Ionomer-PVA Coatings for Low-Energy Substrate Processing
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Solution Overview
Problem
Existing methods for forming coatings comprising blends of ionomers and poly(vinyl alcohol)s on substrates are complex and require rigorous conditions, such as high pressure and high shear processes, which are energy-intensive and pose safety concerns.
Innovation Solution
A method involving a blend composition of poly(vinyl alcohol) with a hydrolysis level of 85 to 93 mol % and an ionomer composition with 18 to 30 weight % copolymerized units of acrylic or methacrylic acid, neutralized to 50-70% carboxylic acid salts, applied as an aqueous dispersion or preformed film, allowing for coating at lower temperatures and pressures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If high pressure and high shear processes are used to form ionomer-poly(vinyl alcohol) coatings, then the coating can be formed, but the process becomes energy-intensive and poses safety concerns
Solution Approach 1:
The patent changes the process parameters by using lower temperatures (below boiling point of water) and reduced pressure conditions instead of high pressure and high shear processes. This allows the coating to be formed under milder conditions that are less energy-intensive and safer, while still achieving proper coating formation through controlled evaporation and bonding of the ionomer-poly(vinyl alcohol) blend.
2Ease of manufacture
If high pressure and high shear processes are used to form ionomer-poly(vinyl alcohol) coatings, then the coating can be formed, but safety concerns arise
Solution Approach 1:
The patent changes the process parameters by using lower temperatures (below boiling point of water) and reduced pressure conditions instead of high pressure and high shear processes. This allows the coating to be formed under milder conditions that are less energy-intensive and safer, while still achieving proper coating formation through controlled evaporation and bonding of the ionomer-poly(vinyl alcohol) blend.
3Reliability
If conventional ionomer dispersion methods are used, then coatings can be formed, but the processes are complex and require rigorous conditions
Solution Approach 1:
The patent merges the ionomer and poly(vinyl alcohol) into a single blend composition that can be applied together in one coating step. This combination approach simplifies the process by eliminating the need for separate coating steps and reducing the complexity of handling multiple materials and processes, while maintaining reliable coating formation through the synergistic properties of the blended composition.
4Manufacturing precision
If rigorous process conditions are used to form coatings, then the coating properties are improved, but energy consumption increases
Solution Approach 1:
The patent changes the process parameters by using lower temperatures (below boiling point of water) and reduced pressure conditions instead of high pressure and high shear processes. This allows the coating to be formed under milder conditions that are less energy-intensive and safer, while still achieving proper coating formation through controlled evaporation and bonding of the ionomer-poly(vinyl alcohol) blend.
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
This method simplifies the coating process, reduces energy consumption, and provides a waterproof, heat-sealable surface with improved printing properties and recyclable substrates, while maintaining the self-dispersibility and thermoplastic properties of the ionomers.
Implementation Method 1
The invention provides a method to form a coating comprising a blend of ionomer and poly(vinyl alcohol) on a substrate... providing a blend composition comprising... (a) a poly(vinyl alcohol) composition... and (b) an ionomer composition... coating the blend composition onto the substrate
Implementation Method 2
This method simplifies the coating process, reduces energy consumption, and provides a waterproof, heat-sealable surface
Implementation Method 3
provides a waterproof, heat-sealable surface
Data Source
AI summary
Disclosed are methods to form coatings on a substrate, the coatings comprising a blend of a poly(vinyl alcohol) composition comprising a poly(vinyl alcohol) characterized by (i) a hydrolysis level of from about 85 to about 93 mol % and a 4 weight % aqueous viscosity of 15 centipoise (cp) or less; or (ii) a hydrolysis level of about 95 mol % to 100%; and an ionomer comprising a parent acid copolymer that comprises ethylene and about 18 to about 30 weight % of acrylic acid or methacrylic acid, the acid copolymer having a melt flow rate from about 200 to about 1000 g/10 min., wherein about 50% to about 70% of the carboxylic acid groups of the copolymer are neutralized to carboxylic acid salts comprising potassium cations, sodium cations or combinations thereof. Multilayer structures comprising the blend composition on a substrate are also disclosed.