Biodegradable Polyester Paper Coating Melt Resonance Control
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Solution Overview
Problem
Existing methods for coating paper with polyesters and polyester mixtures result in thick, slow-forming layers, which are not suitable for efficient paper coating.
Innovation Solution
The use of biodegradable aliphatic-aromatic polyesters with specific molecular compositions and melt volume rates, combined with other biodegradable polymers like polylactic acid, to create polymer mixtures that enhance flowability and suitability for paper coating, allowing for thinner, more stable layers with reduced melt resonance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional polyesters and polyester mixtures are used for paper coating, then coating layers can be formed, but the layers become thick and form slowly, reducing coating efficiency
Solution Approach 1:
The patent changes the chemical composition parameters of the polyester by specifying precise molar ratios of dicarboxylic acid derivatives (40-70 mol%) to terephthalic acid derivatives (30-60 mol%), and controlling the melt volume rate to 3-50 cm³/10 min. These parameter changes optimize the polymer's flow characteristics and coating performance, enabling thinner layers to form faster without compromising quality
Solution Approach 2:
The patent creates a composite coating system by combining biodegradable aliphatic-aromatic polyesters with specific properties (controlled MVR, molecular weight, and composition) with paper substrates. This composite approach optimizes the interaction between coating material and substrate, improving coating efficiency and reducing required layer thickness
2Quantity of substance
If coating layers are made thinner to reduce material usage, then material efficiency improves, but coating stability and uniformity deteriorate
Solution Approach 1:
The patent optimizes multiple parameters simultaneously: molecular weight of the polyester, melt volume rate (3-50 cm³/10 min), and chemical composition ratios. These coordinated parameter changes ensure that even at reduced thickness, the coating maintains stability and uniformity by controlling flow behavior and adhesion properties
Solution Approach 2:
The patent introduces dynamic control of coating parameters during the coating process, allowing adjustment of flow rates, temperatures, and application speeds to maintain coating stability regardless of layer thickness. This dynamic approach enables thin coatings to form uniformly without defects
3Productivity
If high web speeds are used to increase productivity, then coating efficiency improves, but melt resonance occurs, disrupting coating quality
Solution Approach 1:
The patent modifies the rheological parameters of the polyester by controlling its melt volume rate (3-50 cm³/10 min) and molecular weight, which changes the melt's viscosity and flow characteristics. These parameter changes reduce the tendency for melt resonance at high web speeds, allowing faster coating without quality loss
Solution Approach 2:
The patent converts the potential harmful effect of high-speed coating (melt resonance) into a benefit by carefully selecting polyester properties that actually suppress resonance. The specific MVR range and composition create a melt that remains stable even at high velocities, turning the high-speed condition from problematic to advantageous
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 described process enables the production of thinner, more stable paper coatings with improved flowability and adhesion, reducing material usage and preventing melt resonance, thus achieving higher web speeds and better coating performance.
Implementation Method 1
The use of biodegradable aliphatic-aromatic polyesters with specific molecular compositions and melt volume rates, combined with other biodegradable polymers like polylactic acid, to create polymer mixtures that enhance flowability and suitability for paper coating
Implementation Method 2
The described process enables the production of thinner, more stable paper coatings with improved flowability and adhesion
Data Source
AI summary
The present invention relates to a process for coating paper, wherein the coating material used is a biodegradable, aliphatic-aromatic polyester having a melt volume rate (MVR) according to EN ISO 1133 (190° C., 2.16 kg weight) of from 3 to 50 cm3/10 min.