Solvent-Based Oxygen Barrier Coating Composition for Flexible Packaging
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Solution Overview
Problem
Existing oxygen barrier coating layers in flexible packaging materials, particularly those made from metals and chlorinated polymers, pose health and environmental concerns and limit recyclability, while water-based polyvinyl alcohol (PVOH) solutions restrict printing speed due to slow drying times.
Innovation Solution
A solvent-based composition for preparing an oxygen barrier coating, comprising a binder polymer with polar functional groups, an acid with reactive acidic groups, and an organic solvent, allowing for faster drying and increased printing speed without adverse effects on the coating's barrier properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If water-based polyvinyl alcohol (PVOH) solutions are used for oxygen barrier coating, then environmental and health problems are addressed, but printing speed is significantly reduced due to slow drying times
Solution Approach 1:
The patent changes the solvent parameter from water to organic solvent (alcohol, ester, or ketone), which fundamentally alters the drying characteristics and enables faster evaporation while maintaining the oxygen barrier function and environmental compatibility
Solution Approach 2:
The patent introduces an organic solvent as an intermediary medium that facilitates faster drying compared to water, while still providing the necessary dissolution medium for the binder polymer and maintaining compatibility with flexographic printing processes
2Reliability
If high coating weights are applied with water-based compositions, then sufficient oxygen barrier protection is achieved, but drying becomes difficult and printing speed is reduced
Solution Approach 1:
The patent changes the solvent parameter from water to organic solvent, which has higher volatility and faster evaporation rate. This enables high coating weights to be applied and dried quickly, maintaining both barrier protection and printing speed
3Ease of manufacture
If water-based oxygen barrier coating is printed as the last layer to allow sufficient water evaporation, then drying is improved, but flexibility in printed structures is reduced
Solution Approach 1:
The patent inverts the conventional approach by making the oxygen barrier coating solvent-based rather than water-based. This allows it to be printed on earlier layers without causing drying issues, enabling greater flexibility in printing sequences and multi-layer structures
4Device complexity
If conventional drying systems are used for water-based compositions, then existing infrastructure is maintained, but drying capacity is insufficient for high coating weights
Solution Approach 1:
The patent changes the solvent parameter to organic solvent, which evaporates faster than water. This reduces the drying capacity requirement of existing systems while maintaining the ability to handle high coating weights, avoiding the need for upgraded drying infrastructure
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 solvent-based composition enables the production of oxygen barrier coatings with improved printing speed and flexibility, while maintaining excellent oxygen barrier properties and being suitable for use in a wide range of flexible packaging applications.
Implementation Method 1
the organic solvent can be evaporated more easily than water
Implementation Method 2
a binder polymer containing polar functional groups that are capable of interacting with an acidic group; an acid containing at least two reactive acidic groups
Data Source
AI summary
The present invention is related to a solvent-based composition for preparing an oxygen barrier coating, comprising a binder polymer containing polar functional groups that are capable of interacting with an acidic group; an acid containing at least two reactive acidic groups; and an organic solvent. The present invention is furthermore related to a coated product comprising said oxygen-barrier coating layer, and to a method for making a coated product.