Aqueous dispersions of soybean oil acrylate polymers for barrier coatings

Overview

This solution leverages poly(acrylated epoxidized soybean oil) (PAESO), a soybean-oil-derived thermoplastic elastomer, as an aqueous dispersion for barrier coatings on paper and paperboard substrates. PAESO is manufactured at commercial scale and combines the processing advantages of elastomeric latex systems with the barrier performance characteristics associated with alkyd-type resins. As a renewable, bio-based platform polymer, it offers converters and brand owners a pathway to replace petroleum-derived barrier chemistries with sustainable alternatives. The material is rich in functional groups, allowing property tuning either before or after coating application to meet specific performance targets.

Technical specifications

Key features:

• Bio-based platform polymer: Derived from soybean oil, providing a renewable alternative to styrene/butadiene latex and alkyd resin barrier systems.
• Aqueous emulsion application: Designed to be applied as a water-based dispersion, simplifying coating processes and eliminating the need for complex crosslinking schemes or compatibilizing layers.
• Cellulose compatibility: Functional handles on the polymer are expected to interact favorably with the hydroxyl and epoxy sites on cellulose substrates, promoting adhesion to paper and paperboard.
• Tunable performance: Functional groups allow pre-application modification or post-application functionalization and curing to dial in barrier and mechanical properties.
• Target barrier performance: Initial testing will focus on oxygen and water vapor barrier properties, with the goal of achieving improvements comparable to or exceeding existing vegetable-oil-derived barrier coatings.

Validation approach:

• Apply neat polymer as an emulsion to substrate at elevated dosage and measure oxygen and water barrier performance.
• Conduct mechanical testing to confirm durability under handling conditions such as curling, folding, and creasing.
• Adjust polymer functionality as needed over a 12-month development cycle to meet performance goals.

Technology readiness level

PAESO itself is manufactured at commercial scale, with initial products developed for additives and coatings in the paving and construction industries. However, its specific application as a paper barrier coating has not yet been tested. The development plan calls for initial application and barrier testing of the neat polymer within the first three months, followed by functionalization and optimization over the subsequent nine months. Vegetable-oil-derived barrier coatings have demonstrated 3-4x barrier improvements over neat substrates in published studies, providing a strong foundation for expected performance. The technology is positioned at an early applied research stage for this specific end use, with a clear pathway from laboratory validation to commercial deployment.