Aqueous Polymer Coating for Grease-Resistant Paper
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Solution Overview
Problem
Existing barrier coating compositions for paper and paperboard lack environmental friendliness, safety, and effectiveness in providing oil and grease resistance, foldability, and recyclability.
Innovation Solution
An aqueous composition comprising a combination of at least one first polymer derived from ethylenically substituted aromatic compounds and at least one second polymer, which is the reaction product of a partially neutralized, acid-functional support resin and ethylenically-unsaturated monomers, providing improved barrier properties, block resistance, and foldability while being environmentally friendly and recyclable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorochemicals are used in coating compositions to provide oil and grease resistance, then barrier properties are improved, but environmental friendliness and safety deteriorate due to toxic nature
Solution Approach 1:
The patent removes harmful fluorochemicals from the coating composition while maintaining barrier properties through alternative polymers. The aqueous composition uses conventional polymers that provide grease resistance without the toxic effects of fluorochemicals, effectively extracting the harmful substance while preserving the desired function.
Solution Approach 2:
The patent changes the chemical composition parameters of the coating by using specific polymer combinations with controlled molecular weights and functional groups. This parameter change allows achieving barrier properties through non-toxic materials, transforming the coating chemistry from fluorochemical-based to polymer-based formulations.
2Reliability
If plastic films such as polyethylene and polypropylene are used to provide barrier properties and flexibility, then barrier properties and foldability are improved, but recyclability and pulpability deteriorate
Solution Approach 1:
The patent changes the material composition from plastic films to water-based polymer coatings with specific solubility parameters. This allows the coating to be recycled with paper through repulping processes, as the polymers can be dissolved or detached in alkaline solutions, restoring the paper's recyclability while maintaining barrier properties.
Solution Approach 2:
The patent creates a composite coating system using multiple polymers with complementary properties - one polymer provides barrier functionality while another ensures recyclability. This composite approach allows simultaneous achievement of grease resistance and recyclability that single-material solutions cannot provide.
3Object-affected harmful factors
If water based coatings are used as environmentally friendly alternative, then environmental friendliness and recyclability are improved, but foldability deteriorates due to cracks forming in folds
Solution Approach 1:
The patent uses a composite polymer system where one polymer component provides flexibility and crack resistance while another provides barrier properties. This combination allows the coating to bend without cracking, solving the foldability problem inherent in water-based coatings while maintaining environmental benefits.
Solution Approach 2:
The patent adjusts physical parameters of the polymer coating including molecular weight, crosslinking density, and film thickness to optimize flexibility. By controlling these parameters, the coating achieves sufficient elongation and crack resistance to accommodate folding operations while remaining water-based and environmentally friendly.
4Reliability
If coating compositions provide oil and grease resistance, then barrier properties are improved, but blocking resistance deteriorates causing layers to stick together
Solution Approach 1:
The patent applies different polymer components with distinct functions at different locations within the coating structure. One polymer provides grease resistance at the coating-oil interface, while another polymer with lower polarity and different surface properties provides blocking resistance at the coating-coating interface, achieving both properties simultaneously through spatial differentiation of functions.
Data Source
AI summary
Described herein is an aqueous composition to improve barrier properties. Particularly, described herein is a polymer-based grease resistant aqueous composition for coating paper and paper products.