Aqueous Coated Paperboard Oil Grease Resistance

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Solution Overview

Problem

Current paperboard coatings for oil and grease resistance face challenges such as non-recyclability, environmental and safety concerns, and a tendency to block, which are not addressed by existing technologies like wax or fluorochemical treatments.

Innovation Solution

A paperboard coated with two layers of aqueous coating, using conventional binders and pigments, applied either on a paper machine or off-line, providing high oil and grease resistance without fluorochemicals or wax, ensuring full repulpability and no blocking.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If wax or polyethylene coating is used to provide oil and grease resistance, then oil and grease resistance is improved, but repulpability and recyclability deteriorate

Engineering Contradiction:

Improveoil and grease resistanceVSAvoidrepulpability and recyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The invention changes the chemical composition parameters of the coating by using aqueous-based specialty chemicals instead of wax or polyethylene. This parameter change maintains oil and grease resistance while improving repulpability and recyclability, as the aqueous coating can be more easily broken down in the repulping process.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The invention uses a water-based coating that is designed to be removable and replaceable rather than permanent. The aqueous coating can be easily removed during repulping, allowing the paperboard to be recycled multiple times, whereas wax and polyethylene coatings are difficult to remove and limit recyclability.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Reliability

If fluorochemicals are used to provide oil and grease resistance, then oil and grease resistance is improved, but environmental and safety concerns worsen

Engineering Contradiction:

Improveoil and grease resistanceVSAvoidenvironmental and safety concerns

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes fluorochemicals from the coating formulation. By eliminating these harmful substances entirely and replacing them with water-based specialty chemicals, the invention maintains oil and grease resistance performance while eliminating the environmental and safety concerns associated with fluorochemicals.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention converts the harmful effect of fluorochemicals into a benefit by using water as the base vehicle instead. This substitution eliminates toxic emissions and environmental contamination while maintaining the functional performance of the coating, turning a harmful approach into a beneficial one.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Ease of manufacture

If aqueous coating is used to improve recyclability, then repulpability is improved, but blocking tendency worsens

Engineering Contradiction:

ImproverepulpabilityVSAvoidblocking tendency

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The invention uses a water-based coating formulation that provides sufficient but not excessive adhesion to the paperboard. This partial action approach allows the coating to perform its barrier function while remaining easily removable during repulping, and prevents excessive adhesion that would cause blocking during storage and handling.

Inventive Principle:

Principle #16Partial or excessive action

4Reliability

If specialty chemicals are used to provide oil and grease resistance, then oil and grease resistance is improved, but cost increases

Engineering Contradiction:

Improveoil and grease resistanceVSAvoidcost

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The invention uses water-based specialty chemicals that are less expensive than fluorochemicals or wax treatments. The aqueous coating can be applied at lower material costs and requires less complex application equipment, reducing overall processing costs while maintaining effective oil and grease resistance performance.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 solution achieves excellent oil and grease resistance, compliance with safety and environmental regulations, and cost-effectiveness, with the coated paperboard being fully repulpable and non-blocking, matching the performance of polyethylene extrusion coatings.

Implementation Method 1

aqueous coating... providing high resistance to oil and grease

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

coat the 'barrier' side of a paperboard with two layers of aqueous coating

Methodology Applied

Scientific EffectBarrier coating: Coatings

Implementation Method 3

The paperboard also has good moisture resistance

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Data Source

PatentUS9771688B2Oil, grease, and moisture resistant paperboard

Publication Date: 2017.09.26 WESTROCK MWV LLC

AI summary

A coated paperboard is disclosed which includes a base coat and top coat containing substantially no fluorochemical or wax, exhibiting good resistance to oil and grease, no tendency toward blocking, and being fully repulpable. Improved moisture resistance is also exhibited.