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A Comparative Study on the Roll-to-Roll Processing of a Silicate-Polyvinyl Alcohol Composite Barrier Lacquer Using
Stefan Schiessl1,2, Esra Kucukpinar2, Noémie Rivollier3,4
1TUM School of Life Sciences Weihenstephan, Technical University of Munich, Alte Akademie 8, 85354 Freising, Germany.
Polymers
|July 14, 2023
Summary
This study optimized polyvinyl alcohol-based barrier lacquers with montmorillonite for roll-to-roll coating. Tailoring lacquer properties achieved excellent oxygen barrier performance using slot-die and reverse gravure techniques.
Area of Science:
- Materials Science
- Polymer Science
- Surface Engineering
Background:
- Platelet-shaped montmorillonite particles enhance polyvinyl alcohol (PVA) oxygen barrier properties.
- Roll-to-roll (R2R) coating of PVA-montmorillonite composite barrier lacquers requires further research.
- Optimizing R2R coating techniques is crucial for advanced packaging materials.
Purpose of the Study:
- To investigate R2R coating of PVA-montmorillonite barrier lacquers using slot-die and reverse gravure.
- To analyze the impact of coating techniques on lacquer properties and coating performance.
- To achieve high oxygen barrier performance through tailored lacquer formulations and particle orientation.
Main Methods:
- Two R2R coating techniques: slot-die and reverse gravure.
- Analysis of lacquer viscosity, surface energy, and dried coating properties (oxygen barrier, morphology, particle orientation).
- Formulation adjustments based on coating technique requirements.
Main Results:
- Achieved low permeability coefficients indicating a high oxygen barrier (0.14 cm³/µm/m²/d/bar for slot-die, 0.12 cm³/µm/m²/d/bar for reverse gravure).
- Demonstrated that lacquer properties must be adjusted to the specific coating technique.
- Successfully controlled montmorillonite particle orientation in both coating methods.
- Identified optimal solid content ranges: low (≤3 wt%) for slot-die, high (≤9 wt%) for reverse gravure.
Conclusions:
- R2R coating of PVA-montmorillonite composites is feasible with both slot-die and reverse gravure.
- Tailoring lacquer formulation and solid content is key to optimizing oxygen barrier performance for each technique.
- Controlled particle orientation significantly contributes to the enhanced barrier properties.
