Cellulose Additive Composition for Barrier Strength Without Coatings
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Solution Overview
Problem
Current cellulose-based compositions face challenges in enhancing specific properties like oil and grease resistance, water resistance, and strength without adversely affecting other attributes, and also struggle with recycling and reclamation in the papermaking process.
Innovation Solution
Incorporating an aqueous polyolefin dispersion comprising ethylene-based or propylene-based thermoplastic polymers, partially or fully neutralized ethylene-acid copolymers, and neutralizing agents into cellulose-based articles to improve properties such as oil and grease resistance, water resistance, and strength, while maintaining softness and enabling recycling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fluorocarbon treatment is used to improve oil and grease resistance, then oil and grease resistance is improved, but consumer perception deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by using hydrophobic and oleophobic additives instead of fluorocarbons, achieving the same oil and grease resistance function without the negative consumer perception associated with fluorocarbon treatments
Solution Approach 2:
The patent employs alternative additive compositions that are perceived more favorably by consumers while maintaining the desired oil and grease resistance properties, effectively replacing the problematic fluorocarbon treatment with shorter-lived but more acceptable alternatives
2Object-affected harmful factors
If LDPE coating is used to improve oil and grease resistance, then oil and grease resistance is improved, but coating thickness increases
Solution Approach 1:
The patent changes the approach by using chemical additives incorporated into the papermaking process rather than physical polymer coatings, achieving oil and grease resistance with minimal to no coating thickness
Solution Approach 2:
The patent extracts the oil and grease resistance function from the polymer coating layer and integrates it directly into the paper matrix through additive incorporation, eliminating the need for separate thick coating layers
3Object-affected harmful factors
If wax coating is used to improve water resistance, then water resistance is improved, but recyclability deteriorates
Solution Approach 1:
The patent changes from physical wax coatings to chemical additive compositions that can be incorporated into the papermaking process, providing water resistance while maintaining the paper's recyclability characteristics
Solution Approach 2:
The patent merges the water resistance function with the papermaking process itself by incorporating hydrophobic additives during fiber suspension preparation, eliminating the separate wax coating step that hinders recycling
4Strength
If polymer coating is used to improve strength, then strength is improved, but softness deteriorates
Solution Approach 1:
The patent changes the method of strength enhancement from adding external polymer coatings to using additive compositions that modify the paper matrix properties, achieving strength improvement while preserving softness through controlled chemical interactions
Data Source
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AI summary
In one embodiment, the present invention provides a method of forming a cellulose article having a specific volume of less than 3 cc/gm. The method includes the step of incorporating cellulose fibers with a compound, wherein the compound includes an aqueous dispersion. The aqueous dispersion may have at least one polymer selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof; at least one polymeric stabilizing agent; and water. In certain embodiments, a combined amount of the at least one polymer and the at least one stabilizing agent comprises about 25 to about 74 volume percent of the aqueous dispersion.