Stable Aqueous Starch Dispersion for Hydrocarbon Barrier
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Solution Overview
Problem
Current starch-based coating compositions for paper substrates are excessively viscous and prone to retrogradation, making it difficult to form uniform barrier layers against saturated and aromatic hydrocarbons, which are commonly found in recycled paper products used in food packaging.
Innovation Solution
The development of stable aqueous dispersions using destructurized starch complexed with polymers of varying hydrophilicity, which maintains a consistent dynamic viscosity and solid content, allowing for uniform deposition and resistance to hydrocarbons, and can be adjusted for different applications such as coatings, fillers, and microencapsulants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If gelatinised starch is used in coating compositions, then the coating can provide barrier properties against hydrocarbons, but the dispersion becomes extremely viscous and difficult to deposit uniformly
Solution Approach 1:
The patent changes the physical-chemical parameters of starch by using destructurized starch instead of gelatinised starch, and controlling the molecular weight to 10,000-1,000,000 Da. This parameter change reduces the viscosity of the aqueous dispersion while maintaining the barrier properties against hydrocarbons, making the coating composition easier to deposit uniformly.
Solution Approach 2:
The patent creates a composite coating composition by combining destructurized starch with specific polymers (polyacrylic acid, polyacrylamide, or carboxymethyl cellulose) in defined ratios. This composite material provides both the necessary barrier properties and appropriate rheological characteristics for uniform deposition, resolving the contradiction between protection and ease of application.
2Reliability
If gelatinised starch is used in coating compositions, then the coating can form a barrier layer, but the starch undergoes retrogradation and precipitates as gels, complicating the deposition process
Solution Approach 1:
The patent changes the structural parameters of starch by using destructurized starch with controlled molecular weight rather than gelatinised starch. This parameter change prevents the retrogradation phenomenon that causes gel formation, ensuring composition stability throughout storage and application while maintaining barrier layer formation capability.
Solution Approach 2:
The patent introduces specific polymers (polyacrylic acid, polyacrylamide, or carboxymethyl cellulose) as intermediary substances that interact with destructurized starch to form stable complexes. These intermediaries prevent starch molecules from undergoing retrogradation and precipitating as gels, thereby maintaining composition stability while enabling barrier layer formation.
3Ease of operation
If low solids content is used in the dispersion, then the viscosity is lower, but insufficient quantity can be deposited to form an effective barrier layer
Solution Approach 1:
The patent develops composite materials consisting of destructurized starch combined with specific polymers in optimized ratios. This composite structure allows the dispersion to maintain low viscosity (10-500 mPa·s) even at high solids content (5-55%), enabling both ease of deposition and sufficient quantity delivery to form effective barrier layers.
Solution Approach 2:
The patent changes the molecular weight parameter of starch to 10,000-1,000,000 Da and controls the solids content parameter to 5-55%. These parameter changes enable the dispersion to achieve an optimal balance between viscosity and solids content, allowing sufficient quantity deposition while maintaining ease of application.
4Ease of manufacture
If recycled paper is used for food packaging, then costs are reduced and pollution from incineration is reduced, but the paper contains traces of saturated and aromatic hydrocarbons from printing inks
Solution Approach 1:
The patent applies a coating treatment that extracts or removes the harmful effect of hydrocarbon contamination by creating a barrier layer on the recycled paper surface. The destructurized starch-based coating forms a protective barrier that prevents hydrocarbon migration to food, allowing the use of cost-effective recycled paper while eliminating the harmful contamination issue.
Solution Approach 2:
The patent introduces a starch-based polymer coating as an intermediary barrier between the recycled paper (containing hydrocarbon traces) and the food. This intermediary layer prevents direct contact and migration of hydrocarbons to food, enabling the use of recycled packaging materials while ensuring food safety.
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 stable aqueous dispersion provides a uniform, resistant barrier layer against saturated and aromatic hydrocarbons, enabling effective food packaging while being biodegradable and suitable for various industrial uses without the need for immediate preparation, and can be used in conventional coating machines without modifications.
Implementation Method 1
comprises destructurized starch in a form complexed with at least one polymer containing groups of different hydrophilicity intercalated in the backbone or outside the backbone
Implementation Method 2
polymer containing groups of different hydrophilicity intercalated in the backbone or outside the backbone
Implementation Method 3
making stable aqueous dispersions having a high solids content capable of producing uniform bather layers which are resistant to saturated and aromatic hydrocarbons
Implementation Method 4
produce a barrier layer against compounds of the saturated and aromatic hydrocarbon type such as for example the compounds commonly known as MOSH (Mineral Oil Saturated Hydrocarbons) and MOAH (Mineral Oil Aromatic Hydrocarbons)
Data Source
AI summary
Provided is a stable aqueous dispersion suitable for application to different substrates and especially to paper substrates for producing a barrier layer against compounds of the saturated and aromatic hydrocarbon type. The aqueous dispersion comprises destructurized starch in a complexed form. Also provided is the use of aqueous dispersion as a coating composition for paper based substrates, as a microencapsulant of fragrances and as a film-forming component for paints.