Omniphobic Polyolefin Coating for Paper Barrier
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Solution Overview
Problem
Existing omniphobic barrier coatings for paper and paperboard require ammonia or organic bases as neutralizing agents, which pose environmental and safety concerns, and often need functionalized ethylene copolymers for effective oil/grease resistance, leading to emissions and regulatory issues.
Innovation Solution
A single-layered omniphobic coating process using an aqueous dispersion of polyolefin particles, comprising a copolymer dispersant with an acid value of 130 or less, a non-functionalized ethylene-co-alkene base polymer, and a hard neutralizing agent like potassium hydroxide, excluding low-boiling-point organic bases, to form a cured film with enhanced water and oil barrier properties without adhesion issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If ammonia or organic bases are used as neutralizing agents in omniphobic barrier coatings, then effective oil and grease resistance is achieved, but environmental emissions and safety issues arise
Solution Approach 1:
The patent changes the chemical parameter of the neutralizing agent from ammonia or low-boiling organic bases to high-boiling organic bases (boiling point ≥250°C), specifically tertiary amines like triethylamine, tributylamine, or triisopropylamine. This parameter change maintains the neutralization function while eliminating harmful emissions and safety issues associated with low-boiling agents.
Solution Approach 2:
The patent employs a base polymer system using ethylene-co-(meth)acrylic acid copolymer that neutralizes carboxylic acid groups in the dispersant through in-situ reaction during coating application. This eliminates the need for separate neutralizing agent applications and reduces overall chemical usage while achieving effective omniphobic performance.
2Reliability
If functionalized ethylene copolymers are used to achieve oil resistance, then barrier performance is improved, but emissions and regulatory compliance issues occur
Solution Approach 1:
The patent creates a composite coating system combining a non-functionalized ethylene copolymer base polymer with a carboxylic acid-containing dispersant. The composite achieves omniphobic performance through the synergistic interaction between the hydrophobic polyolefin matrix and the carboxylic acid groups that provide oil resistance, eliminating the need for separately applied functionalized copolymers.
Solution Approach 2:
The patent merges the functions of base polymer, dispersant, and neutralizing agent into a single integrated coating composition. The base polymer provides structural framework, the dispersant provides oil resistance through carboxylic acid groups, and the high-boiling amine neutralizing agent maintains stability while enabling effective barrier performance against both water and oil.
3Quantity of substance
If a thin coating is applied to reduce material usage, then coating efficiency is improved, but adequate barrier coverage may be compromised
Solution Approach 1:
The patent optimizes the molecular weight and composition parameters of the ethylene copolymer base polymer and dispersant to achieve maximum barrier efficiency at minimal thickness. The specific ratio of ethylene to (meth)acrylic acid units in the dispersant and the melt flow index are controlled to ensure proper film formation and barrier performance at thin coating weights.
Solution Approach 2:
The composite nature of the coating system, combining hydrophobic polyolefin with carboxylic acid-functionalized dispersant and high-boiling amine, creates a highly efficient barrier structure that provides omniphobic protection at reduced thickness compared to conventional single-polymer coatings.
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 solution provides a thin, effective omniphobic film with low water uptake and high oil resistance, eliminating the need for undesirable neutralizing agents and functionalized polymers, ensuring compliance with environmental regulations and improving coating performance.
Implementation Method 1
The composition is applied to paper or paperboard and heated to form a cured film that provides water and oil barrier properties
Implementation Method 2
a single layered coating of an omniphobic barrier layer that provides a barrier to water and oil
Implementation Method 3
heating the composition to form a cured film
Data Source
AI summary
The present invention relates to an article and a method for its preparation; the article comprises a cured polymeric film superposing paper or paperboard. The polymeric film is derived from a dispersion which comprises:a) a dispersant which is a copolymer with an acid value of 130 or less, comprising structural units of ethylene and a carboxylic acid monomer, wherein the copolymer has a melt flow index in the range of from 50 to 2000 g/10 min at 190° C./2.16 kg; wherein the weight-to-weight ratio of structural units of ethylene to carboxylic acid monomer is in the range of from 95:5 to 70:30; and wherein the dispersant has a concentration in the range of from 9 to 50 weight percent based on the weight of polymer solids in the dispersion;b) a base polymer comprising non-functionalized ethylene-co-alkene copolymers, wherein the weight-to-weight ratio of the structural units of ethylene to alkene is in the range of from 99.8:0.2 to 50:50; andc) a neutralizing agent which is a hard base and excludes an organic base having a boiling point of less than 250° C.; wherein the concentration of the neutralizing agent is sufficient to neutralize at least half of the carboxylic acid groups associated with the dispersion composition.The article of the present invention is useful as a barrier to a wide range of hydrophobic and hydrophilic materials.