Polyolefin-Coated Paper for Low Coat Weight Moisture Barrier
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Solution Overview
Problem
Existing technologies struggle to achieve ultra-low coat weights of <10 g/m2 for polyolefin coatings on paper substrates while meeting moisture vapor transmission rate (MVTR) and coefficient of friction (CoF) requirements, especially in flexible packaging applications requiring >85 wt % fiber recycling.
Innovation Solution
A paper substrate coated with a dry coating comprising poly-C2-C3-olefin, a dispersant, and a C5-C26-alkyl primary fatty amide, applied as an aqueous dispersion and dried at elevated temperatures, achieving coat weights between 1 g/m2 to 20 g/m2 with improved MVTR and CoF properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyolefin coating is applied to enhance barrier properties, then moisture vapor transmission rate improves, but coating areal density increases
Solution Approach 1:
The invention changes the chemical composition parameters of the coating by incorporating specific additives (fatty acid amides and silane-modified polyethylene wax) into the polyolefin matrix. This compositional modification allows the coating to achieve superior moisture vapor barrier properties at lower areal densities compared to conventional polyolefin coatings
Solution Approach 2:
The invention creates a composite coating material by combining polyolefin with fatty acid amides and silane-modified polyethylene wax. This composite structure synergistically enhances the barrier properties while maintaining low areal density, resolving the contradiction between performance and material quantity
2Quantity of substance
If coating areal density is reduced to meet recycling requirements, then fiber recycling content increases, but barrier performance deteriorates
Solution Approach 1:
By modifying the chemical composition of the coating with specific additives, the invention achieves enhanced barrier performance per unit mass, allowing ultra-low areal densities (1-20 g/m2) that meet recycling requirements while maintaining superior moisture vapor transmission rate properties
Solution Approach 2:
The invention creates localized enhancement of barrier properties through the strategic distribution of fatty acid amides and silane-modified polyethylene wax within the coating matrix, achieving high performance at minimal material thickness
3Quantity of substance
If ultra-thin coating is applied to reduce coat weight, then material usage decreases, but coefficient of friction becomes difficult to control
Solution Approach 1:
The invention modifies the surface properties of the ultra-thin coating by incorporating fatty acid amides, which alter the surface chemistry and friction characteristics. This allows control of coefficient of friction at coat weights as low as 1-20 g/m2, where conventional coatings fail to provide adequate friction control
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 desirable MVTR and CoF properties, enabling recyclable paper substrates suitable for flexible packaging with ultra-low coat weights and high fiber recycling potential.
Implementation Method 1
applied as an aqueous dispersion and dried at elevated temperatures
Data Source
AI summary
The present invention relates to an article comprising paper superposed with a coating comprising a poly-C2-C3-olefin. a dispersant, and a C5-C26-alkyl primary fatty amide: wherein the coating has a coat weight in the range of from 1 g/m2 to 20 g/m2. The article of the present invention has desirable moisture vapor transition rate and coefficient of friction properties.