Recyclable Paper Barrier Laminate with Water-Soluble Coating

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Solution Overview

Problem

Conventional paper-based packaging struggles with poor barrier properties, leading to issues with moisture, oxygen, and grease transmission, which can affect product integrity and environmental sustainability due to the need for non-biodegradable coatings that hinder recyclability and biodegradability.

Innovation Solution

A recyclable paper barrier laminate is developed, comprising a water-soluble polymeric layer, a water-dispersible barrier layer made from hydrophilic nanoplatelets, and a second water-soluble polymeric layer, which are applied using specific methods to ensure compatibility with industrial recycling and composting, while maintaining biodegradability if improperly disposed.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a polyethylene coating is added to improve barrier properties, then moisture and gas barrier properties are improved, but recyclability in commercial paper recycling systems deteriorates

Engineering Contradiction:

Improvebarrier propertiesVSAvoidrecyclability

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the chemical composition parameters of the coating layer by using water-soluble polymers (such as polyvinyl alcohol) instead of conventional polyethylene. This parameter change allows the coating to dissolve during paper recycling, resolving the contradiction between providing barrier properties and maintaining recyclability.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates a composite coating structure combining water-soluble polymers with hydrophilic nanoplatelets. This composite material provides enhanced barrier properties while the water-soluble component ensures the coating does not interfere with paper recycling processes.

Inventive Principle:

Principle #40Composite materials

2Ease of operation

If a polyethylene coating is added to make the package sealable, then sealability is improved, but biodegradability deteriorates

Engineering Contradiction:

ImprovesealabilityVSAvoidbiodegradability

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The patent changes the chemical nature of the coating from non-biodegradable polyethylene to water-soluble biodegradable polymers. This parameter change enables the coating to break down in composting environments while still providing the necessary sealability for packaging applications.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a disposable coating designed to degrade after use. The water-soluble polymer coating provides temporary protection and sealability during use, then naturally degrades in composting conditions, eliminating persistent microplastic pollution.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Ease of manufacture

If the polyethylene coating is made very thin to maintain recyclability, then recyclability is improved, but barrier properties deteriorate

Engineering Contradiction:

ImproverecyclabilityVSAvoidbarrier properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses a composite coating system where water-soluble polymers provide the base matrix and hydrophilic nanoplatelets provide enhanced barrier properties. This composite structure achieves superior barrier performance at thin coating thicknesses, maintaining both recyclability and protection.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent incorporates hydrophilic nanoplatelets that create a tortuous path for moisture and gas transmission. This nanoporous structure provides high barrier properties at minimal coating thickness, resolving the contradiction between thin coating for recyclability and effective barrier protection.

Inventive Principle:

Principle #31Porous materials

4Ease of manufacture

If uncoated paper is used to maintain recyclability, then recyclability is improved, but barrier properties deteriorate

Engineering Contradiction:

ImproverecyclabilityVSAvoidbarrier properties

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent changes the surface properties of paper by applying a water-soluble polymer coating that can be easily removed during recycling. This parameter change allows the paper to maintain its recyclability while gaining the necessary barrier properties for protecting sensitive products.

Inventive Principle:

Principle #35Parameter changes

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 laminate provides enhanced barrier properties against moisture and gases, ensuring product integrity and environmental sustainability by being fully recyclable and biodegradable, reducing the risk of persistent microplastics and improving consumer acceptance of natural packaging materials.

Implementation Method 1

a first water-soluble polymeric layer having an outer surface and an inner surface

Methodology Applied

Scientific EffectWater solubility: Solvation

Implementation Method 2

a water-dispersible barrier layer made from hydrophilic nanoplatelets

Methodology Applied

Scientific EffectHydrophilic nanoplatelets dispersion: Dispersion (of waves)

Implementation Method 3

enhanced barrier properties against moisture and gases

Methodology Applied

Scientific EffectBarrier layer resistance: Permeation

Data Source

PatentUS11913174B2Recyclable paper barrier laminate

Publication Date: 2024.02.27 PROCTER & GAMBLE CO

AI summary

A recyclable paper laminate comprising a water-dispersible barrier against any permeation.