Polyolefin Dispersion in Cellulose Articles for Barrier and Recyclability
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Solution Overview
Problem
Current cellulose-based compositions face challenges in enhancing specific properties like oil and grease resistance, water resistance, and strength while maintaining softness, and these improvements often negatively impact other attributes, such as recyclability and manufacturing efficiency.
Innovation Solution
Incorporating an aqueous polyolefin dispersion comprising ethylene-based or propylene-based thermoplastic polymers, a polymeric stabilizing agent, and water into cellulose-based articles, which can be applied during the papermaking process to form a paper web with improved properties without adverse effects on recyclability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If fluorocarbon treatment is used to improve oil and grease resistance, then oil and grease resistance is improved, but consumer perception deteriorates
Solution Approach 1:
The patent changes the chemical composition parameters by using polyolefin dispersions (ethylene or propylene-based) instead of fluorocarbons. This substitution maintains the oil and grease resistance function while eliminating the consumer perception issues associated with fluorocarbon treatments.
Solution Approach 2:
The patent employs a disposable-like approach by using a polyolefin dispersion coating that provides the necessary oil and grease resistance for single-use or limited-use packaging applications, eliminating the need for durable, potentially harmful fluorocarbon treatments.
2Object-affected harmful factors
If LDPE coating is used to improve oil and grease resistance, then oil and grease resistance is improved, but coating thickness increases and costs increase
Solution Approach 1:
The patent changes the dispersion composition parameters (polymer type, stabilizing agent concentration, particle size distribution) to achieve effective oil and grease resistance with reduced coating thickness compared to traditional LDPE coatings.
Solution Approach 2:
The patent uses a composite dispersion system combining polyolefin polymers with specific stabilizing agents to create a coating that provides superior oil and grease resistance at thinner applications compared to conventional LDPE coatings alone.
3Object-affected harmful factors
If wax coatings are used to improve water resistance, then water resistance is improved, but recyclability deteriorates
Solution Approach 1:
The patent changes the coating material from wax to polyolefin dispersion, adjusting the chemical parameters to achieve comparable water resistance while improving recyclability. The polyolefin-based coating can be more easily separated and processed in recycling streams.
Solution Approach 2:
The patent employs a coating system designed for packaging applications where the article may be disposed of, using polyolefin dispersion that provides adequate water resistance for the intended service life while being more environmentally compatible than wax coatings.
4Object-affected harmful factors
If polymer coating is applied after forming the paper to improve specific properties, then desired properties are improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies the polyolefin dispersion coating during the papermaking process itself (at the wet end or in the dryer section) rather than as a separate post-forming operation. This preliminary action integrates the coating step into the existing manufacturing flow, reducing overall process complexity.
Solution Approach 2:
The patent merges the coating application with the papermaking process by incorporating the polyolefin dispersion into the paper web formation or drying stages, combining two operations (papermaking and coating) into a single integrated process.
5Object-affected harmful factors
If coating thickness is increased to improve water resistance, then water resistance is improved, but manufacturing costs increase
Solution Approach 1:
The patent optimizes the dispersion formulation parameters (polymer molecular weight, stabilizing agent type and concentration, particle size) to achieve maximum water resistance at minimum coating thickness, improving material efficiency and reducing costs.
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 achieves enhanced oil and grease resistance, water resistance, controlled coefficients of friction, thermal embossability, and improved strength and softness in cellulose-based articles, while maintaining recyclability and reducing manufacturing costs.
Implementation Method 1
Incorporating an aqueous polyolefin dispersion comprising ethylene-based or propylene-based thermoplastic polymers, a polymeric stabilizing agent, and water into cellulose-based articles, which can be applied during the papermaking process to form a paper web with improved properties
Implementation Method 2
Incorporating an aqueous polyolefin dispersion comprising ethylene-based or propylene-based thermoplastic polymers, a polymeric stabilizing agent, and water into cellulose-based articles, which can be applied during the papermaking process to form a paper web with improved properties
Data Source
AI summary
In one embodiment, the present invention provides a method of forming a cellulose article having a specific volume of less than 3 cc/gm. The method includes the step of incorporating cellulose fibers with a compound, wherein the compound includes an aqueous dispersion. The aqueous dispersion may have at least one polymer selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof; at least one polymeric stabilizing agent; and water. In certain embodiments, a combined amount of the at least one polymer and the at least one stabilizing agent comprises about 25 to about 74 volume percent of the aqueous dispersion.