Cellulose-based coated paper with high water vapor barrier properties through multi-scale structural synergy for...

Cellulose-based paper packaging has emerged as a promising alternative to petrochemical plastic packaging due to its renewable raw material sources, biodegradability, and environmental friendliness. However, the inherent hydrophilicity of cellulose and the porous structure of paper-based materials often lead to weak oil/water resistance and water vapor barrier performances. In this work, multilayer composite paper-based materials were prepared by successively coating calcium chloride-treated Kraft paper with modified sodium alginate (M-SA), acrylic emulsion (AE), and polyvinyl butyral (PVB). Among these coatings, the PVB coating served the purpose of preventing significant amounts of liquid water from permeating through. Sodium alginate underwent ionic crosslinking with Ca²⁺ to form cross-linked network, within which SiO₂ nanoparticles were embedded to reduce the free volume. The AE and M-SA coatings enhanced complex permeation pathways for water vapor and oil, where water molecules and non-polar oil were either trapped or repelled by the polar hydroxyl groups present in the M-SA coating. The resultant M-SA/AE/PVB coated paper exhibits excellent water resistance (Cobb value of 0.44 g/m²), oil resistance (Kit rating of 12/12), and water vapor barrier property (16.02 g/(m²·24 h)). These performances give the coated paper the ability to have a fresh-keeping effect on strawberries, effectively extending the shelf life of strawberries more than 7 days. Furthermore, the M-SA/AE/PVB coated paper shows desirable durability and recyclability. This work provides a novel approach for the development of sustainable paper-based packaging materials with high barrier properties.