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Waterborne spray platform: rheology-guided, probe-sonicated nanofillers; optional electrospun interlayer adds tortuosity and pinhole control; designed to debond during repulp.
About
California State University, Long Beach — Soft Materials & Interfaces Lab develops waterborne, debond-on-repulp barrier coatings for fiber-based packaging. Our resin-agnostic spray platform couples rheology mapping (nozzle-ready viscosity) with probe-sonicated, SAM-tuned nanofillers for stable, uniform coats; an optional electrospun nano-interlayer enables ultra-low coat weight and pinhole control. We validate in-house via gravimetric WVTR screening, relative OTR diffusion-cell screening, coat-weight/roughness metrology, and bench-scale repulp tests, then confirm finalists at certified labs. Facilities include a rheometer, optical profilometer, optical tensiometer, fluorescence microscope, precision balances, and an air-compressor spray setup. For rapid prototyping we operate three 3D printers (extrusion-based bio, SLA, FDM) and a CO₂ laser cutter to build spray jigs, ASTM E96 cups/lids with O-ring seals, bottle mock-ups, and repulp fixtures. A probe-type ultrasonic homogenizer is requested via sponsored research; an electrospinning unit is being installed. We collaborate with industry to translate to pilot lines.
Key Benefits
- Recyclability-first: The coating is designed to debond under repulping conditions to enable high fiber recovery, and the formulation is PFAS-free and fully waterborne to reduce EHS risk.
- Barrier at low mass: By combining SAM-tuned nanofillers with an optional electrospun interlayer, the system increases tortuosity and controls pinholes, achieving strong moisture/oxygen resistance at ultra-low coat weight.
- Fast, low-risk scale-up: Rheology-guided, nozzle-ready formulations define a clear spray window and reduce setup time and clogging on standard HVLP or ultrasonic hardware, accelerating transfer to pilot lines.
- In-house metrology & prototyping: We use profilometry, tensiometry, and fluorescence imaging, and we 3D-print/laser-cut E96 cups/lids, bottle mock-ups, and spray jigs, which enables rapid iteration and lowers development cost.
- Clear compliance path: We prioritize food-contact-friendly chemistries and will confirm migration at certified laboratories, providing a transparent route to regulatory acceptance.
Applications
- Primary: interior spray barrier for fiber-based beverage bottles (350 mL–1 L) that must preserve repulpability while improving moisture/oxygen resistance.
- Secondary: paper cartons, cups, molded-fiber containers/liners needing recyclable, waterborne barrier coats.
- Customers: global beverage brands, packaging converters, paper mills, and coating/equipment suppliers implementing spray steps on R&D/pilot lines. Worldwide applicability with regional food-contact and repulping compliance.