Polyolefin Dispersion Coating for Ultra-Low-Weight Paper Barriers
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Solution Overview
Problem
Existing technologies struggle to achieve ultra-low coat weights of <10 g/m2 with polyolefin coatings on paper substrates while maintaining desirable moisture vapor transmission rate (MVTR) and coefficient of friction (CoF) properties, especially for flexible packaging applications requiring >85 wt % fiber recycling.
Innovation Solution
A composition comprising an aqueous dispersion of poly-C2-C3-olefin particles, a dispersant copolymer of ethylene and a carboxylic acid monomer, and a C5-C26-alkyl primary fatty amide, with specific concentration ranges, is used to create ultra-thin coatings on paper substrates, enhancing MVTR and CoF properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin coating is applied to enhance barrier performance and heat-seal properties, then coating functionality is improved, but achieving ultra-low coat weights of 2 g/m2 or less remains elusive
Solution Approach 1:
The patent changes the chemical composition parameters of the polyolefin dispersion by incorporating specific additives (fatty amide at 0.1-5 wt%, carboxylic acid dispersant at 1-20 wt%) to modify the coating's barrier properties and heat-seal characteristics, enabling ultra-low coat weights while maintaining functionality
Solution Approach 2:
The patent creates a composite polyolefin dispersion system combining polyolefin particles with specific additives and dispersants, where the synergistic interaction of components enables achieving ultra-low coat weights while maintaining barrier performance and heat-seal properties
2Quantity of substance
If waterborne polyolefin emulsion is applied to achieve ultra-thin coatings, then coat weight is reduced, but meeting targets for moisture vapor transmission rate and coefficient of friction remain elusive
Solution Approach 1:
The patent modifies the chemical composition parameters by adding specific fatty amide additives and carboxylic acid dispersants to the waterborne polyolefin emulsion, which changes the coating's surface properties and barrier characteristics to meet MVTR and CoF targets at ultra-low coat weights
Solution Approach 2:
The patent uses carboxylic acid dispersants as intermediary agents that facilitate proper distribution and adhesion of polyolefin particles, enabling uniform coating at ultra-low weights while maintaining functional properties like MVTR and CoF
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 composition achieves coat weights in the range of 1-12 g/m2 with improved MVTR and CoF, meeting the requirements for recyclable and flexible packaging applications.
Implementation Method 1
a dispersant which is a copolymer of ethylene and a carboxylic acid monomer or a salt thereof
Implementation Method 2
a dispersant which is a copolymer of ethylene and a carboxylic acid monomer or a salt thereof
Implementation Method 3
a C5-C26-alkyl primary fatty amide
Implementation Method 4
a C5-C26-alkyl primary fatty amide
Implementation Method 5
Barrier performance of paper is known to be enhanced with polyolefin coatings
Implementation Method 6
applying a waterborne polyolefin emulsion onto the paper substrate, followed by curing
Data Source
AI summary
The present invention relates to a composition comprising a) poly-C2-C3-olefin particles: b) a dispersant: and c) a C5-C26-alkyl primary fatty amide. The composition of the present invention is useful for preparing coatings on paper with desirable moisture vapor transition rate and coefficient of friction properties.