Organic Particle Barrier Coating for Flexible Packaging
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Solution Overview
Problem
Conventional barrier films with inorganic particle dispersed phases experience significant viscosity increases at low particle concentrations, making it difficult to form a uniform and thin barrier layer, particularly when using gravure coating technology, which hinders the production of effective moisture vapor and oxygen barrier films.
Innovation Solution
A composite film with a polymeric base layer and a barrier layer comprising discrete particles of a water-insoluble organic polymer dispersed in a continuous matrix of a water-soluble organic polymer, where the coating composition includes a crosslinking agent and surfactant, is deposited and heated to crosslink the polymers, reducing viscosity and enhancing barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If inorganic particles are dispersed in the polymer matrix to improve barrier properties, then water vapor and oxygen transmission resistance is improved, but viscosity increases significantly at low particle concentrations
Solution Approach 1:
The patent changes the chemical composition parameters of the dispersed particles from inorganic materials to organic polymers with specific solubility characteristics. This parameter change resolves the viscosity issue while maintaining barrier properties, as organic polymer particles do not exhibit the same ionic charge effects that cause viscosity spikes in inorganic particle systems.
Solution Approach 2:
The patent creates a composite barrier layer combining water-insoluble organic polymer particles (for barrier properties) dispersed in a water-soluble organic polymer matrix. This composite structure achieves both high barrier performance and manageable viscosity, overcoming the limitations of using inorganic particles alone.
2Reliability
If inorganic particles are used to create discontinuities in the matrix, then the path of water and oxygen molecules is blocked, but handling of the solution becomes difficult due to high viscosity
Solution Approach 1:
The patent changes the particle material parameter from inorganic to organic polymer, which fundamentally alters the interaction between particles and the polymer matrix. This change eliminates the ionic charge effects that make inorganic particle solutions difficult to handle, while preserving the particle dispersion mechanism that blocks molecular transmission paths.
3Manufacturing precision
If a uniform and thin barrier layer is formed, then transmission resistance is improved, but high viscosity prevents formation of uniform thin layers
Solution Approach 1:
The patent employs a composite system where water-insoluble organic polymer particles are dispersed in a water-soluble organic polymer continuous phase. This composite structure provides the particle dispersion needed for barrier properties while the water-soluble matrix ensures low viscosity and uniform coating formation, resolving the contradiction between uniformity and viscosity.
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 flexible film with improved moisture vapor and oxygen transmission resistance, suitable for packaging applications, without the viscosity issues associated with inorganic particle dispersions, allowing for higher solids content and better barrier properties.
Implementation Method 1
The coating composition is heated to crosslink the barrier layer polymers and evaporate solvent
Implementation Method 2
heated to crosslink the barrier layer polymers
Data Source
AI summary
A moisture vapor and oxygen transmission resistant flexible film has a polymeric base layer and a barrier layer of discrete particles of a first organic polymer dispersed throughout a matrix of a second organic polymer. Preferably, the first and second polymers are water insoluble and water soluble, respectively. The barrier layer is formed by depositing onto the base layer a coating composition of finely divided insoluble organic polymer particles suspended in an aqueous solution of the water soluble organic polymer, a crosslinking agent and surfactant. The coating composition is heated to crosslink the barrier layer polymers and evaporate solvent to provide a barrier film suitable for packaging applications. Optionally, the film can be metalized to increase barrier properties.