Modern packaging materials face severe corrosion challenges when exposed to acidic contents, moisture, and environmental stresses. Testing shows that aluminum barrier layers can deteriorate within months when exposed to pH levels below 4 or above 9, while conventional polymer coatings often fail to prevent oxygen and water vapor transmission rates from climbing above 1.0 cm³/m²/day and 1.0 g/m²/day respectively.

The challenge lies in developing multi-layer barrier systems that maintain their protective properties while meeting food safety requirements and remaining cost-effective for mass production.

This page brings together solutions from recent research—including aluminum particle coatings with water-soluble polymer matrices, carboxy-modified polyolefin heat seal layers, cross-linkable acrylic copolymers, and targeted molecular weight polyester materials. These and other approaches focus on preventing barrier degradation while maintaining package integrity throughout its service life.

1. Coating Compositions for Containers Using Crosslinkable Acrylic Copolymers with Styrene-Mimicking Polycyclic Monomers

SWIMC LLC, 2024

Coating compositions for food and beverage containers that do not contain extractible quantities of compounds like BPA, Bisphenol A glycidyl ether, PVC, or styrene. The compositions are self-crosslinking or crosslinkable acrylic copolymers that can be applied to packaging substrates using spray coating techniques. The copolymers are made from styrene-mimicking monomers containing cyclic groups and ethylenically-unsaturated pendant groups, with at least some of the styrene-mimicking monomers being polycyclic compounds with ring unsaturation. This allows styrene-like properties without the use of styrene itself. The compositions can provide coatings with desirable properties like blush resistance, corrosion resistance, pot life stability, and initial metal exposure when applied to food and beverage

US2024352272A1-patent-drawing

2. Export Packaging Case with Rust Prevention Oil-Infused Panel and Cylindrical Block Closure

HA TAE BUM, 2023

Export packaging case with enhanced durability and rust prevention by injecting rust prevention oil into the interior of a rust prevention panel and absorbing it into the exterior. This provides continuous rust protection during long-term shipping. The panel is made of wooden boards with center bars spaced apart. One end is closed with a cylindrical block and oil is injected. The other end is closed. This prevents rust from spreading through the panel during transportation.

3. Canister with Carbon-Coated Inner Surfaces for Corrosion Prevention in Precursor Vaporizer Systems

G O ELEMENT CO LTD, 2023

A canister for preventing corrosion of precursor vaporizer systems used in semiconductor manufacturing, particularly when using corrosive precursors containing chlorine. The canister has a carbon coating layer applied to at least the inner surfaces in contact with the precursor. This prevents corrosion of the stainless steel canister during high-temperature reactions with chlorine-containing precursors. The carbon coating forms a barrier to prevent chemical reactions between the precursor and canister materials.

4. Canister with Carbon-Coated Inner Surfaces for Corrosion Prevention

G O ELEMENT CO LTD, 2023

A canister for preventing corrosion inside the canister when using certain precursors that cause corrosion in stainless steel canisters. The canister has a carbon coating layer applied to at least the inner surfaces that contact the precursor. This prevents chemical and physical interactions between the precursor and the canister that can cause corrosion at high temperatures.

KR20230097938A-patent-drawing

5. Biodegradable VCI Compositions with Polyester Blends and Fillers Exhibiting Reduced Water Vapor Transmission Rates

NORTHERN TECH INTERNATIONAL CORP, 2022

Biodegradable volatile corrosion inhibitor (VCI) compositions for packaging that improve corrosion protection compared to conventional VCI compositions. The biodegradable VCI compositions contain a blend of biodegradable polyesters, volatile corrosion inhibitors, and fillers. The compositions have lower water vapor transmission rates (WVTR) than conventional VCI compositions but still provide effective corrosion inhibition. The lower WVTR is achieved using fillers like talc, calcium carbonate, and clay. The blended polyesters, which can be homopolymers or copolymers, provide desirable properties like tear strength and transparency. The blended composition with lower WVTR and good properties provides better corrosion inhibition than conventional compositions with higher WVTR.

6. Method for Producing Aluminum Packaging Material with Integrated Vaporizable Rust Inhibitors and Antistatic Polyethylene Wax Coating

CHOI CHOO-SUK, 2022

Manufacturing method for aluminum vacuum packaging material that has both rust prevention and antistatic properties. The method involves mixing rust inhibiting agents like calcium benzoate, potassium sorbate, sodium caprylate, glyceryl monostearate, zinc oxide, and silicon dioxide to create a vaporizable rust preventive agent. This agent is then mixed with polyethylene wax and sprayed between the aluminum foil and sack during packaging. The wax coating prevents rusting of the packaged metal objects and also reduces static electricity compared to conventional aluminum packaging.

7. Sealable Varnish with Line-Separating Anti-Corrosive Concentration for Packaging Films

CONSTANTIA PIRK GMBH & CO KG, 2021

A sealable anti-corrosion varnish for packaging films for aggressive fillings like acids that provides both corrosion protection and high sealing strength. The varnish is applied in a single line that separates during drying, concentrating the anti-corrosive component on the aluminum surface. The varnish composition has specific solvents, binders, sealing component, and acid catalyst ratios to achieve this.

EP3596171B1-patent-drawing

8. Multi-Layer Rust-Preventive Film with Nitrobenzoic Acid and Sodium Nitrite Composition

NIHON PARKERIZING CO LTD, 2021

A rust-preventive film for packaging metal materials that provides superior rust protection regardless of the method of use. The film has an inner layer containing nitrobenzoic acid and ammonium benzoate in specific amounts, along with a thermoplastic resin. The outer layer contains sodium nitrite. The inner layer ratios are 0.1-6.0 parts nitrobenzoic acid and 0.1-6.0 parts ammonium benzoate per 100 parts resin. The inner layer has a nitrobenzoic acid to ammonium benzoate ratio of 1:1. The outer layer has 0.1-4.0 parts sodium nitrite per 100 parts resin, and the inner and outer layer ratios are 8:2 to 6:4 parts total ammonium to sodium nitrite per volume.

9. Polyester Polymer Coating with THEIC Segment and Titanium Catalyst for Metal Containers

SWIMC LLC, 2020

Coating composition for metal containers like aerosol cans that provides improved corrosion resistance and adhesion when coated on internal surfaces of metal packaging containers. The coating is made from a polyester polymer containing a tris-2-hydroxyethyl isocyanurate (THEIC) segment. It also includes a catalyst containing titanium or a quaternary ammonium compound. This allows the coating to cure at lower temperatures compared to similar compositions. The coating can further have an adhesion promoter to overcome issues with cleanliness of the metal substrate.

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10. Food and Beverage Packaging Coating Comprising Acid-Group Polymer and Polyoxazoline Compound

PPG INDUSTRIES OHIO INC, 2020

Coating food and beverage packaging with a formula that contains a polymer with acid groups and a polyoxazoline compound. The coating is applied to the package surface and cured to provide a safe, formaldehyde-free coating that can be used in food contact applications. The coating composition can be applied by spraying, dipping, or coil coating methods. The coated package provides improved properties like adhesion, corrosion resistance, and barrier protection for food packaging applications.

11. Packaging Material Coating Comprising Acid-Functional Polymer and Polyoxazoline

PPG IND OHIO INC, 2020

Coating packaging materials like cans and tubes with a specific composition to improve performance and safety. The coating contains a polymer with acid functional groups and a polyoxazoline. It can be applied to the inside or outside of packages using methods like spraying, dipping, or roll coating. The coating provides properties like adhesion, barrier protection, and corrosion resistance when cured. It's suitable for food contact and can be applied to metal, plastic, and laminate packages.

12. Corrugated Cardboard Packaging with Integrated Rust-Inhibiting Layer for Steel Coils

ANYPACK CO LTD, 2020

An anti-corrosion packaging material for protecting steel coils during transportation and storage to prevent damage and deformation. The packaging material covers the outer and inner peripheral surfaces of the steel coil. It consists of a corrugated cardboard outer plate, an inner plate, and a rust-preventing layer between them. The rust-preventing layer can be applied or coated on the inner and outer surfaces of the plates. It contains a polyethylene base with rust inhibitors like orthophosphates, silicate, nitrite, chromate, benzoate, lime, polyphosphate, alkylallyl sulfonate, petroleum sulfonate, metal soap, or rust inhibitors. This layer prevents rusting of the steel coil from external impact.

13. Iron Coil Packaging with Dual Sealed Wrappings and Vacuum Air Evacuation

HYUNDAI STEEL CO, 2020

A packaging method for iron coils that prevents rust and staining by blocking oxygen inside the packaging. The coil is wrapped with an outer packaging material, then an inner wrapping material is inserted around the coil. Both wrappings are sealed against the coil to prevent air ingress. Vacuum caps can be used to evacuate any remaining air. This creates an oxygen-free environment inside the coil packaging to prevent rust and staining. The wrapping materials can be flexible synthetic films like polypropylene, ABS, or polyethylene. Additives like UV blockers, antistatics, rubbers, and pigments can be included in the wrapping materials.

14. Packaging Film Coating with Reactive Binders and Solvent System for Corrosion Resistance and High Sealing Resistance

CONSTANTIA PIRK GMBH & CO KG, 2020

Sealable anticorrosive coating for packaging films for aggressive products like chemicals that provides both corrosion protection and high sealing resistance when sealed with materials like polypropylene. The coating contains specific solvents, reactive binders, sealing component, and acid catalyst ratios to achieve both properties. The solvents have boiling points between 30-250°C, the binders have Tg between 0-200°C, the sealing component has Tg between -80 to 100°C, and the acid catalyst.

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15. Multi-Layer Rust-Preventive Film with Gas Barrier and Vaporizable Inhibitor for Deep Drawing Applications

MITSUBISHI CHEMICAL CORP, 2019

A rust-preventive film for deep drawing applications that provides both rust protection and gas barrier properties. The film is a multi-layer construction with an outer layer, an intermediate layer, and an innermost layer. The outermost layer has a gas barrier layer made of polyamide or ethylene-vinyl acetate copolymer saponified resin. The innermost layer contains a vaporizable rust inhibitor. The film has a thickness distribution where the outermost layer is 30-90% of the total thickness. This allows deep drawing without cracking while still providing rust prevention and gas barrier. The film can be manufactured by coextrusion.

16. Latex Emulsion Coating with Reactive Functional Groups for Metal Container Corrosion Protection

PPG IND OHIO INC, 2019

Coated food and beverage containers that provide corrosion protection without using BPA or styrene. The coating is made from a latex emulsion containing a polymerized latex polymer with reactive functional groups like hydroxyl or carboxylic acid. The latex is applied to the container interior and cured with crosslinkers like hydroxyalkylamides or hydroxyalkyl ureas. The reactive latex forms a crosslinked network on the container surface to prevent corrosion. The coating can be used on metal containers like cans without BPA or styrene.

EP3303490B1-patent-drawing

17. Chromium-Chromium Oxide Coating with Single-Stage Electrolytic Deposition Using Formic Acid, Potassium Chloride, and Potassium Bromide

TATA STEEL IJMUIDEN BV, 2019

Chromium-chromium oxide (Cr-CrOx) coating for steel packaging substrates that replaces chromium VI (hexavalent chromium) and provides improved corrosion resistance and adhesion without the hazards of hexavalent chromium. The Cr-CrOx coating is deposited in a single electrolytic stage using a specific electrolyte composition. The coating consists of mixed chromium metal and chromium oxide layers, preventing separate chromium metal and chromium oxide layers. This allows electrodeposition of both chromium species in the same stage. The electrolyte has a formic acid chelating agent, potassium chloride conductivity enhancer, and potassium bromide depolarizer. The coating provides equivalent or better corrosion resistance and adhesion compared to conventional tinplate, while avoiding hexavalent chrom

18. Coated Containers with Polycarbodiimide Resin Composition Featuring Terminal NCO Functionality and Enhanced Corrosion and Solvent Resistance

PPG IND OHIO INC, 2019

Coated containers with improved resistance to corrosion and solvents for food and beverage packaging. The coating is made from a specific composition containing a crosslinking polycarbodiimide resin with specific functional groups. The coating composition can be applied by roll coating or sheet coating methods to metal substrates like steel or aluminum for forming containers like cans. The coating composition has a polycarbodiimide resin with terminal NCO functionality, an organic group-containing polyisocyanate, and a compound containing active hydrogen added before, during, or after polycarbodiimide formation. This composition provides improved adhesion, resistance to solvents like MEK, and color stability compared to traditional coatings.

MX2018008547A-patent-drawing

19. Coating Composition with Emulsion Polymerized Latex and Reactive Surfactant for Corrosion-Resistant Packaging

PPG IND OHIO INC, 2019

Coating composition for packaging materials like metal cans and plastic bottles that provides corrosion protection, chemical resistance, and food safety. The coating composition contains a latex polymer made by emulsion polymerization with a reactive surfactant. The latex is mixed with water and optionally other components like phosphorus-containing acid. The coating composition can be applied to the inner surface of the packaging to prevent corrosion, protect against chemicals, and not affect food quality. The latex polymer provides flexibility and adhesion while the reactive surfactant allows crosslinking for strength. The phosphorus acid enhances corrosion resistance.

20. Coating Composition for Packaging Films with Segregating Corrosion Protection and Sealability Properties

CONSTANTIA HUECK FOLIEN GMBH & CO KG, 2018

Sealable corrosion protection coating for packaging films used in aggressive product packaging applications like food containers. The coating has two properties: corrosion protection on the aluminum foil and high seal strength on the free surface adjacent to the product. This is achieved by a paint that segregates during drying and concentrates on the aluminum for corrosion resistance and on the free surface for sealability. The paint composition has solvents, reactive binders, a sealing component, and an acid catalyst with specific properties for segregation and adherence.

WO2018167033A1-patent-drawing

21. Sealable Corrosion Protection Coating for Packaging Films with Specific Solvent Composition and Reactive Binder

22. Anticorrosive Packaging Material with Flexible Barrier Layer and Nonwoven Corrosion Inhibitor Layer

23. Coating Composition for Food Containers with Polyether Polymer Containing Cyclic and Phenol Groups

24. Coatings with Polycyclic Aromatic Epoxy Resins for Enhanced Corrosion and Adhesion on Metal Containers

25. Packaging Laminate with Silicatized or Titanized Aluminum Layer for Enhanced Adhesion to Polyolefin

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