Multilayer Coating for Paper Substrate Water Oil Grease Resistance
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Solution Overview
Problem
Paper-based substrates have poor resistance to water, oil, and grease penetration, which compromises their mechanical strength and recyclability, and existing coatings like wax and polymer extrusion have limitations such as non-repulpability and temperature sensitivity.
Innovation Solution
A multilayer coating comprising a water-based inner primer, an intermediate polymeric extrusion coating, and a water-based top barrier coating, using low-density polyethylene and high-density polyethylene, along with inorganic fillers, to provide water, oil, and grease resistance while maintaining printability and gluability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If wax coating is applied to provide water resistance, then water resistance is improved, but recyclability and repulpability deteriorate
Solution Approach 1:
The coating is divided into multiple functional layers: a wax layer for water resistance, a polymer extrusion layer for barrier properties, and a water-based top coating for recyclability. Each layer performs a specific function, allowing the composite structure to achieve both water resistance and recyclability that single-layer coatings cannot provide
Solution Approach 2:
The invention uses a composite multilayer coating structure combining different materials (wax, polymer, and water-based coating) to achieve properties that individual materials cannot provide alone. The composite structure enables simultaneous water resistance, barrier properties, and recyclability
2Object-affected harmful factors
If polymer extrusion coating is applied to provide water-, oil- and grease-resistance, then barrier properties are improved, but temperature resistance deteriorates
Solution Approach 1:
The coating is segmented into layers with different temperature stabilities. The water-based top coating and primer layer remain stable at corrugation temperatures, while the intermediate polymer layer provides barrier properties. This segmentation allows the system to withstand corrugation temperatures without compromising barrier functionality
3Object-affected harmful factors
If coating is applied to enhance water resistance, then barrier properties are improved, but printability and gluability deteriorate
Solution Approach 1:
The coating system provides different properties at different locations and depths. The water-based top coating and primer layers maintain surface porosity and chemical reactivity for printability and gluability, while the intermediate polymer layer provides the water and grease barrier. This local differentiation of properties allows simultaneous achievement of barrier protection and surface functionality
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 effectively enhances the mechanical strength and barrier properties of paper-based substrates, ensuring resistance to elevated temperatures and abrasion, while allowing for recyclability and maintaining printability and gluability.
Implementation Method 1
The water-based inner primer coating may act as an adhesion promoter for the intermediate polymeric extrusion coating
Implementation Method 2
The intermediate polymeric extrusion coating may provide flexibility, water, oil and grease barrier properties
Implementation Method 3
The water-based top barrier coating may provide an additional water, oil and grease barrier properties onto the intermediate polymeric extrusion coating
Implementation Method 4
The water-based top barrier coating may act as a protective layer for the intermediate polymeric extrusion coating for corrugated applications
Data Source
AI summary
The present invention relates to a water-, oil- and grease-resistant multilayer coating for a paper-based substrate comprising a water-based inner primer coating, an intermediate polymeric extrusion coating, and a water-based top barrier coating, wherein a surface of the paper-based substrate coated therewith has water, oil and grease barrier properties, and wherein the paper-based substrate coated therewith is repulpable and recyclable.