Multilayer Coating for Paper Substrate Flexibility

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Solution Overview

Problem

Conventional paper and paperboard coatings struggle to provide effective oil and grease resistance, oxygen barrier properties, and water vapor barrier properties while maintaining flexibility, often becoming brittle or stiff due to high plasticizer use, which compromises their barrier effectiveness.

Innovation Solution

A multilayer coating system is applied to paper or paperboard, comprising a first and second water vapor barrier layer formed from a latex-based coating composition, with a biopolymer barrier layer positioned between them, using a low amount of plasticizer to enhance flexibility and maintain barrier properties even under mechanical stress.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If high amounts of plasticizers are incorporated into the coating to increase flexibility, then the flexibility of the coating is improved, but the oxygen barrier properties are lost and resistance to water vapor penetration decreases

Engineering Contradiction:

ImproveflexibilityVSAvoidbarrier properties

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The coating is divided into multiple functional layers: a polymer layer providing flexibility and a biopolymer layer providing barrier properties. This segmentation allows each layer to perform its specialized function without compromising the other, resolving the contradiction between flexibility and barrier effectiveness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite coating system combining different materials (polymer and biopolymer) with complementary properties. The polymer provides flexibility while the biopolymer provides barrier properties, creating a composite material that achieves both flexibility and effective barrier performance simultaneously.

Inventive Principle:

Principle #40Composite materials

2Reliability

If large amounts of coating agents such as latexes, gelatins, starches, modified starches, and vegetable proteins are used to impart oil and grease resistance, then OGR properties are improved, but the treated paper becomes too stiff and brittle for many uses

Engineering Contradiction:

Improveoil and grease resistanceVSAvoidflexibility

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention changes the chemical composition parameters of the coating by using specific biopolymers (starch, gelatin, or protein) in controlled amounts combined with polymer plasticizers. This parameter optimization provides adequate OGR protection while maintaining flexibility, avoiding the brittleness caused by excessive coating agents.

Inventive Principle:

Principle #35Parameter changes

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 multilayer coating achieves improved oil and grease resistance, oxygen barrier properties, and water vapor barrier properties, retaining effectiveness after mechanical stress, such as creasing and folding, with reduced plasticizer usage, ensuring flexibility and enhanced performance.

Implementation Method 1

the biopolymer barrier layer can include a biopolymer, a plasticizer, and a pigment

Methodology Applied

Scientific EffectAdsorption: Adsorption

Implementation Method 2

water vapor barrier layers that sandwich biopolymer barrier layers

Methodology Applied

Scientific EffectPhysical barrier:

Implementation Method 3

a first and second water vapor barrier layer formed from a latex-based coating composition

Methodology Applied

Scientific EffectFilm formation:

Data Source

PatentEP2344698B1Multilayer coating for paper based substrate

Publication Date: 2017.02.15 DOW GLOBAL TECHNOLOGIES LLC

AI summary

Embodiments include a coated paper or paperboard with a multilayer coating and methods of forming a coated paper or paperboard with the multilayer coating. The multilayer coating includes a first water vapor barrier layer, a biopolymer barrier layer, and a second water vapor barrier layer and provides the paperboard with improved oil and grease resistant properties, oxygen barrier properties, and water vapor barrier properties.