates to a method for forming products that are resistant and / or impermeable to water, oil, and / or gas, and to the products formed thereby.

[0002]

[0002] Commercial products in many applications benefit from resistance and / or impermeability to water, oil, and / or gas. For example, paper, cardboard, and other materials commonly used as packaging for commercial products often include such walls, barriers, or container parts for applications where liquids or gases need to be kept in or out of the product in question. The migration of water, oil, gas, and other fluids has traditionally been controlled by using functional coatings utilizing impermeable plastic materials or composites. In many industries, such as the food and beverage industry, plastics can be applied to media that are otherwise permeable to facilitate the retention of liquid products within a particular package. Similar methods can also be used to prevent the ingress of fluids into items that may be damaged by exposure to water, air, or other fluids. In one example, some paper or cardboard products are subjected to a process called internal sizing or surface sizing, in which hydrocarbon-derived materials, such as microplastics, are used to improve the porosity, adsorption, wear resistance, or other properties of the material. Materials used to manufacture existing functional coatings are typically produced from raw materials that have associated environmental costs. For example, plastic materials are typically sourced from hydrocarbon feedstocks, while metal coatings may be obtained from mining activities. The materials or compounds used to manufacture such functional coatings, and associated by-products, may also be toxic. Some materials may also degrade over time to produce particles, such as microplastics. Furthermore, many such materials may release potentially harmful species upon use. For example, perfluoroalkyl and polyfluoroalkyl materials have been associated with public health risks, but have been used to form water-resistant materials since the 1940s. Thus, there are ongoing health and environmental concerns regarding many common materials found in both consumer products and industrial environments that are used to impart resistance and / or impermeability to water, oil, and / or gas to commercial products.Additionally, although wood may be used as a plastic replacement in some applications (e.g., disposable cutlery), the relative strength of wood before and after exposure to water and / or oil requires a greater thickness to be used than would otherwise be desirable, and thus the potential for wood to be used as a plastic replacement is limited by the properties of wood.

[0003]

[0003] The present inventors have discovered a new and unexpected method of forming water, oil, and / or gas resistant and / or impermeable products, which provide a non-toxic and practical alternative to commonly used products that contain or are formed from plastics. In particular, products formed using the methods described herein may be only water resistant, only water impermeable, only oil resistant, only oil impermeable, only gas resistant, only gas impermeable, or any combination of water, oil, or gas resistant and / or impermeable. Water, oil, and / or gas resistant and / or impermeable may also provide products with increased tensile strength, dimensional stability, improved smoothness, any combination thereof, and the like. The present inventors have also realized that the method of the present invention may be used to fix dyes or pigments, thereby rendering the water, oil, and / or gas resistant and / or impermeable products colored products. The present inventors have still further realized that the methods of the present invention may be used to form antimicrobial and / or ultraviolet light (UV) resistant products.

[0004] According to one aspect of the present invention, there is provided a method for forming a water, oil, and / or gas resistant and / or impermeable product, comprising the steps of: (a) coating the product with a composition, the composition comprising a protein and / or shellac, the protein being a plant-derived protein, an animal-derived protein, a fungal-derived protein, or any combination thereof; and (b) heating the coated product to form a product that is resistant and / or impermeable to water, oil, and / or gas.

[0005]

[0005] Embodiments of the present invention are described below with reference to the following drawings: [Brief description of the drawings]

[0006] [Figure 1] A method (100) for forming a water, oil, and / or gas resistant and / or impermeable product is shown.

[0007] [Detailed Description]

[0006] The method of the present invention may be used with products including cellulose-based products, such as paper, cardboard, or wood-based products. Thus, the method of the present invention is suitable for forming water-, oil-, and / or gas-resistant and / or impermeable products including cellulose-based products, such as paper, cardboard, or wood-based products. The water-, oil-, and / or gas-resistant and / or impermeable paper, cardboard, or wood-based products formed according to the method of the present invention are biodegradable and / or compostable, and therefore can be disposed of with normal household waste without causing plastic or microplastic pollution.

[0008]

[0007] The composition used in the method of the present invention comprises protein and / or shellac. The protein used in the method of the present invention, when present, may comprise a plant-derived protein, and optionally the plant-derived protein comprises a prolamin protein. The protein may comprise a vegetable protein, a nut protein, a seed protein, a legume protein, a bean protein, a pulse protein, a grass protein, or any combination thereof. The protein may comprise a corn protein, a pea protein, a soy protein, an oat protein, a chickpea protein, a wheat protein, a barley protein, a rye protein, a sorghum protein, or any combination thereof. The protein may comprise a corn protein, and optionally the corn protein is a zein protein. The protein may comprise an animal-derived protein, and optionally the protein may be a milk protein, an egg protein, a poultry protein, a livestock protein, or any combination thereof. The protein may comprise a whey protein. The protein may comprise a fungal derived protein, and optionally the protein is a Chytridiomycota protein, a Zygomycota protein, a Glomeromycota protein, an Ascomycota protein, a Basidiomycota protein, or any combination thereof.

[0009]

[0008] Shellac, when present, refers to a resin produced by the lac insect typically found in the forests of India and Thailand.

[0010]

[0009] The composition may be free of shellac. More specifically, the composition may include protein and may be free or substantially free of shellac. Alternatively, the composition may be free of protein. More specifically, the composition may include shellac and may be free or substantially free of protein. For the avoidance of doubt, the term "substantially free" as used herein may refer to the presence of nearly 0% of a material, except for minor contaminants or unavoidable residual traces present in the product or composition. For example, a product or composition that is "substantially free" of a material may have about 0%, less than about 0.1%, less than about 0.2%, less than about 0.3%, less than about 0.4%, or less than about 0.5% of the material.

[0011]

[0010] The composition may include a solvent. The solvent may be introduced or applied to the coating and / or product at any time during the process. The solvent may include water, one or more alcohols, a carboxylic acid, and / or any combination thereof. Optionally, the solvent may include water, methanol, ethanol, isopropanol, butanol, ethylene glycol, methanoic acid (formic acid), ethanoic acid (acetic acid), propanoic acid, or any combination thereof. The protein and / or shellac, if present, may be dissolved and / or dispersed in the solvent. The protein and / or shellac may be used in the method of the invention in solid form. The solid form may be a solid powder. The solid may be a sheet, layer, etc. The solid may be discrete particles of various sizes, including at least some larger than a powder. When the protein and / or shellac are used in solid form, the method may exclude the use of a solvent. In the alternative, a solvent may be used in one or more of the method steps before, after, or during the use of the solid protein and / or shellac.

[0012]

[0011] The solvent, when present, may be a combination of solvents. When the solvent is a combination of solvents, the solvent may include a first solvent and a second solvent in a ratio of the first solvent to the second solvent, either by volume of solvent or by mass of solvent. For example, the ratio of the first solvent to the second solvent may be about 5:95, about 10:90, about 15:85, about 20:80, about 25:75, about 30:70, about 35:65, about 40:60, about 45:55, about 50:50, about 55:45, about 60:40, about 65:35, about 70:30, about 75:25, about 80:20, about 85:15, about 90:10, or about 95:5. In particular examples where the solvent includes an alcohol, the solvent may include 50% alcohol and 50% water, 60% alcohol and 40% water, 70% alcohol and 30% water, or 80% alcohol and 20% water. In examples where the solvent includes a carboxylic acid, the solvent may include 50% carboxylic acid and 50% water, 60% carboxylic acid and 40% water, 70% carboxylic acid and 30% water, or 80% carboxylic acid and 20% water.

[0013] According to the method of the present invention, the product may be coated with the composition by spraying the composition onto the product, dipping the product into the composition, soaking the product in the composition, roller coating the product with the composition, brushing the composition onto the product, wiping the composition onto the product, impregnating the product with the composition by padding, draining the composition onto the product, flowing the composition onto the product, using a slit coating technique, using a blade application technique, or any combination thereof. Those skilled in the art will be able, with the benefit of this disclosure, to identify the appropriate technique for coating the product depending on the composition used and the form and physiochemical properties of the product to be coated.

[0014]

[0013] The product may be coated by more than one coating technique and / or may be coated more than once. When a coating is applied to the product more than once, the coating technique used for each coating process may be the same or different. For example, the product may first be sprayed with the composition and then dipped into the composition. Alternatively, the product may be dipped into the composition two separate times to apply the coating. When more than one coating process, technique, or method step is used, the coating processes may occur sequentially, thereby occurring in immediate uninterrupted succession. Additionally or alternatively, any two coating processes may be separated by one or more other processes, such as drying, heating, or any other method or process substantially as described herein.

[0015]

[0014] A portion of the coating, or "excess" coating, may be removed from the product after application of the coating to the product. The portion of the coating, or excess coating, may be removed by any suitable technique, including, but not limited to, tapping, blotting, gravity flow, vibration techniques, shaking, sieving, blading, scraping, grinding, air-based techniques such as the use of an air knife, application of additional solvent, etching, or any combination thereof. The portion of the coating, or excess coating, may be removed to provide a thinner or more uniform thickness of coating on the surface or surface of the product. The thickness of the coating may change the properties and characteristics of the coating and / or product when a product is formed that is resistant and / or impermeable to water, oil, and / or gas. The portion of the coating, or excess coating, may be removed at any suitable point in the method. For example, the portion of the coating, or excess coating, may be removed after application of the coating to the product. If the coating is liquid, or semi-liquid, then the coating may be most appropriately removed by techniques effective for liquids, such as dabbing, blotting, flowing, etc. If the coating is solid, or partially solid, then the coating may be most appropriately removed by techniques effective for solids, such as blading, scraping, abrading, etching, etc. In methods in which a portion of the coating, or excess coating, is removed from the product, such coating may be removed before, after, or both before and after the product is heated to form a product that is resistant and / or impervious to water, oil, and / or gas.

[0016]

[0015] The temperature to which the coated product is heated depends on the thermal properties and thermal behavior of the composition and / or material from which the coated product is formed. However, the inventors have found, quite surprisingly, that the coated product may be heated to a temperature above the ignition temperature of the uncoated product and / or above the thermal decomposition temperature of the protein and / or shellac. For example, coated products (including coated cellulose-based products, such as paper, cardboard, or wood-based products) may be heated to a temperature between 200°C and 300°C without damaging the coated product by ignition or thermal decomposition. In some examples, coated products including cardboard or wood-based products may be heated to even higher temperatures, from 300°C to 500°C or higher, without the product igniting or thermal decomposition. Thus, the coated product may be heated to a temperature of 200°C to 500°C or higher without ignition or thermal decomposition. Without wishing to be bound by theory, it is believed that heating the coated product results in the loss of hydroxyl groups on the surface of the coated product, allowing the composition to interact with the surface of the product to form a product that is resistant and / or impermeable to water, oil, and / or gas.

[0017] Optionally, the coated product may be heated to about 200°C, about 205°C, about 210°C, about 215°C, about 220°C, about 225°C, about 230°C, about 235°C, about 240°C, about 245°C, about 250°C, about 255°C, about 260°C, about 265°C, about 270°C, about 275°C, about 280°C, about 285°C, about 290°C, about 295°C, about 300°C, about 305°C, about 310°C, about 315°C, about 320°C, about 325°C, about 330°C, about 335°C, about 340°C, about 345°C. , about 350°C, about 355°C, about 360°C, about 365°C, about 370°C, about 375°C, about 380°C, about 385°C, about 390°C, about 395°C, about 400°C, about 405°C, about 410°C, about 415°C, about 420°C, about 425°C, about 430°C, about 435°C, about 440°C, about 445°C, about 450°C, about 455°C, about 460°C, about 465°C, about 470°C, about 475°C, about 480°C, about 485°C, about 490°C, about 495°C, or about 500°C. Optionally, the coated product may be heated to a temperature of greater than 200°C, greater than 205°C, greater than 210°C, greater than 215°C, greater than 220°C, greater than 225°C, greater than 230°C, greater than 235°C, greater than 240°C, greater than 245°C, greater than 250°C, greater than 255°C, greater than 260°C, greater than 265°C, greater than 270°C, greater than 275°C, greater than 280°C, greater than 285°C, greater than 290°C, greater than 295°C, or greater than 300°C.Optionally, the coated product can be heated at 200°C to 300°C, 200°C to 290°C, 200°C to 280°C, 200°C to 270°C, 200°C to 260°C, 200°C to 250°C, 200°C to 240°C, 200°C to 230°C, 200°C to 220°C, 200°C to 210°C, 210°C to 300°C, 210°C to 2 90℃, 210℃~280℃, 210℃~270℃, 210℃~260℃, 210℃~250℃, 210℃~240℃, 210℃~230℃, 210℃~220℃, 220℃~300℃, 220℃~290℃, 220℃~280℃, 220℃~270℃, 220℃~260℃, 220℃~250℃ , 220℃~240℃, 220℃~230℃, 230℃~300℃, 230℃~290℃, 230℃~280℃, 230℃~270℃, 230℃~260℃, 230℃~250℃, 230℃~240℃, 240℃~300℃, 240℃~290℃, 240℃~280℃, 240℃~270℃, 24 It may be heated to a temperature of 0°C to 260°C, 240°C to 250°C, 260°C to 300°C, 260°C to 290°C, 260°C to 280°C, 260°C to 270°C, 270°C to 300°C, 270°C to 290°C, 270°C to 280°C, 280°C to 300°C, 280°C to 290°C, or 290°C to 300°C. It may be beneficial to heat the product to a temperature of 240°C or above 240°C. For example, 240°C, 245°C, or 250°C may be particularly beneficial.

[0018] The time for which the coated product is heated may depend on the shape, thickness, dimensions, or spatial topography of the product. The time for which the coated product is heated may also depend on the method, process, or device by which the coated product is heated. Additionally, or alternatively, the time for which the coated product is heated may depend on the composition and / or material from which the coated product is formed. The coated product may be heated for a time of less than 1 minute, between 1 minute and 1 hour, between 5 minutes and 1 hour, or optionally for about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes, about 40 minutes, about 45 minutes, about 50 minutes, about 55 minutes, or about 1 hour. In some circumstances, such as when the product is large or a large amount of composition is used, heating times of more than 1 hour may be appropriate. For example, about 1 hour 5 minutes, about 1 hour 10 minutes, about 1 hour 15 minutes, about 1 hour 20 minutes, about 1 hour 25 minutes, about 1 hour 30 minutes, about 1 hour 35 minutes, about 1 hour 40 minutes, about 1 hour 45 minutes, about 1 hour 50 minutes, about 1 hour 55 minutes, or about 2 hours. In some circumstances, such as when the product is small, when the product has a large exposed surface area, when only a small amount of composition is used, or when a large amount of thermal energy is transferred to the product in a short period of time, heating times of 15 minutes or less may be appropriate. In certain applications where the product is exposed to large amounts and / or high intensity thermal energy for a short period of time, it may be beneficial to heat the coated product for only a short period of time, such as for about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds, about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 6 minutes, about 7 minutes, about 8 minutes, about 9 minutes, about 10 minutes, or about 15 minutes.

[0019] The time for which the coated product is heated may be up to 5 seconds, up to 6 seconds, up to 7 seconds, up to 8 seconds, up to 9 seconds, up to 10 seconds, up to 11 seconds, up to 12 seconds, up to 13 seconds, up to 14 seconds, up to 15 seconds, up to 16 seconds, up to 17 seconds, up to 18 seconds, up to 19 seconds, up to 20 seconds, up to 25 seconds, up to 30 seconds, up to 35 seconds, up to 40 seconds, up to 45 seconds, up to 50 seconds, up to 55 seconds, up to 1 minute, up to 2 minutes, up to 3 minutes, up to 4 minutes, up to 5 minutes, up to 6 minutes, up to 7 minutes, up to 8 minutes, up to 9 minutes, up to 10 minutes, up to 15 minutes, up to 20 minutes, up to 25 minutes, up to 30 minutes, up to 35 minutes, up to 40 minutes, up to 45 minutes, up to 50 minutes, up to 55 minutes, or up to 1 hour. The time for which the coated product is heated is: 0 min - 1 hr, 1 min - 1 hr, 5 min - 1 hr, 10 min - 1 hr, 15 min - 1 hr, 20 min - 1 hr, 25 min - 1 hr, 30 min - 1 hr, 35 min - 1 hr, 40 min - 1 hr, 45 min - 1 hr, 50 min - 1 hr, 55 min - 1 hr, 5 min - 55 min, 10 min - 55 min, 15 min ~55 minutes, 20 minutes ~ 55 minutes, 25 minutes ~ 55 minutes, 30 minutes ~ 55 minutes, 35 minutes ~ 55 minutes, 40 minutes ~ 55 minutes, 45 minutes ~ 55 minutes, 50 minutes ~ 55 minutes, 5 minutes ~ 50 minutes, 10 minutes ~ 50 minutes, 15 minutes ~ 50 minutes, 20 minutes ~ 50 minutes, 25 minutes ~ 50 minutes, 30 minutes ~ 50 minutes, 35 minutes ~ 50 minutes, 40 minutes ~ 50 minutes, 45 minutes ~ 50 minutes, 5 minutes ~ 45 minutes, 1 0-45 min, 15-45 min, 20-45 min, 25-45 min, 30-45 min, 35-45 min, 40-45 min, 5-40 min, 10-40 min, 15-40 min, 20-40 min, 25-40 min, 30-40 min, 35-40 min, 5-35 min, 10-35 min, 15-35 min, 20-35 min , 25 to 35 minutes, 30 to 35 minutes, 5 to 30 minutes, 10 to 30 minutes, 15 to 30 minutes, 20 to 30 minutes, 25 to 30 minutes, 5 to 25 minutes, 10 to 25 minutes, 15 to 25 minutes, 20 to 25 minutes, 5 to 20 minutes, 10 to 20 minutes, 15 to 20 minutes, 5 to 15 minutes, 10 to 15 minutes, or 5 to 10 minutes.

[0020] The step of heating the coated product may include heating the coated product to a first temperature for a first time and then heating the coated product to a second temperature for a second time. The first temperature may be higher or lower than the second temperature. The first time may be longer than, the same as, or shorter than the second time. For brevity, the first time and / or the second time may be any time disclosed herein for the timing or duration of heating. For example, the first time may be for a period of time from less than 1 minute to 1 hour, optionally about 1 minute, about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes, about 40 minutes, about 45 minutes, about 50 minutes, about 55 minutes, or about 1 hour. The second time period may be a time period from less than 1 minute to 1 hour, optionally about 1 minute, about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes, about 40 minutes, about 45 minutes, about 50 minutes, about 55 minutes, or about 1 hour. The temperature to which the product is heated at the first time may differ from the temperature to which the product is heated at the second time by 5° C., 10° C., 15° C., 20° C., 25° C., 30° C., 35° C., 40° C., 45° C., 50° C., or even more than 50° C. For example, the product may be heated to a temperature of 200° C. at a first time and then heated to a temperature of 250° C. at a second time. In another example, the product may be heated to a temperature of 300° C. at a first time and then heated to a temperature of 280° C. at a second time. In other examples, the temperature for the first time may be 225°C and the temperature for the second time may be 240°C, 245°C, 250°C, 255°C, or 260°C.

[0021] The apparatus used to heat the coated product in the present method may be any suitable form of heating apparatus. In one example, the apparatus may be a heat press type apparatus. If a heat press is used, the heat press may be a planar press or a mold press depending on the desired shape and properties of the product. In one example, the apparatus may be a conventional oven type apparatus. In such examples, the heating energy and / or thermal energy may be provided by a heat source including one or more gas burners, oil burners, electrically heated filaments, any combination thereof, and the like. Additionally or alternatively, the apparatus may include one or more infrared (IR) heating devices, such as IR lamps, as a heat source. Some heating devices or heating methods may be more suitable for some specific product types than others. For example, a heat press apparatus may be preferred for some products having a sheet structure, such as paper sheets, cardboard sheets, or wooden boards. Infrared heating may be preferred for products having a larger product thickness, such as wooden planks or cardboard structures. However, to avoid concerns, any suitable heating apparatus may be used to heat any suitable product.

[0022]

[0021] When multiple heat sources or heating devices are used to heat the product, each heat source and / or heating device of one or more heating devices may be the same as or different from one or more other heat sources and / or heating devices of the one or more heating devices. For example, when two heat sources are used, the first heat source may be an electrically heated filament and the second heat source may be an IR heater. In another example where two heat sources are used, both heat sources may be IR heaters, each having a different energy rate and / or providing different infrared radiation wavelengths. For example, the IR heaters may irradiate the sample with short and / or long wavelength infrared radiation. The short wavelength infrared radiation may be in the wavelength range of about 700 nm to about 500,000 nm. The long wavelength infrared radiation may be in the wavelength range of about 500,000 nm to about 1 mm. The energy rate of the or each IR heater may be about 1.0 kW, about 1.2 kW, about 1.4 kW, about 1.6 kW, about 1.8 kW, about 2.0 kW, about 2.2 kW, about 2.4 kW, about 2.6 kW, about 2.8 kW, about 3.0 kW, about 3.2 kW, about 3.4 kW, about 3.6 kW, about 3.8 kW, about 4.0 kW, about 4.2 kW, about 4.4 kW, about 4.6 kW, about 4.8 kW, about 5.0 kW, about 5.2 kW, about 5.4 kW, about 5.6 kW, about 5.8 kW, about 6.0 kW, about 6.2 kW, about 6.4 kW, about 6.6 kW, about 6.8 kW, about 6.0 kW, about 6.2 kW, about 6.4 kW, about 6.6 kW, about 6.8 kW, about 7.0 kW, about 7.2 kW, about 7.4 kW, about 7.6 kW, about 7.8 kW, about 8.0 kW, about 8.2 kW, about 8.4 kW, about 8.6 kW, about 8.8 kW, about 9.0 kW, about 9.2 kW, about 9.4 kW, about 9.6 kW, about 9.8 kW, or about 10.0 kW. In one particular example, four IR lamps rated at 9 kW may be used to heat the product. In another particular example, a single IR lamp rated at 1.2 kW may be used to heat the product. In yet another particular example, a single IR lamp rated at 9 kW may be used to heat the product. In yet a further example, two IR lamps rated at 1 kW may be used to heat the product.In yet another further example, an IR lamp rated at 1.2 kW may be used to heat the product, followed by four IR lamps rated at 9 kW.

[0023]

[0022] The method may be of any suitable type. For example, the method may be a batch, semi-batch, or continuous process. In one example, the method may be a batch process, where the coated product or products may be steadily placed in an oven in fixed numbers, heated, and then removed. In another example, the method may be a continuous process, where the coated product may pass through the oven on a conveyor or similar system, while additional coated products are formed and fed to the oven by a conveyor or similar system over a period of time. The batch, semi-batch, or continuous process may be combined with any type of heating device or heating method described herein. For example, the batch process may use an infrared oven to heat the product. In another method, the batch process may use a gas-heated chamber to heat the product. In another method, the product may be passed through a conveyor system, whereby the product is passed through the infrared heating device in a continuous manner.

[0024]

[0023] The method may include one or more drying processes. The product may be dried before coating the product with the composition. The product may be air dried, dried at a temperature, or dried by any other suitable method. In one example, the product may be air dried for 12 hours, 24 hours, or any other suitable time before applying the composition to the product. In another example, the product may be oven dried at 50°C, 60°C, 70°C, 80°C, 90°C, 100°C, or any other suitable temperature for 5 minutes, 10 minutes, 15 minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 60 minutes, 90 minutes, 120 minutes, 150 minutes, 180 minutes, 240 minutes, 300 minutes, or any other suitable time. In examples where the composition includes a solvent, the coated product may be dried before heating. The coated product may be air dried, dried at a temperature, or dried by any other suitable method. In one example, the coated product may be air dried for 12 hours, 24 hours, or any other suitable time period before heating the coated product. In another example, the coated product may be oven dried at 50° C., 60° C., 70° C., 80° C., 90° C., 100° C., or any other suitable temperature for 5 minutes, 10 minutes, 15 minutes, 20 minutes, 30 minutes, 40 minutes, 50 minutes, 60 minutes, 90 minutes, 120 minutes, 150 minutes, 180 minutes, 240 minutes, 300 minutes, or any other suitable time period before further heating the coated product.

[0025]

[0024] The method may include a step of storing the product for a period of time. The storage may occur at any time after the product is coated. For example, the storage may occur after coating. The storage may occur after heating. In methods in which the product is dried, the storage may occur after drying. In one example, the product may be coated and then dried before storage. After storage, the coated product may be heated as described herein to form a product that is impermeable to water, oil, and / or gas. If the product is stored, it may be stored for about 5 minutes, about 10 minutes, about 15 minutes, about 30 minutes, about 1 hour, about 2 hours, about 5 hours, about 12 hours, about 24 hours, about 2 days, about 1 week, about 2 weeks, about 1 month, about 2 months, about 6 months, about 1 year, or any other suitable period of time. Thus, the product may be stored for up to 5 minutes, up to 10 minutes, up to 15 minutes, up to 30 minutes, up to 1 hour, up to 2 hours, up to 5 hours, up to 12 hours, up to 24 hours, up to 2 days, up to 1 week, up to 2 weeks, up to 1 month, up to 2 months, up to 6 months, up to 1 year, or for periods of time greater than 1 year. The present inventors have surprisingly found that products coated with the compositions described herein may be optionally dried prior to heating and then stored without impairing the resistance and / or impermeability to water, oil, and / or gas that would be obtained if the product were coated and heated without any intermediate drying and storage steps.

[0026]

[0025] The method may include the step of rotating, turning, and / or reorienting the product. The step of rotating, turning, and / or reorienting the product, if present, may occur during the heating and / or drying portion of the method. Additionally or alternatively, the step of rotating, turning, and / or reorienting may occur between any two method steps in which heat is applied to the product. For example, the step of rotating, turning, and / or reorienting may occur between a first heating step and a second heating step. In another example, the step of rotating, turning, and / or reorienting may occur between a heating step and a drying step. The step of rotating, turning, and / or reorienting may be performed by any suitable means. For example, the rotating, turning, and / or reorienting steps may be performed mechanically, whereby the product is moved, guided, and / or forced to mechanically rotate, turn, and / or reorient. Additionally or alternatively, the rotating, turning, and / or reorienting steps may be performed by non-mechanical methods. In one example, air may be used to exert a force on the product to rotate, turn, and / or reorient the product. In an example where the method is performed by a continuous process, passing the product may result in the product being rotated, turned, and / or reoriented without the use of additional motive force on the product.

[0027]

[0026] Those skilled in the art, with the benefit of this disclosure and the accompanying examples, can select the appropriate heating temperature, heating time, heating method, and associated process conditions to prepare a suitable water, oil, and / or gas resistant and / or impermeable product. As various process conditions are mentioned herein, the preferred method and associated process conditions for a particular product will depend on the characteristics of the product and the ingredients of the composition on which the product is coated. For example, a product with a small surface area compared to its mass may need to be heated for a longer period of time than a product with a larger exposed surface area of ​​a comparable mass. The nature of the material may also affect the preferred characteristics of the method, since a material with a large heat capacity may need to be heated in a more energy-intensive system or for a longer period of time than a material with a smaller heat capacity. In other examples, the type of product, the desired throughput of the product, or the preferred heating conditions may determine whether the process is preferably a batch process, a semi-batch process, or a continuous process. When infrared heating methods are used, the wavelength and energy rate of the IR device can be selected to impart a particular energy flux to the product in a particular time frame depending on the properties of the product and / or coating composition.

[0028] The inventors of the present invention have realized that the method described herein has other surprising advantages. The use of infrared heating eliminates the release of tannin from products containing tannin. When products contain tannin, oven heating has been shown to release various levels of tannin when the product comes into contact with water or other solvents. The infrared heating process has been shown to not release tannin in all tested examples shown later in Examples 8-15. Furthermore, some compositions have shown improved surface texture and / or resistance and / or impermeability to water, oil, and / or gas when heated gradually or by a multi-step heating process as described herein. Without wishing to be bound by theory, it is believed that some compositions experience a type of thermal shock when exposed to a high temperature from a starting temperature that is ambient temperature. Exposing the product and coating composition to a lower temperature and then exposing the product and coating to a higher temperature can surprisingly improve the adhesion, smoothness, and / or consistency of the product. However, it should be noted that some compositions have shown comparable surface properties when heated by a single heating process when compared to a multi-step heating process.

[0029]

[0028] The composition used in the method of the present invention may further comprise a functional additive, optionally the functional additive may comprise a dye, a pigment, a pH-sensitive material, a temperature-sensitive material, a conductive material, a fluorescent material, any other suitable functional additive, or any combination thereof. In one example, the composition may comprise a pigment. In another example, the composition may comprise nanocellulose or microcellulose. The use of nanocellulose or microcellulose may improve one or more properties of the coating formed using the method of the present invention. For example, the use of nanocellulose or microcellulose may improve the texture, smoothness, aesthetic appeal, and / or color intensity of the product. In one example, when the product is a cutlery item or other cookware, the use of nanocellulose or microcellulose as a functional additive may improve the mouth feel of the utensil or cutlery.

[0030]

[0029] In another example, the composition may include a sol as a functional additive. The sol as a functional additive may improve the strength of the coating composition or the product that is resistant and / or impermeable to water, oil, and / or gas. The sol may be formed by dispersing one or more materials of suitable small particle size in a solution. Some sols may further include additional components, such as a catalyst or functional component. Sols suitable for use in the method of the present invention typically include at least a functional metal alkoxide and a solvent. The term "metal alkoxide" includes metal-containing alkoxides, metal-containing organically modified alkoxides, metalloid-containing alkoxides, and metalloid-containing organically modified alkoxides. The solvent used to form the sol may include water, one or more alcohols, any other suitable solvent, or any combination thereof. When present, the one or more alcohols may include methanol, ethanol, butanol, ethylene glycol, isopropanol, any other suitable alcohol, and any combination thereof. The sol may optionally include a biopolymer, such as a starch-based polymer, a hemicellulose-based polymer, a cellulose-based polymer, a lignin-based polymer, any other suitable biopolymer or modified biopolymer, and any combination thereof. Additionally or alternatively, the sol may include one or more powders derived from natural materials. Metal alkoxides are typically represented by the general formula M(OR)x or R C -M(OR) x According to the above, "M" represents any metal that forms a metal alkoxide that can be hydrolyzed in the presence of a suitable solvent. C " represents an alkyl residue, typically of 1 to 30 carbon atoms, which may take any suitable form, e.g., linear, branched, aromatic, or complex. "x" usually corresponds to the valency of the corresponding metal ion "M". In certain instances, R may be a methyl, ethyl, propyl, or butyl residue. When the metal ion "M" has a valency greater than one, each R group may be the same. R Crepresents any suitable organic group that will form and maintain a covalent bond with the metal "M" after hydrolysis of the alkoxide. In some examples, R and R C In other examples, R and R C may vary. Any suitable metal alkoxide may be used. An example of a suitable metal alkoxide is Si(OR) 4 , Ti(OR) 4 , Al(OR) 3 , Zr(OR) 3 , and Sn(OR) 4 , and R C -Si(OR) 3 , R C -Ti(OR) 3 , R C -Al(OR) 2 , R C -Zr(OR) 2 , and R C -Sn(OR) 3 In particular examples, R may be a methyl, ethyl, propyl, or butyl residue. In some particular examples, R C may be a phenyl group, a cyclopentyl group, or any other suitable organic group capable of maintaining a covalent bond with the metal. The metal of the metal alkoxide may include silicon, titanium, aluminum, zirconium, tin, or any other suitable metal. In a particular example, the metal alkoxide is Ti(isopropoxy) 4 , Al(isopropoxy) 3 , Al(sec-butoxy) 3 , Zr(n-butoxy) 4 , Zr(n-propoxy) 4, n-propyltriethoxysilane, tetrapropyl orthosilicate, titanium(IV) tert-butoxide, titanium(IV) isopropoxide, triethyloxysilane, methyltriethyloxysilane, triethoxy(octyl)silane, phenyl-triethoxysilane, titanium(iv) ethoxide, triethoxy-silylcyclopentane, (3-glycidyloxypropyl)trimethoxysilane, cyclopentyltriethoxysilane, 3-amino-propyltriethoxysilane, triethoxy-3-(2-imidazolin-1-yl)propylsilane, and any combination thereof. In selected examples, the metal alkoxide may be selected from the group including tetraethoxysilane, phenyltriethoxysilane, methyltriethyloxysilane, and any combination thereof. In further selected examples, the metal alkoxide may be selected from the group including tetrapropyl orthosilicate, titanium(IV) tert-butoxide, titanium(IV) isopropoxide, triethyloxysilane, methyltriethyloxysilane, triethoxy(octyl)silane, phenyl-triethoxysilane, titanium(iv) ethoxide, triethoxy-silylcyclopentane, (3-glycidyloxypropyl)trimethoxysilane, cyclopentyltriethoxysilane, or any combination thereof. In further selected examples, the metal alkoxide may be selected from the group including Ti(isopropoxy) 4 , Al(isopropoxy) 3 , Al(sec-butoxy) 3 , Zr(n-butoxy) 4 , Zr(n-propoxy) 4 and n-propyltriethoxysilane based alkoxides, and any combination thereof.

[0031]

[0030] For the avoidance of doubt, the composition may also be free of a sol as described herein. Thus, the composition used in the method of the present invention may be free or substantially free of a sol or sol-gel. For example, the composition used in the method of the present invention may be free of an alkoxide. The composition used in the method of the present invention may be free of a catalyst, and optionally, the composition may be free of an acid and / or free of a base. More specifically, the composition used in the method of the present invention may be free or substantially free of an alkoxide, the composition used in the method of the present invention may be free or substantially free of a catalyst, and / or the composition used in the method of the present invention may be free or substantially free of an acid or a base. The composition may be free of a solvent. For example, the composition may be free of water, alcohol, etc.

[0032]

[0031] Unlike other compositions used for similar applications, the compositions used in the methods of the present invention may exclude, be free, contain, or be substantially free of one or more substances, molecules, or compounds. The compositions used in the methods of the present invention may be free of esters. The compositions used in the methods of the present invention may be free of glycols and / or free of polyols. The compositions used in the methods of the present invention may be free of polysaccharides. The compositions used in the methods of the present invention may be free of synthetic polymers. The compositions used in the methods of the present invention may be free of plastics. In some examples, the compositions used in the methods of the present invention may exclude polyol fatty acid esters and / or may exclude sugar fatty acid esters.

[0033]

[0032] The composition may be free of stabilizers. In some examples, the composition may be free of, excluded, free of, or substantially free of stabilizers such as carboxymethylcellulose, hydroxyethylcellulose, methylcellulose, ethylcellulose, hydroxyethylpropylcellulose, methylhydroxypropylcellulose, carboxymethylhydroxyethylcellulose, xanthan gum, guar gum, gum arabic, gum acacia, carrageenan gum, furcellaran gum, gum ghatti, locust bean gum, karaya gum, tragacanth gum, polyacrylate, polyoxyethylene sorbitan monooleate sodium lauryl sulfate, cetyltrimethylammonium bromide, magnesium carbonate, magnesium sulfate, magnesium silicate, alkenylsuccinic anhydride, alkylketene dimer, styrene maleic anhydride, octynylsuccinic anhydride, rosin, rosin derivatives, styrene acrylic acetate, styrene acrylic emulsion, polyurethane dispersion, wax dispersion, and / or other stabilizers. The composition may be free of plasticizers. In some examples, the composition may be free, excluded, free of, or substantially free of plasticizers, such as adipates, azelates, citrates, benzoates, ortho-phthalates, terephthalates, sebacates, and trimellitates.

[0034] According to a further aspect of the present invention there is provided a water, oil and / or gas resistant and / or impermeable article formed by the method of the present invention.

[0035]

[0034] The water, oil and / or gas resistant and / or impermeable products of the present invention may include cellulose-based products, such as paper, cardboard, or wood-based products.

[0036]

[0035] The water, oil, and / or gas resistant and / or impermeable products of the present invention may be used to form part or all of containers for use in the food and beverage industry, such as food storage boxes, food storage bags, oil and grease resistant (OGR) papers, hot or cold beverage containers, beverage container lids, plates, trays, and bowls. Additionally, the method of the present invention may be used to form water, oil, and / or gas resistant and / or impermeable products, such as cutlery or cooking utensils, that may be used in the preparation or consumption of food. In some instances, the products formed by the method of the present invention may be used to form part or all of disposable or multiple use packaging. The water, oil, and / or gas resistant and / or impermeable products of the present invention may be washable in a dishwasher, a washing machine, or the like, without loss of shape, adhesion, or performance. In a further example, the water-, oil-, and / or gas-resistant and / or impermeable products of the present invention may be washed many times in a dishwasher, a washing machine, or the like and still retain their desired functionality. Thus, although suitable for use in replacing disposable plastic items, the water-, oil-, and / or gas-resistant and / or impermeable products of the present invention are also suitable for reuse.

[0037]

[0036] The methods described herein are not limited to application in the food and beverage industry. Products processed using the methods described herein may be advantageously applied in any sector or industry in which the product may find use. For example, products formed using the methods described may be used in industries including construction, furniture, shipbuilding, bridges, railways, tiles and flooring, fencing, decoration, horticulture, plywood structures, panels, cladding, hand tools, artwork, musical instruments, sporting goods, toys, office supplies and stationery, medical equipment, any other suitable industry, etc.

[0038] The water, oil, and / or gas resistant and / or impermeable products of the present invention may be formed from functional additives including dyes or pigments, resulting in a colored product.

[0039]

[0038] The water, oil, and / or gas resistant and / or impermeable products of the present invention can have increased tensile strength compared to corresponding products not treated using the methods described herein. Additionally, or alternatively, the water, oil, and / or gas resistant and / or impermeable products of the present invention can have increased dimensional stability, increased scratch resistance, improved smoothness, and / or improved stain resistance compared to products not treated using the methods described herein. These increased breakage resistances help make the products of the present invention suitable for reuse.

[0040]

[0039] Figure 1 shows a method (100) for forming a product that is resistant and / or impermeable to water, oil, and / or gas. The method (100) comprises the step of coating the product with a composition (101), the composition comprising a protein, which may be a plant-derived protein, an animal-derived protein, a fungal-derived protein, or any combination thereof, and / or shellac. The method (100) further comprises the step of heating the coated product (102) to form a product that is resistant and / or impermeable to water, oil, and / or gas. Optionally, the method (100) may comprise one or more further method steps, provided that the method comprises the steps of coating (101) and heating (102). Optional method steps are represented as part of the method using dashed lines to indicate optional characteristics of the related method steps. Optional method steps may include further coating the coated product (102), further heating the coated product (103), drying the coated product (104), and / or reorienting the coated product (105). Reorienting the product may include flipping or rotating the product as described herein. Optional method steps (103, 104, 105, 106) may occur between the coating step (101) and the heating step (102) and / or after the heating step (102). One of ordinary skill in the art, with the benefit of this disclosure, will be able to determine any method steps appropriate to obtain the desired product characteristics.

[0041] [Example] Example 1 A piece of untreated wood was placed in an oven at 200°C for 10 minutes. After heating, the wood was removed from the oven. The wood showed some charring and discoloration. A drop of water was placed on the surface of the wood and observed to be quickly absorbed by the surface. A drop of oil placed on the surface of the wood and subsequently heated was also observed to be absorbed into the surface structure.

[0042] Example 2 A composition was prepared by mixing 100 ml of ethanol with 10 g of zein corn protein powder. The zein powder was mixed with the solvent. A piece of untreated wood was dipped into the composition, allowed to dry, and then placed in an oven at 240° C. for 10 minutes. After heating, the wood was removed from the oven. The surface of the wood was observed to be smooth in appearance. A drop of water was placed on the surface of the wood and allowed to rest on the surface for one hour, at which point observation was stopped. The water drop was retained throughout the entire observation period and was not absorbed by the surface. The experiment was repeated with a drop of oil, and the oil drop was also retained on the surface of the treated wood.

[0043] Example 3 The experiment conducted in Example 2 was repeated using 20 g, 30 g, and 40 g of zein corn protein powder. The experiment was further repeated using a solvent of 70 wt% ethanol in water. The compositions prepared and those prepared in Example 2 were also diluted with 40 wt% tert-butanol and used as described in Example 2. Each of the wood samples demonstrated resistance and / or impermeability to water and / or oil.

[0044] Example 4 A piece of untreated wood was coated in zein protein powder and the powder was pressed against the wood surface several times. The coated piece of wood was placed in an oven at 250°C for 8 minutes. After heating, the wood was removed from the oven. The wood surface was observed to have a smooth appearance. A drop of water was placed on the wood surface and allowed to rest on the surface for 5 minutes before observation was stopped. The water drop was retained throughout the entire observation period and was not absorbed by the surface. The experiment was repeated with a drop of oil and the oil drop was also retained on the treated wood surface.

[0045] Example 5 Shellac was added to the protein compositions prepared in Examples 2 and 3 at concentrations between 5 and 50 wt% (based on the weight of the solid components). Samples of 20 g shellac in 100 ml of (i) water, (ii) ethanol, and (iii) 70 wt% ethanol and water were also prepared without any protein. A piece of wood was treated with each composition, the treated piece of wood was dried, and then heated in an oven at 250°C for 10 minutes. Once cool, the treated wood was cooled and water and oil droplets were placed on the surface of each piece of wood for 10 minutes after which observations were stopped. The treated samples showed no absorption of water and oil droplets.

[0046] Example 6 A composition was prepared by mixing 3 wt% (based on the total weight of the composition) nanocellulose with 100 ml of water. A piece of untreated wood was immersed in the composition and placed in an oven at 240°C for 10 minutes. After heating, the wood was removed from the oven. The surface of the wood was observed to be smooth in appearance. A drop of water was placed on the surface of the wood and allowed to stand on the surface for 1 hour before observation was stopped. The water drop was gradually absorbed into the surface of the wood throughout the observation period, but at a slower rate than observed for the untreated wood piece in Example 1. This indicates that nanocellulose alone provides some water resistance but not impermeability as observed in Examples 2 and 3. The experiment was repeated with a drop of oil, which was also gradually absorbed into the surface of the treated wood.

[0047] Example 7 Wooden spoons were thoroughly coated in each of the compositions described in Examples 2-5 and heated in an oven at 250° C. for 10 minutes. The treated spoons were cooled, after which each spoon and an untreated spoon were immersed in boiling water for 2 minutes. The untreated wooden spoons were saturated with water, soft, and easily broke with the application of small force. The treated wooden spoons showed no visible water absorption after immersion and retained their strength and dimensional stability.

[0048] Examples 8-15 In Examples 8-15, wooden spoons were coated with each of the compositions shown in Table 1. The compositions contained various amounts of zein corn protein in addition to various solvents and, optionally, some sol additives. Two different heating systems were tested. The first system included an infrared heating device. The composition heated by the first heating device was processed under conditions equivalent to a continuous processing medium, whereby the product was coated and moved through the heating device using a solid conveyor system. The IR heating system used two IR lamps rated at 1 kW. Samples passing through the IR device were heated to at least 240°C. The second heating device tested was a conventional filament heated laboratory oven. Samples were placed in the oven under conditions equivalent to a batch process and heated to temperatures between 240°C and 280°C. The results are shown in Table 1.

[0049] All samples of Examples 8-15 exhibited varying degrees of hydrophobicity. Samples rated "1" for hydrophobicity were observed to exhibit a larger contact angle when a drop of water was placed on the product and / or to cause water to run off the surface of the product more quickly than samples rated "2", etc., with the least significant contact angle and / or slowest flow rate of water observed down to "4". Samples rated "1" for appearance and / or texture were observed to have a smoother surface and / or a more satisfactory mouth feel than samples rated "2", and samples rated "4" had the worst smoothness and / or least satisfactory mouth feel of the samples tested. Surprisingly, samples heated by the infrared heating device showed no substantial release of tannins from the wooden spoons when the spoons were subsequently immersed in water. Samples heated using a conventional oven showed some loss of tannins, with samples rated "2" releasing less tannins than samples rated "3".

[0050] Example 16 A pilot scale infrared heating apparatus was used to treat samples of wooden spoons coated with a composition containing shellac. The compositions tested were the same as those described above for Examples 8-15, except that the zein corn protein was replaced with the same amount of shellac. Using conveyor speeds between 0.8 m / min and 3 m / min, the samples were heated using four IR lamps rated at 9 kW and one IR lamp rated at 1.2 kW located at the beginning of the belt.

[0051]

[0050] The use of all IR heating lamps in the lamp configuration resulted in poorer hydrophobicity and less desirable texture of the product. The best hydrophobicity and texture was observed by heating the product using a slower belt speed and only some of the IR lamp configuration. Treating the product in a two-step process using a low energy IR lamp followed by a higher energy rate IR lamp configuration showed even further improvement in the hydrophobicity and texture of the final product.

[0052] [Table 1]

[0053] Example 17

[0051] Paper sheets were dipped into (1) a composition containing corn protein or (2) a composition containing shellac. The paper sheets were transferred to a heat press and pressed at 250°C for times up to 5 seconds. After the paper sheets were cooled, the sheets were tested for water and oil permeability. All paper sheet samples showed both water and oil resistance, and in some cases impermeability. All samples showed improved scratch resistance.

[0054] Example 18 The experiment of Example 17 was repeated, but instead, the paper samples were air-dried after soaking in the protein composition or the shellac composition. The air-dried samples were then stored for times of (i) 1 day, (ii) 1 week, (iii) 2 weeks, (iv) 1 month, (v) 2 months, and (vi) 6 months, and then heated in a heat press at 250° C. for times up to 10 seconds. All of the stored and then pressed samples exhibited both water and oil resistance, and some samples exhibited impermeability. All samples exhibited improved scratch resistance.

Claims

1. A method for forming a product that is resistant to and / or impermeable to water, oil, and / or gas, (a) A step of coating a product with a composition, wherein the composition comprises a protein and / or shellac, and the protein is a plant-derived protein, an animal-derived protein, a fungal-derived protein, or any combination thereof, (b) A method comprising the step of heating a coated product to form a product that is resistant to and / or impermeable to water, oil, and / or gas.

2. The method according to claim 1, wherein the product includes a cellulose-based product, such as paper, cardboard, or wood-based product.

3. The composition contains a solvent, Optionally, the solvent comprises water, one or more carboxylic acids, one or more alcohols, and / or any combination thereof. The method according to claim 1, wherein the solvent optionally includes water, methanol, ethanol, isopropanol, butanol, ethylene glycol, methaneic acid, ethaneic acid, propanoic acid, or any combination thereof.

4. The composition comprises a protein, and the protein comprises a plant-derived protein. Optionally, the plant-derived protein includes prolamin protein, Optionally, the protein may include vegetable protein, nut protein, seed protein, legume protein, bean protein, grass protein, or any combination thereof. Optionally, the protein includes corn protein, pea protein, soy protein, oat protein, chickpea protein, wheat protein, barley protein, rye protein, sorghum protein, or any combination thereof. Optionally, the protein includes corn protein. Optionally, the corn protein may be zein protein, The composition comprises a protein, and the protein comprises an animal-derived protein. Optionally, the protein may be milk protein, egg protein, poultry protein, livestock protein, or any combination thereof. Optionally, the protein may include whey protein, The composition comprises a protein, and the protein comprises a fungal-derived protein. The method according to claim 1, wherein the protein is optionally a chytridiomycete protein, a zygomycete protein, a glomus protein, an ascomycete protein, a basidiomycete protein, or any combination thereof.

5. The method according to claim 1, wherein the composition contains protein but does not contain shellac.

6. The method according to claim 1, wherein the composition comprises shellac and does not contain protein.

7. The method according to claim 1, wherein the product is coated with the composition by spraying the composition onto the product, immersing the product in the composition, soaking the product in the composition, roller coating the product with the composition, brushing the composition onto the product, wiping the product with the composition, impregnating the product with the composition by padding, discharging the composition onto the product, flowing the composition onto the product, using a slit coating method, using a blade coating method, or any combination thereof.

8. The step of heating the coated product to form a product that is resistant to and / or impermeable to water, oil, and / or gas, One or more gas burners, oil burners, electrically heated filaments, any combination thereof, and / or The method according to claim 1, which is carried out using one or more infrared (IR) heating devices.

9. The method according to claim 1, wherein the step of heating the coated product includes heating to a temperature between 200°C and 500°C, optionally to about 200°C, about 210°C, about 220°C, about 230°C, about 240°C, about 250°C, about 260°C, about 270°C, about 280°C, about 290°C, or about 300°C.

10. The method according to claim 1, wherein the step of heating the coated product includes heating for a time of 5 seconds to 1 hour, arbitrarily, about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, about 20 seconds, about 25 seconds, about 30 seconds, about 35 seconds, about 40 seconds, about 45 seconds, about 50 seconds, about 55 seconds, about 60 seconds, about 1 minute, about 2 minutes, about 3 minutes, about 4 minutes, about 5 minutes, about 10 minutes, about 15 minutes, about 20 minutes, about 25 minutes, about 30 minutes, about 35 minutes, about 40 minutes, about 45 minutes, about 50 minutes, about 55 minutes, or about 1 hour.

11. The method according to claim 1, wherein the step of heating the coated product includes heating the coated product to a first temperature for a first time, and then heating the coated product to a second temperature for a second time.

12. The method according to claim 11, wherein the first temperature is higher or lower than the second temperature, and optionally the temperature at which the product is heated in the first time differs from the temperature at which the product is heated in the second time by 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, or more than 50°C.

13. The method according to claim 11, wherein the first time is longer than, the same as, or shorter than the second time.

14. The method according to claim 1, wherein the composition further comprises a functional additive, optionally comprising a dye, a pigment, a pH-sensitive material, a temperature-sensitive material, a conductive material, a fluorescent material, an alkoxide, and a solvent, or a combination thereof.

15. The method according to claim 14, wherein the functional additive comprises nanocellulose or microcellulose.

16. The composition is free of alkoxides and / or The composition is catalyst-free, and optionally, the composition is acid-free and / or base-free and / or The composition is free of esters and / or, The composition is free of glycol and / or polyol and / or The composition is free of polysaccharides and / or The composition does not contain synthetic polymers, and / or The composition does not contain a sol and / or a sol gel, and / or The composition is free of stabilizers and / or The method according to any one of claims 1 to 15, wherein the composition does not contain a plasticizer.

17. A product that is resistant to and / or impermeable to water, oil, and / or gas, formed by the method described in claim 1.

18. A water, oil, and / or gas-resistant and / or gas-impermeable product according to claim 17, comprising a cellulose-based product, such as a paper, cardboard, or wood-based product.

19. A water, oil, and / or gas-resistant and / or gas-impermeable product according to claim 17, comprising forming part or all of a container for use in the food and beverage industry, and optionally forming a lid.

20. A product of water, oil, and / or gas resistance and / or impermeability, which is cutlery or cooking utensil, as described in claim 17.

21. A water, oil, and / or gas-resistant and / or impermeable product according to claim 17, having increased tensile strength, increased dimensional stability, increased scratch resistance, improved smoothness, and / or improved antifouling properties compared to a corresponding uncoated product used in any one of claims 1 to 15.

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