Dual-Layer Coated Substrate Water Oil Barrier
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Solution Overview
Problem
Existing coated substrates are ineffective in preventing the permeation of both water and oil, which can lead to contamination and spoilage of packaged products, and often require higher coat weights to achieve adequate barrier properties.
Innovation Solution
A substrate coated with a first layer of an alcohol-based binder and an inorganic particulate material, and a second layer of a latex binder and talc, where the first layer is in direct contact with the substrate and the second layer is in contact with the first layer, enhancing both water and oil barrier properties while reducing coat weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single coating composition is used to coat a substrate, then the coating process is simple, but the coating cannot effectively prevent the permeation of both water and oil
Solution Approach 1:
The coating system is divided into two distinct layers: a first coating composition containing an alcohol-based binder and inorganic particulate material for oil barrier properties, and a second coating composition containing a latex binder and phyllosilicate for water barrier properties. Each layer performs a specific barrier function, and together they provide comprehensive protection against both water and oil permeation through the substrate.
2Reliability
If higher coat weights are used to achieve adequate barrier properties, then water and oil permeation is better prevented, but the coat weight increases
Solution Approach 1:
Each coating layer is formulated with specific materials optimized for its particular barrier function. The first coating uses alcohol-based binder with inorganic particulate material specifically for oil resistance, while the second coating uses latex binder with phyllosilicate specifically for water resistance. This localized optimization allows each thin layer to perform its specific barrier function efficiently, achieving comprehensive protection without requiring excessive coat weight.
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 dual-layer coating significantly reduces moisture and oil vapour transmission rates, providing improved barrier properties for both water and oil, protecting the substrate from detrimental influences and allowing for reduced coat weights, while being easily recyclable.
Implementation Method 1
the coating composition reduces or prevents the permeation of gases, vapours and liquids through the substrate
Data Source
AI summary
A substrate coated with a first coating composition comprising an alcohol-based binder and an inorganic particulate material and a second coating composition comprising a latex binder and a phyllosilicate, and methods for making said coated substrate.