Carrier-Free Oxygen Scavenging Masterbatch for Stable Catalyst Loading
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Solution Overview
Problem
Current oxygen scavenging compositions using transition metal catalysts require carriers, which increase costs and processing complexity, and are prone to degradation during high-temperature processing, while direct addition of powdered catalysts cause odor and content changes.
Innovation Solution
Development of oxygen scavenging master batch compositions comprising a transition metal composition and an oxygen scavenger without a polymer carrier, allowing for high load levels of transition metal catalysts in a solid form that can be easily handled and processed, eliminating the need for carriers and reducing degradation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If transition metal catalysts are used to accelerate oxygen scavenging rate, then oxygen scavenging efficiency is improved, but handling difficulty and degradation risk increase
Solution Approach 1:
The patent uses a polymer carrier as an intermediary substance to deliver the transition metal catalyst. The carrier protects the catalyst from direct exposure to moisture and oxygen during handling, while still allowing it to function when incorporated into the packaging material. This resolves the contradiction by mediating between the need for catalyst activity and the need for stable handling.
Solution Approach 2:
The patent changes the physical state and concentration parameters of the catalyst system. By formulating the catalyst at controlled concentrations within the polymer carrier matrix, the system transitions from highly reactive pure catalyst to a stabilized formulation that maintains scavenging efficiency while improving handling characteristics through parameter optimization.
2Manufacturing precision
If carrier materials are used to distribute catalyst evenly, then distribution uniformity is improved, but cost and processing complexity increase
Solution Approach 1:
The patent merges the catalyst and polymer carrier into a single integrated formulation rather than treating them as separate components. This combination eliminates the need for additional processing steps to separate or recombine components, reducing overall processing complexity while maintaining uniform distribution through the inherent mixing capability of the formulation process.
Solution Approach 2:
The polymer carrier serves multiple functions simultaneously: it acts as a distribution medium for uniform catalyst dispersion, provides structural support for handling, and serves as part of the final packaging material matrix. This multi-functionality reduces the need for separate carrier removal or additional processing steps, simplifying the overall process.
3Productivity
If high load levels of transition metal catalyst are used, then oxygen scavenging rate is improved, but degradation during processing increases
Solution Approach 1:
The patent applies beforehand cushioning by incorporating the transition metal catalyst into a polymer carrier formulation before processing. This pre-protection strategy cushions the catalyst against degradation during high-temperature processing by providing a protective matrix that stabilizes the catalyst while still allowing it to function at high load levels for accelerated oxygen scavenging.
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 provides a cost-effective, easy-to-handle, and stable oxygen scavenging system that maintains packaging integrity by minimizing degradation and odor issues, ensuring effective oxygen scavenging in packaging materials.
Implementation Method 1
oxygen scavenging compositions... when oxygen permeates a polymeric composition or article, it can cause oxidative damage to the contents of the package
Implementation Method 2
it is advantageous to use transition metal catalysts, such as cobalt II neodecanoate ('CoNDA') or octoate, in order to accelerate the scavenging rate
Data Source
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AI summary
The disclosure relates to oxygen scavenging compositions, methods of making the compositions, articles prepared from the compositions, and methods of making the articles. This abstract is intended as a scanning tool for purposes of searching in the particular art and is not intended to be limiting of the present invention.