Biodegradable Polymer Blend for High-Speed Paper Coating
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Solution Overview
Problem
Existing extrusion coating technologies using thermoplastic polymers face issues such as excessive odor emissions, incompatibility with heat-sensitive polymers, and lack of biodegradability, while compostable or biodegradable polymers struggle with adhesion to paper substrates and are not suitable for high coating line speeds.
Innovation Solution
A biodegradable polymer blend comprising specific ratios of aliphatic-aromatic polyesters, aliphatic polyesters, and polycaprolactone with a high viscosity number, enhancing adhesion to paper substrates and allowing high coating line speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermoplastic polymers (polyethylene, polypropylene) are used for extrusion coating, then processability and coating application are improved, but biodegradability is lost and harmful emissions (aldehydes, excessive odor) are generated
Solution Approach 1:
The patent changes the chemical composition parameters of the coating material from conventional thermoplastics to a specific blend of biodegradable polymers (PLA, PBAT, PCL) in defined ratios. This parameter change eliminates harmful emissions while maintaining processability through optimized formulation and processing conditions
Solution Approach 2:
The patent creates a composite material system combining multiple biodegradable polymers (polylactide, poly(butylene adipate terephthalate), and polycaprolactone) in specific weight ratios. This composite approach leverages the complementary properties of each polymer to achieve both biodegradability and adequate processing characteristics
2Object-generated harmful factors
If biodegradable polymers (PLA, PBAT blends) are used for extrusion coating, then biodegradability and environmental compatibility are improved, but adhesion to paper substrates deteriorates
Solution Approach 1:
The patent modifies the compositional parameters by introducing polycaprolactone (PCL) at specific weight percentages (5-30%) into the biodegradable polymer blend. This parameter change improves adhesion to paper substrates while preserving the biodegradable nature of the coating material
Solution Approach 2:
The patent develops a multi-component composite material system combining polylactide, poly(butylene adipate terephthalate), and polycaprolactone. The synergistic interaction between these biodegradable polymers in optimized ratios enhances adhesion properties while maintaining environmental compatibility
3Object-generated harmful factors
If biodegradable polymers are used for extrusion coating, then environmental compatibility is improved, but suitability for high coating line speeds deteriorates
Solution Approach 1:
The patent adjusts the molecular weight and viscosity parameters of the biodegradable polymers, particularly selecting PCL with specific viscosity ranges. These parameter modifications enable the coating material to flow and adhere properly at high line speeds while maintaining biodegradability
Solution Approach 2:
The patent optimizes the local properties of the coating material by carefully selecting the viscosity and molecular weight characteristics of each polymer component. This local quality optimization ensures proper coating performance at high speeds without compromising the overall biodegradable nature of the material
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 polymer blend improves adhesion to substrates, reduces material waste, and maintains processability, enabling higher web speeds and production of durable, biodegradable packaging materials.
Implementation Method 1
modifying biodegradable polymer blends comprising at least one biodegradable polyester by adding polycaprolactone (PCL) having a specific molecular weight results in improved adhesion at high coating lines speed
Data Source
AI summary
The present invention relates to a biodegradable polymer blend based on a biodegradable aliphatic aromatic polyester and/or aliphatic polyester comprising: The blend comprises—10 to 80% by weight, based on the total weight of polyester a), polymer b) and polycaprolactone c), of at least one biodegradable polyester a) selected from the group consisting of aliphatic-aromatic polyesters, aliphatic polyesters, which are different from polymers b) and c), and mixtures thereof;—18 to 88% by weight, based on the total weight of polyester a), polymer b) and polycaprolactone c), of at least one polymer b), selected from the group consisting of polyhydroxyalkanoates, polylactides, polyglycolic acid and mixtures thereof;—2 to 72% by weight, based on the total weight of polyester a), polymer b) and polycaprolactone c), of at least one polycaprolactone c) having a viscosity number of at least 110 ml/g, in particular at least 150 ml/g, preferably at least 200 ml/g, especially at least 250 ml/g, as determined according to DIN 53728-3:1985-1; wherein the total weight of polyester a), polymer b) and polycaprolactone c) is at least 50% by weight, based on the total weight of the blend. The present invention relates to the use of the blend for coating substrates or for producing a rigid packaging article, to a mono-layered or multi-layered film comprising at least one layer comprising a biodegradable polymer blend, as defined hereinafter and to a process for coating a substrate layer. The present invention also relates to a laminate comprising at least one mono-layered or multi-layered film comprising at least one layer comprising a biodegradable polymer blend, as defined hereinafter, and to packaging materials.