Molecularly self-assembling nanocomposite barrier coating for gas barrier application and flame retardancy
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Solution Overview
Problem
Current gas barrier technologies for food packaging and OLED protection are either expensive, opaque, or require multiple layers, failing to provide sufficient oxygen transmission rate (OTR) and transparency, while also generating waste and using harmful chemicals for flame retardancy.
Innovation Solution
A self-assembling highly ordered polymer nanocomposite coating is formed using a water dispersible polymer with polar or ionic side groups and platy nanoparticles, applied in bilayers with sequential drying to achieve high gas barrier and flame retardancy without sacrificing transparency, using a process that minimizes processing steps and waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If aluminized coatings are used on polymer substrates for gas barrier, then barrier properties are improved, but transparency is lost and cost increases
Solution Approach 1:
The patent uses ultrathin inorganic barrier layers (few nanometers thick) deposited on flexible polymer substrates. These thin films provide effective gas barrier properties while maintaining transparency, unlike thick aluminized coatings. The thin film structure allows light transmission while still blocking gas molecules through the tortuous path mechanism.
Solution Approach 2:
The patent creates composite structures combining organic polymer matrices with inorganic barrier layers (such as silicon oxide, silicon nitride, or aluminum oxide). This composite approach provides both the flexibility and transparency of polymers and the gas barrier properties of inorganic materials, resolving the contradiction between barrier performance and transparency.
2Reliability
If multiple layer structures are used to improve barrier properties, then oxygen transmission rate is reduced, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent segments the barrier function into multiple ultrathin inorganic layers deposited on a single polymer substrate. Instead of using multiple thick polymer layers, the invention uses several nanometer-thick inorganic coatings, each contributing to the overall barrier performance while maintaining a relatively simple single-substrate structure.
Solution Approach 2:
The patent transitions from thickness-based barrier protection (multiple thick layers) to surface-based barrier protection (multiple ultrathin surface coatings). By depositing inorganic layers in the nanometer scale on the substrate surface, the invention achieves high barrier properties without increasing the overall device complexity or manufacturing complexity significantly.
3Object-affected harmful factors
If conventional flame retardant chemicals are used, then flame retardancy is achieved, but harmful factors are introduced
Solution Approach 1:
The patent employs inorganic oxide layers (such as silicon oxide, aluminum oxide) that form protective barriers during combustion. These inorganic coatings are inherently flame retardant without requiring additional toxic chemical additives, providing flame protection through their physical barrier properties and high thermal stability.
Solution Approach 2:
The patent utilizes the high thermal stability and flame resistance of inorganic oxide materials to protect the organic polymer substrate from combustion. The inorganic layers act as thermal barriers, preventing oxygen and heat penetration, thereby converting the potential harm of polymer flammability into a benefit of enhanced flame retardancy without toxic additives.
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 coating achieves extremely low oxygen transmission rates and flame retardancy while maintaining transparency, extending the shelf life of food and protecting OLEDs from degradation, with potential for direct application on fruits and vegetables, and reduced environmental impact.
Implementation Method 1
The coated substrate may further comprise a platy nanoparticle with a large aspect ratio that may have small ions or molecules on their surfaces that can readily be exchanged through ion exchange or ion-dipole bonding
Implementation Method 2
The coated substrate may further comprise a platy nanoparticle with a large aspect ratio that may have small ions or molecules on their surfaces that can readily be exchanged through ion exchange or ion-dipole bonding
Implementation Method 3
A self-assembling highly ordered polymer nanocomposite coating is formed using a water dispersible polymer with polar or ionic side groups and platy nanoparticles
Implementation Method 4
The coating achieves extremely low oxygen transmission rates and flame retardancy while maintaining transparency
Implementation Method 5
A self-assembling highly ordered polymer nanocomposite coating is formed using a water dispersible polymer with polar or ionic side groups and platy nanoparticles, applied in bilayers with sequential drying to achieve high gas barrier and flame retardancy
Data Source
AI summary
Disclosed is a transparent self-assembling polymer clay nanocomposite coating that is useful in food, drink and electronic packaging as a gas barrier and on textiles and clothing as a flame retardant coating. The coating includes two main components a water dispersible polymer and a sheet like nanoparticle. The coatings may be applied to any substrate. The coatings are applied sequentially with polymer being applied first followed by the nanoparticles. This sequence results in the self-assembly of a highly ordered nanocomposite film that exhibits high barrier properties and flame retardancy. The desired level of gas barrier or flame retardancy desired can be adjusted by the number of bilayers applied.