EP3227493B1 - Coated substrate - Google Patents
Coated substrate Download PDFInfo
- Publication number
- EP3227493B1 EP3227493B1 EP15804500.5A EP15804500A EP3227493B1 EP 3227493 B1 EP3227493 B1 EP 3227493B1 EP 15804500 A EP15804500 A EP 15804500A EP 3227493 B1 EP3227493 B1 EP 3227493B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- coating
- substrate
- less
- gsm
- equal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
Links
- 239000000758 substrate Substances 0.000 title claims description 131
- 238000000576 coating method Methods 0.000 claims description 157
- 239000011248 coating agent Substances 0.000 claims description 123
- 239000011230 binding agent Substances 0.000 claims description 113
- 239000008199 coating composition Substances 0.000 claims description 112
- 229910052615 phyllosilicate Inorganic materials 0.000 claims description 81
- 239000011236 particulate material Substances 0.000 claims description 66
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 claims description 51
- 239000000454 talc Substances 0.000 claims description 50
- 229910052623 talc Inorganic materials 0.000 claims description 50
- 229920000126 latex Polymers 0.000 claims description 49
- 239000004816 latex Substances 0.000 claims description 49
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 claims description 44
- 239000005995 Aluminium silicate Substances 0.000 claims description 43
- 235000012211 aluminium silicate Nutrition 0.000 claims description 43
- 238000000034 method Methods 0.000 claims description 33
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 21
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 21
- -1 alkaline earth metal carbonate Chemical class 0.000 claims description 18
- 230000005540 biological transmission Effects 0.000 claims description 16
- 239000004927 clay Substances 0.000 claims description 16
- 239000002174 Styrene-butadiene Substances 0.000 claims description 14
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical group C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 claims description 14
- 239000011115 styrene butadiene Substances 0.000 claims description 14
- 229920003048 styrene butadiene rubber Polymers 0.000 claims description 14
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 8
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 8
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 7
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 6
- QAOWNCQODCNURD-UHFFFAOYSA-L Sulfate Chemical compound [O-]S([O-])(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-L 0.000 claims description 5
- 239000010459 dolomite Substances 0.000 claims description 5
- 229910000514 dolomite Inorganic materials 0.000 claims description 5
- 229910021653 sulphate ion Inorganic materials 0.000 claims description 5
- 239000005909 Kieselgur Substances 0.000 claims description 4
- 229910052784 alkaline earth metal Inorganic materials 0.000 claims description 4
- HPTYUNKZVDYXLP-UHFFFAOYSA-N aluminum;trihydroxy(trihydroxysilyloxy)silane;hydrate Chemical compound O.[Al].[Al].O[Si](O)(O)O[Si](O)(O)O HPTYUNKZVDYXLP-UHFFFAOYSA-N 0.000 claims description 4
- 239000010427 ball clay Substances 0.000 claims description 4
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 4
- 239000010440 gypsum Substances 0.000 claims description 4
- 229910052602 gypsum Inorganic materials 0.000 claims description 4
- 229910052621 halloysite Inorganic materials 0.000 claims description 4
- ZLNQQNXFFQJAID-UHFFFAOYSA-L magnesium carbonate Chemical compound [Mg+2].[O-]C([O-])=O ZLNQQNXFFQJAID-UHFFFAOYSA-L 0.000 claims description 4
- 239000001095 magnesium carbonate Substances 0.000 claims description 4
- 229910000021 magnesium carbonate Inorganic materials 0.000 claims description 4
- 239000010445 mica Substances 0.000 claims description 4
- 229910052618 mica group Inorganic materials 0.000 claims description 4
- 239000010451 perlite Substances 0.000 claims description 4
- 235000019362 perlite Nutrition 0.000 claims description 4
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 claims description 3
- SHFGJEQAOUMGJM-UHFFFAOYSA-N dialuminum dipotassium disodium dioxosilane iron(3+) oxocalcium oxomagnesium oxygen(2-) Chemical compound [O--].[O--].[O--].[O--].[O--].[O--].[O--].[O--].[Na+].[Na+].[Al+3].[Al+3].[K+].[K+].[Fe+3].[Fe+3].O=[Mg].O=[Ca].O=[Si]=O SHFGJEQAOUMGJM-UHFFFAOYSA-N 0.000 claims description 3
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 3
- 239000000347 magnesium hydroxide Substances 0.000 claims description 3
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 3
- 239000000123 paper Substances 0.000 description 58
- 230000004888 barrier function Effects 0.000 description 28
- 239000002245 particle Substances 0.000 description 24
- 239000000203 mixture Substances 0.000 description 23
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 21
- 235000019422 polyvinyl alcohol Nutrition 0.000 description 20
- 239000003921 oil Substances 0.000 description 16
- 239000000654 additive Substances 0.000 description 13
- 230000007062 hydrolysis Effects 0.000 description 12
- 238000006460 hydrolysis reaction Methods 0.000 description 12
- 239000010410 layer Substances 0.000 description 12
- 239000007787 solid Substances 0.000 description 12
- 229910052500 inorganic mineral Inorganic materials 0.000 description 11
- 239000000463 material Substances 0.000 description 11
- 239000011707 mineral Substances 0.000 description 11
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical group CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 10
- 238000007639 printing Methods 0.000 description 10
- 239000004094 surface-active agent Substances 0.000 description 10
- 239000012535 impurity Substances 0.000 description 9
- PPBRXRYQALVLMV-UHFFFAOYSA-N Styrene Chemical compound C=CC1=CC=CC=C1 PPBRXRYQALVLMV-UHFFFAOYSA-N 0.000 description 7
- 229920000642 polymer Polymers 0.000 description 7
- 239000007900 aqueous suspension Substances 0.000 description 6
- 239000002734 clay mineral Substances 0.000 description 6
- 235000013305 food Nutrition 0.000 description 6
- 239000007788 liquid Substances 0.000 description 6
- 239000002002 slurry Substances 0.000 description 6
- JVBXVOWTABLYPX-UHFFFAOYSA-L sodium dithionite Chemical compound [Na+].[Na+].[O-]S(=O)S([O-])=O JVBXVOWTABLYPX-UHFFFAOYSA-L 0.000 description 6
- 238000003490 calendering Methods 0.000 description 5
- 239000006185 dispersion Substances 0.000 description 5
- 150000002148 esters Chemical class 0.000 description 5
- LYCAIKOWRPUZTN-UHFFFAOYSA-N ethylene glycol Natural products OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 5
- 239000002480 mineral oil Substances 0.000 description 5
- 229920002689 polyvinyl acetate Polymers 0.000 description 5
- 239000011118 polyvinyl acetate Substances 0.000 description 5
- 230000008569 process Effects 0.000 description 5
- 239000004971 Cross linker Substances 0.000 description 4
- IMNFDUFMRHMDMM-UHFFFAOYSA-N N-Heptane Chemical compound CCCCCCC IMNFDUFMRHMDMM-UHFFFAOYSA-N 0.000 description 4
- 230000000996 additive effect Effects 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 125000004432 carbon atom Chemical group C* 0.000 description 4
- 229910001919 chlorite Inorganic materials 0.000 description 4
- 229910052619 chlorite group Inorganic materials 0.000 description 4
- QBWCMBCROVPCKQ-UHFFFAOYSA-N chlorous acid Chemical compound OCl=O QBWCMBCROVPCKQ-UHFFFAOYSA-N 0.000 description 4
- DIOQZVSQGTUSAI-UHFFFAOYSA-N decane Chemical compound CCCCCCCCCC DIOQZVSQGTUSAI-UHFFFAOYSA-N 0.000 description 4
- 230000001627 detrimental effect Effects 0.000 description 4
- 238000000227 grinding Methods 0.000 description 4
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 238000003801 milling Methods 0.000 description 4
- 235000010446 mineral oil Nutrition 0.000 description 4
- 239000000178 monomer Substances 0.000 description 4
- 239000000825 pharmaceutical preparation Substances 0.000 description 4
- 229940127557 pharmaceutical product Drugs 0.000 description 4
- 230000002829 reductive effect Effects 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 239000000725 suspension Substances 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- 125000000218 acetic acid group Chemical group C(C)(=O)* 0.000 description 3
- 235000013361 beverage Nutrition 0.000 description 3
- 239000003795 chemical substances by application Substances 0.000 description 3
- 229920001577 copolymer Polymers 0.000 description 3
- 239000004519 grease Substances 0.000 description 3
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 3
- 229910052622 kaolinite Inorganic materials 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- GLDOVTGHNKAZLK-UHFFFAOYSA-N octadecan-1-ol Chemical compound CCCCCCCCCCCCCCCCCCO GLDOVTGHNKAZLK-UHFFFAOYSA-N 0.000 description 3
- 238000007645 offset printing Methods 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 2
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerol Natural products OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 125000000217 alkyl group Chemical group 0.000 description 2
- WYTGDNHDOZPMIW-RCBQFDQVSA-N alstonine Natural products C1=CC2=C3C=CC=CC3=NC2=C2N1C[C@H]1[C@H](C)OC=C(C(=O)OC)[C@H]1C2 WYTGDNHDOZPMIW-RCBQFDQVSA-N 0.000 description 2
- 239000005030 aluminium foil Substances 0.000 description 2
- 239000012736 aqueous medium Substances 0.000 description 2
- 239000011324 bead Substances 0.000 description 2
- 238000004061 bleaching Methods 0.000 description 2
- 239000007844 bleaching agent Substances 0.000 description 2
- 239000001110 calcium chloride Substances 0.000 description 2
- 229910001628 calcium chloride Inorganic materials 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- 239000001913 cellulose Substances 0.000 description 2
- 229920002678 cellulose Polymers 0.000 description 2
- 239000000919 ceramic Substances 0.000 description 2
- 235000013339 cereals Nutrition 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000032798 delamination Effects 0.000 description 2
- 239000002270 dispersing agent Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 150000002170 ethers Chemical class 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 238000005189 flocculation Methods 0.000 description 2
- 230000016615 flocculation Effects 0.000 description 2
- 238000005188 flotation Methods 0.000 description 2
- 235000013312 flour Nutrition 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 239000006081 fluorescent whitening agent Substances 0.000 description 2
- 239000011888 foil Substances 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 239000008187 granular material Substances 0.000 description 2
- BXWNKGSJHAJOGX-UHFFFAOYSA-N hexadecan-1-ol Chemical compound CCCCCCCCCCCCCCCCO BXWNKGSJHAJOGX-UHFFFAOYSA-N 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 239000011777 magnesium Substances 0.000 description 2
- HCWCAKKEBCNQJP-UHFFFAOYSA-N magnesium orthosilicate Chemical compound [Mg+2].[Mg+2].[O-][Si]([O-])([O-])[O-] HCWCAKKEBCNQJP-UHFFFAOYSA-N 0.000 description 2
- 239000000391 magnesium silicate Substances 0.000 description 2
- 229910052919 magnesium silicate Inorganic materials 0.000 description 2
- 235000019792 magnesium silicate Nutrition 0.000 description 2
- 238000007885 magnetic separation Methods 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000002736 nonionic surfactant Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 238000004806 packaging method and process Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920000573 polyethylene Polymers 0.000 description 2
- 229920001451 polypropylene glycol Polymers 0.000 description 2
- 229910052903 pyrophyllite Inorganic materials 0.000 description 2
- 238000009895 reductive bleaching Methods 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000007127 saponification reaction Methods 0.000 description 2
- 238000012216 screening Methods 0.000 description 2
- 239000000741 silica gel Substances 0.000 description 2
- 229910002027 silica gel Inorganic materials 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- ALSTYHKOOCGGFT-KTKRTIGZSA-N (9Z)-octadecen-1-ol Chemical compound CCCCCCCC\C=C/CCCCCCCCO ALSTYHKOOCGGFT-KTKRTIGZSA-N 0.000 description 1
- QTDIEDOANJISNP-UHFFFAOYSA-N 2-dodecoxyethyl hydrogen sulfate Chemical compound CCCCCCCCCCCCOCCOS(O)(=O)=O QTDIEDOANJISNP-UHFFFAOYSA-N 0.000 description 1
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 241000209761 Avena Species 0.000 description 1
- 235000007319 Avena orientalis Nutrition 0.000 description 1
- 244000043261 Hevea brasiliensis Species 0.000 description 1
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000002202 Polyethylene glycol Substances 0.000 description 1
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 description 1
- 239000004141 Sodium laurylsulphate Substances 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 241000209140 Triticum Species 0.000 description 1
- 235000021307 Triticum Nutrition 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 125000005599 alkyl carboxylate group Chemical group 0.000 description 1
- 150000005215 alkyl ethers Chemical class 0.000 description 1
- PZZYQPZGQPZBDN-UHFFFAOYSA-N aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 description 1
- 150000001412 amines Chemical group 0.000 description 1
- BTBJBAZGXNKLQC-UHFFFAOYSA-N ammonium lauryl sulfate Chemical compound [NH4+].CCCCCCCCCCCCOS([O-])(=O)=O BTBJBAZGXNKLQC-UHFFFAOYSA-N 0.000 description 1
- 238000007774 anilox coating Methods 0.000 description 1
- 125000000129 anionic group Chemical group 0.000 description 1
- 239000003945 anionic surfactant Substances 0.000 description 1
- JXLHNMVSKXFWAO-UHFFFAOYSA-N azane;7-fluoro-2,1,3-benzoxadiazole-4-sulfonic acid Chemical compound N.OS(=O)(=O)C1=CC=C(F)C2=NON=C12 JXLHNMVSKXFWAO-UHFFFAOYSA-N 0.000 description 1
- 235000015173 baked goods and baking mixes Nutrition 0.000 description 1
- 239000003139 biocide Substances 0.000 description 1
- 229920001400 block copolymer Polymers 0.000 description 1
- 235000008429 bread Nutrition 0.000 description 1
- 235000015496 breakfast cereal Nutrition 0.000 description 1
- 238000005282 brightening Methods 0.000 description 1
- 150000007942 carboxylates Chemical class 0.000 description 1
- 239000011111 cardboard Substances 0.000 description 1
- 125000002091 cationic group Chemical group 0.000 description 1
- 239000003093 cationic surfactant Substances 0.000 description 1
- 229940082500 cetostearyl alcohol Drugs 0.000 description 1
- 229960000541 cetyl alcohol Drugs 0.000 description 1
- 235000019504 cigarettes Nutrition 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000002537 cosmetic Substances 0.000 description 1
- 239000013078 crystal Substances 0.000 description 1
- 230000001186 cumulative effect Effects 0.000 description 1
- SYELZBGXAIXKHU-UHFFFAOYSA-N dodecyldimethylamine N-oxide Chemical compound CCCCCCCCCCCC[N+](C)(C)[O-] SYELZBGXAIXKHU-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 239000000975 dye Substances 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 238000001125 extrusion Methods 0.000 description 1
- 150000002191 fatty alcohols Chemical class 0.000 description 1
- 239000000835 fiber Substances 0.000 description 1
- 238000009459 flexible packaging Methods 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 229930182478 glucoside Natural products 0.000 description 1
- 239000007791 liquid phase Substances 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 229940127554 medical product Drugs 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 235000013336 milk Nutrition 0.000 description 1
- 239000008267 milk Substances 0.000 description 1
- 210000004080 milk Anatomy 0.000 description 1
- 239000012764 mineral filler Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- GOQYKNQRPGWPLP-UHFFFAOYSA-N n-heptadecyl alcohol Natural products CCCCCCCCCCCCCCCCCO GOQYKNQRPGWPLP-UHFFFAOYSA-N 0.000 description 1
- 229920006173 natural rubber latex Polymers 0.000 description 1
- 229940055577 oleyl alcohol Drugs 0.000 description 1
- XMLQWXUVTXCDDL-UHFFFAOYSA-N oleyl alcohol Natural products CCCCCCC=CCCCCCCCCCCO XMLQWXUVTXCDDL-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 150000002894 organic compounds Chemical class 0.000 description 1
- 239000003002 pH adjusting agent Substances 0.000 description 1
- 239000011087 paperboard Substances 0.000 description 1
- 235000014594 pastries Nutrition 0.000 description 1
- 239000008194 pharmaceutical composition Substances 0.000 description 1
- 150000003014 phosphoric acid esters Chemical class 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 229920001223 polyethylene glycol Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 125000000075 primary alcohol group Chemical group 0.000 description 1
- 150000003138 primary alcohols Chemical class 0.000 description 1
- 125000001453 quaternary ammonium group Chemical group 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 238000012552 review Methods 0.000 description 1
- 238000000518 rheometry Methods 0.000 description 1
- 239000011435 rock Substances 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 125000003198 secondary alcohol group Chemical group 0.000 description 1
- 150000003333 secondary alcohols Chemical class 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 235000019333 sodium laurylsulphate Nutrition 0.000 description 1
- RYYKJJJTJZKILX-UHFFFAOYSA-M sodium octadecanoate Chemical compound [Na+].CCCCCCCCCCCCCCCCCC([O-])=O RYYKJJJTJZKILX-UHFFFAOYSA-M 0.000 description 1
- 241000894007 species Species 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000010561 standard procedure Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 229940012831 stearyl alcohol Drugs 0.000 description 1
- 229920001909 styrene-acrylic polymer Polymers 0.000 description 1
- 125000001650 tertiary alcohol group Chemical group 0.000 description 1
- 150000003509 tertiary alcohols Chemical class 0.000 description 1
- OULAJFUGPPVRBK-UHFFFAOYSA-N tetratriacontyl alcohol Natural products CCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCCO OULAJFUGPPVRBK-UHFFFAOYSA-N 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- 239000004034 viscosity adjusting agent Substances 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/38—Coatings with pigments characterised by the pigments
- D21H19/40—Coatings with pigments characterised by the pigments siliceous, e.g. clays
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/58—Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H19/60—Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/82—Paper comprising more than one coating superposed
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/82—Paper comprising more than one coating superposed
- D21H19/822—Paper comprising more than one coating superposed two superposed coatings, both being pigmented
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/84—Paper comprising more than one coating on both sides of the substrate
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/16—Sizing or water-repelling agents
Definitions
- the present invention relates generally to coated substrates which have been coated with two different coating compositions.
- the present invention further relates to the use of two different coating compositions to coat a substrate and a method of making a coated substrate.
- Coating compositions are used widely to coat numerous types of substrates (e.g. different materials) which are used for numerous applications.
- coating compositions may be used to coat substrates which are used to package goods such as food and beverage products, electronic products, automotive products, medical/pharmaceutical products and cosmetic products.
- the coated substrate may, for example, be paper or the like.
- the coating composition reduces or prevents the permeation of gases, vapours and liquids through the substrate.
- oils e.g. mineral oils
- coated substrates are not able to effectively reduce or prevent the permeation of both water and oil through the substrate. It is therefore desirable to provide improved or at least alternative coated substrates that can reduce or prevent the permeation of both water and oil through a substrate. For example, it may be desirable to provide a coated substrate which demonstrates improved water barrier properties and/or improved oil barrier properties. This may, for example, allow a reduced coat weight to be used. It may also be desirable to provide a coated substrate that has been coated with water-based coating compositions and may, for example, be easily recyclable.
- WO2013/164646 discloses a fibre based substrate comprising microfibrillated cellulose and having at least first and second barrier coatings formed thereon. These barrier coating may be provided on the opposite or the same side of the substrate.
- a first coating comprising an alcohol-based binder and an inorganic particulate material
- a second coating comprising a latex binder and a phyllosilicate, wherein the phyllosilicate is talc.
- the first coating directly in contact with the substrate and the second coating is directly in contact with the first coating.
- a use of a first coating composition comprising an alcohol-based binder and an inorganic particulate material and a second coating composition comprising a latex binder and a phyllosilicate to coat a substrate (e.g. to make a substrate in accordance with the first aspect of the present invention).
- the phyllosilicate is talc.
- the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating.
- a method of coating a substrate comprising coating the substrate with a first coating composition comprising an alcohol-based binder and an inorganic particulate material and a second coating composition comprising a latex binder and a phyllosilicate, wherein the phyllosilicate is talc. Furthermore, the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating.
- the substrate is paper.
- the alcohol-based binder is polyvinyl alcohol.
- the inorganic particulate material is selected from an alkaline earth metal carbonate or sulphate (e.g. calcium carbonate, magnesium carbonate, dolomite, gypsum), a phyllosilicate, an aluminosilicate (e.g. hydrous kandite clay including kaolin, halloysite clay, ball clay, anhydrous (calcined) kandite clay including metakaolin, fully calcined kaolin and mica), talc, chlorite, pyrophyllite, serpentine, perlite, diatomaceous earth, magnesium hydroxide, aluminium trihydrate and combinations thereof.
- the inorganic particulate material is an aluminosilicate.
- the inorganic particulate material is kaolin.
- the inorganic particulate material has a shape factor equal to or greater than about 10. In certain embodiments, the inorganic particulate material has a shape factor equal to or greater than about 30. In certain embodiments, the inorganic particulate material has a shape factor equal to or greater than about 90.
- the inorganic particulate material and alcohol-based binder are present in the first coating in a weight ratio of from about 5:1 to about 1:5. In certain embodiments, the inorganic particulate material and alcohol-based binder are present in the first coating in a weight ratio of from about 2:1 to about 1:1.
- the latex binder is a styrene butadiene binder.
- the phyllosilicate has a shape factor equal to or greater than about 10. In certain embodiments, the phyllosilicate has a shape factor equal to or greater than about 30. In certain embodiments, the phyllosilicate has a shape factor equal to or greater than about 90.
- the phyllosilicate and latex binder are present in the second coating in a weight ratio of from about 5:1 to about 1:10. In certain embodiments, the phyllosilicate and latex binder are present in the second coating in a weight ratio of from about 2:1 to about 1:1.
- the first coating has a coat weight equal to or less than about 30 gsm (g/m 2 ). In certain embodiments, the first coating has a coat weight equal to or less than about 15 gsm or equal to or less than about 10 gsm. In certain embodiments of any aspect of the present invention, the second coating has a coat weight equal to or less than about 30 gsm (g/m 2 ). In certain embodiments, the second coating has a coat weight equal to or less than about 15 gsm or equal to or less than about 10 gsm. In certain embodiments of any aspect of the present invention, the first and second coatings have a total coat weight equal to or less than about 50 gsm (g/m 2 ). In certain embodiments, the first and second coatings have a total coat weight equal to or less than about 30 gsm or equal to or less than about 20 gsm.
- the first and second coatings are layered such that the first coating is closer to the substrate than the second coating i.e. wherein the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating.
- the substrate has a moisture vapour transmission rate (MVTR) equal to or less than about 200 gsm (g/m 2 ) per day. In certain embodiments, the substrate has a MVTR equal to or less than about 5 gsm (g/m 2 ) per day. In certain embodiments, the substrate has a MVTR equal to or less than about 1 gsm (g/m 2 ) per day. In certain embodiments, the substrate has a MVTR equal to or less than about 0.2 gsm (g/m 2 ) per day.
- MVTR moisture vapour transmission rate
- the substrate has an oil vapour transmission rate (OVTR) equal to or less than about 200 gsm (g/m 2 ) per day. In certain embodiments, the substrate has an OVTR equal to or less than about 8 gsm (g/m 2 ) per day. In certain embodiments, the substrate has a OVTR equal to or less than about 5 gsm (g/m 2 ) per day. In certain embodiments, the substrate has a OVTR equal to or less than about 1 gsm (g/m 2 ) per day.
- OVTR oil vapour transmission rate
- a substrate coated with a first coating and a second coating there is provided herein a substrate coated with a first coating and a second coating.
- the first coating comprises an alcohol-based binder and an inorganic particulate material and the second coating comprises a latex binder and a phyllosilicate.
- a first coating composition comprising an alcohol-based binder and an inorganic particulate material.
- a second coating composition comprising a latex binder and a phyllosilicate.
- the first and second coatings on the substrate may, for example, be a dry residue of the first and second coating compositions respectively.
- inorganic particulate material e.g. phyllosilicate, talc, kaolin
- the inclusion of inorganic particulate material (e.g. phyllosilicate, talc, kaolin) in the coating compositions may advantageously provide benefits such as reduced liquid phase mineral oil transmission, making the system cheaper, improving water barrier properties (i.e., reducing moisture vapour transmission rates through coated substrates such as coated paper) and improving the applicability of the barrier coating composition to the substrate (e.g. paper substrate).
- the inclusion of inorganic particulate material (e.g. phyllosilicate, talc, kaolin) in the coating compositions may also reduce the energy required for drying of the coating compositions.
- the first coating composition comprises an alcohol-based binder and an inorganic particulate material.
- the first coating composition may consist essentially of an alcohol-based binder and an inorganic particulate material, or may consist of an alcohol-based binder and an inorganic particulate material.
- the first coating composition may, for example, be an aqueous suspension/dispersion.
- the solids content of the first coating composition may suitably be as high as possible whilst still giving a suitably fluid composition which may be used in coating a substrate.
- the solids content of the first coating composition may, for example, range from about 10% to about 90% by weight of the composition.
- the solids content of the first coating composition may range from about 10% to about 80%, for example from about 10% to about 70%, for example from about 10% to about 60% by weight of the composition.
- the coating composition may be allowed to dry.
- the first coating may be in the form of a dry residue comprising an alcohol-based binder and an inorganic particulate material.
- an alcohol-based binder is a composition or compound which contains a hydroxyl functional group bonded to a carbon atom, which is capable of functioning as a binder in a coating composition, for example a barrier coating composition, which may be suitable for coating a paper product.
- the alcohol-based binder may comprise a primary alcohol having the general formula RCH 2 OH, a secondary alcohol having the general formula RR'CHOH, a tertiary alcohol having the general formula RR'R"COH, or a combination thereof.
- R, R' and R" represent alkyl groups having from one to twenty carbon atoms.
- R, R' and R" may represent alkyl groups having from one to ten carbon atoms.
- the alcohol-based binder may, for example, comprise primary, secondary and/or tertiary alcohol groups, which may be attached to a polymer backbone.
- the alcohol-based binder may, for example, be a polymer comprising a carboniferous backbone having hydroxyl functional groups appended therefrom.
- the alcohol-based binder may be polyvinyl alcohol.
- Polyvinyl alcohol may be obtained by conventional methods known in the art, such as, for example by partial or complete hydrolysis of polyvinyl acetate to remove acetate groups.
- polyvinyl alcohol obtained by hydrolysis of polyvinyl acetate may contain pendant acetate groups as well as pendant hydroxy groups.
- the polyvinyl alcohol is derived from partially or fully hydrolysed polyvinyl acetate.
- the extent of hydrolysis may be such that at least about 50 mole % of the acetate groups are hydrolysed, for example, at least about 60 mole % of the acetate groups are hydrolysed, for example, at least about 70 mole % of the acetate groups are hydrolysed, for example, at least about 80 mole % of the acetate groups are hydrolysed, for example, at least about 85 mole % of the acetate groups are hydrolysed, for example, at least about 90 mole % of the acetate groups are hydrolysed, for example, at least about 95 mole % of the acetate groups are hydrolysed or, for example, at least about 99 mole % of the acetate groups are hydrolysed.
- the polymer may, for example, be a copolymer of polyvinyl alcohol and other monomers, such as, for example, acetate and acrylate.
- the invention may tend to be discussed in terms of polyvinylalcohol. However, the invention should not be construed as being limited to such embodiments.
- the alcohol-based binder component of the first coating composition may serve not only as binder when applied to the substrate (e.g. a paper substrate), but may also enhance the barrier properties of the first coating composition.
- the moisture vapour transmission rate of the coated substrate may, for example, be improved (e.g. reduced) in comparison to the moisture vapour transmission rate of a coated substrate coated with a first coating that does not comprise an alcohol-based binder.
- the first coating composition may, for example, comprise at least about 20 % by weight alcohol-based binder, based on the total weight of the barrier coating composition, for example, at least about 25 % by weight alcohol-based binder, for example at least about 30 % by weight alcohol-based binder, for example at least about 35 % by weight alcohol-based binder, for example at least about 40% by weight alcohol-based binder, for example at least about 45 % by weight alcohol-based binder, for example at least about 50 % by weight alcohol-based binder, for example at least about 55 % by weight alcohol-based binder, for example at least about 60 % by weight alcohol-based binder, for example at least about 65 % by weight alcohol-based binder, for example at least about 70 % by weight alcohol-based binder or, for example at least about 75 % by weight alcohol-based binder.
- the first coating composition may, for example, comprise up to about 99 % by weight, for example up to about 98 % by weight, for example up to about 95 % by weight, for example up to about 90 % by weight, for example up to about 85 % by weight, for example, up to about 80 % by weight alcohol-based binder.
- the inorganic particulate material may, for example, be selected from an alkaline earth metal carbonate or sulphate (e.g. calcium carbonate, magnesium carbonate, dolomite and gypsum); a phyllosilicate, an aluminosilicate (e.g. hydrous kandite clay including kaolin, halloysite clay, ball clay, anhydrous (calcined) kandite clay such as metakaolin, fully calcined kaolin and mica); talc, chlorite, pyrophyllite, serpentine, perlite, diatomaceous earth, magnesium hydroxide, aluminium trihydrate and combinations thereof.
- an alkaline earth metal carbonate or sulphate e.g. calcium carbonate, magnesium carbonate, dolomite and gypsum
- a phyllosilicate e.g. hydrous kandite clay including kaolin, halloysite clay, ball clay, anhydrous (calcined) kandite clay such as metakaolin
- the inorganic particulate material may, for example, be an aluminosilicate, for example, kaolin.
- the inorganic particulate material may, for example, be kaolin having a high shape factor.
- the inorganic particulate material may, for example, be a magnesium silicate.
- the invention may tend to be discussed in terms of kaolin. However, the invention should not be construed as being limited to such embodiments.
- a kaolin product of high shape factor is considered to be more "platey” than a kaolin product of low shape factor.
- Shape factor is a measure of the ratio of particle diameter to particle thickness for a population of particles of varying size and shape as measured using the electrical conductivity methods, apparatuses, and equations described in U.S. Patent No. 5,576,617 , which is incorporated herein by reference.
- the electrical conductivity of a composition of an aqueous suspension of orientated particles under test is measured as the composition flows through a vessel. Measurements of the electrical conductivity are taken along one direction of the vessel and along another direction of the vessel transverse to the first direction. Using the difference between the two conductivity measurements, the shape factor of the particulate material under test is determined.
- the shape factor of the inorganic particulate material may be equal to or greater than about 10.
- the shape factor may be equal to or greater than about 20, or equal to or greater than about 30, or equal to or greater than about 40, or equal to or greater than about 50, or equal to or greater than about 60 or equal to or greater than about 70.
- the shape factor may be equal to or greater than about 80, for example equal to or greater than about 90 or equal to or greater than about 100.
- the shape factor of the inorganic particulate material may be up to about 95 or up to about 100 or up to about 110 or up to about 150.
- the shape factor may lie in one or more of the following ranges: 20 to 150; 20 to 110; 20 to 100; 30 to 150; 30 to 110; 30 to 100; 40 to 150; 40 to 110; 40 to 100; 50 to 150; 50 to 110; 50 to 100; 60 to 150; 60 to 110; 60 to 100; 70 to 150; 70 to 110; 70 to 100; 80 to 150; 80 to 110; 80 to 100; 90 to 150; 90 to 110; 90 to 100.
- the mean (average) equivalent particle diameter (d 50 value) and other particle size properties referred to herein for the inorganic particulate materials are as measured in a well known manner by sedimentation of the particulate material in a fully dispersed condition in an aqueous medium using a Sedigraph 5100 machine as supplied by Micromeritics Instruments Corporation, Norcross, Georgia, USA (telephone: +1 770 662 3620; web-site: www.micromeritics.com ), referred to herein as a "Micromeritics Sedigraph 5100 unit".
- Such a machine provides measurements and a plot of the cumulative percentage by weight of particles having a size, referred to in the art as the 'equivalent spherical diameter' (esd), less than given esd values.
- the mean particle size d 50 is the value determined in this way of the particle esd at which there are 50% by weight of the particles which have an equivalent spherical diameter less than that d 50 value.
- the term d 90 is the particle size value less than which there are 90% by weight of the particles.
- the inorganic particulate material may, for example, have a mean equivalent particle diameter (d 50 ) less than or equal to about 10 microns ( ⁇ m) (by Sedigraph), e.g. less than or equal to about 8 ⁇ m , or less than or equal to about 6 ⁇ m, or less than or equal to about 4 ⁇ m, or less than or equal to about 2 ⁇ m, or less than or equal to about 1.5 ⁇ m, particularly less than or equal to about 1 ⁇ m, e.g. less than or equal to about 0.5 ⁇ m, e.g. less than or equal to about 0.4 ⁇ m or, e.g., less than or equal to about 0.3 ⁇ m.
- d 50 mean equivalent particle diameter
- ⁇ m microns
- the value of d 50 may, for example, be in the range of about 0.2 ⁇ m to about 2 ⁇ m, for example about 0.3 to about 1.5 ⁇ m, for example about 0.3 to about 1 ⁇ m, or for example about 1 ⁇ m to about 2 ⁇ m.
- the inorganic particulate material may, for example, have a d 90 of less than or equal to about 5 ⁇ m, particularly less than or equal to about 3 ⁇ m, e.g., less than or equal to about 2 ⁇ m.
- the value of d 90 may, for example, be in the range of about 0.5 ⁇ m to about 3 ⁇ m, for example about 1 ⁇ m to about 3 ⁇ m or, for example, about 0.5 ⁇ m to 2 ⁇ m.
- the range of fine content of inorganic particulate i.e. the wt% less than 0.25 ⁇ m may lie in the range of about 5 wt% to about 95 wt%, for example about 40 wt% to about 90 wt% or about 5 wt% to about 20 wt%.
- the kaolin may, for example, have a shape factor equal to or greater than about 30 and a d 90 of less than about 2 ⁇ m.
- the kaolin may have a shape factor equal to or greater than about 60, or 70, or 90, and a d 90 of less than about 2 ⁇ m.
- the kaolin may, for example, have a shape factor between about 10 and about 20 and a d 50 of less than about 1 ⁇ m, for example, less than or equal to about 0.5 ⁇ m.
- the kaolin may, for example, have a shape factor between about 25 and about 50 and a d 50 of less than about 0.3 ⁇ m.
- the inorganic particulate material may, for example, be an aluminosilicate having a shape factor between about 20 and 40, and a d 50 of less than about 0.5 ⁇ m.
- Kaolin clay used in this invention may be a processed material derived from a natural source, namely raw natural kaolin clay mineral.
- the processed kaolin clay may typically contain at least about 50% by weight kaolinite.
- most commercially processed kaolin clays contain greater than about 75% by weight kaolinite and may contain greater than about 90%, in some cases greater than about 95% by weight of kaolinite.
- Kaolin clay used in the present invention may be prepared from the raw natural kaolin clay mineral by one or more other processes which are well known to those skilled in the art, for example by known refining or beneficiation steps.
- the clay mineral may be bleached with a reductive bleaching agent, such as sodium hydrosulfite. If sodium hydrosulfite is used, the bleached clay mineral may optionally be dewatered, and optionally washed and again optionally dewatered, after the sodium hydrosulfite bleaching step.
- a reductive bleaching agent such as sodium hydrosulfite.
- the clay mineral may be treated to remove impurities, e. g. by flocculation, flotation, or magnetic separation techniques well known in the art.
- the clay mineral may be untreated in the form of a solid or as an aqueous suspension.
- the process for preparing the particulate kaolin clay used in the present invention may also include one or more comminution steps, e.g., grinding or milling.
- Light comminution of a coarse kaolin is used to give suitable delamination thereof.
- the comminution may be carried out by use of beads or granules of a plastic (e. g. nylon), sand or ceramic grinding or milling aid.
- the coarse kaolin may be refined to remove impurities and improve physical properties using well known procedures.
- the kaolin clay may be treated by a known particle size classification procedure, e.g., screening and centrifuging (or both), to obtain particles having a desired d 50 value or particle size distribution.
- the inorganic particulate material When the inorganic particulate material is obtained from naturally occurring sources, it may be that some mineral impurities will contaminate the ground material. For example, naturally occurring kaolin may be present in association with other minerals. Thus, the inorganic particulate material may include an amount of impurities. In general, however, the inorganic particulate material will contain less than about 5% by weight, preferably less than about 1% by weight, of other mineral impurities.
- the first coating composition may, for example, comprise at least about 20 % by weight inorganic particulate material, based on the total weight of the barrier coating composition, for example, at least about 25 % by weight inorganic particulate material, for example at least about 30 % by weight inorganic particulate material, for example at least about 35 % by weight inorganic particulate material, for example at least about 40% by weight inorganic particulate material, for example at least about 45 % by weight inorganic particulate material, for example at least about 50 % by weight inorganic particulate material, for example at least about 55 % by weight inorganic particulate material, for example at least about 60 % by weight inorganic particulate material, for example at least about 65 % by weight inorganic particulate material, for example at least about 70 % by weight inorganic particulate material or, for example at least about 75 % by weight inorganic particulate material.
- the first coating composition may, for example, comprise no more than about 99% by weight, for example no more than about 98 % by weight, for example no more than about 95 % by weight, for example no more than about 90 % by weight, for example no more than about 80 % by weight, for example no more than about 70 % by weight, for example no more than about 60 % by weight, for example no more than about 50 % by weight inorganic particulate material.
- the first coating composition may, for example, be applied as a single layer.
- the weight ratio of inorganic particulate material to alcohol-based binder may, for example, range from about 5:1 to about 1:10, for example, from about 5:1 to about 1:9, for example, from about 5:1 to about 1: 7, for example, from about 5:1 to about 1:5, for example, from about 4:1 to about 1:4, for example, from about 3:1 to about 1:3, for example, from about 2:1 to about 1:2, for example, from about 1.5:1 to about 1:1.5, for example, from about 1.25:1 to about 1:1.25.
- the weight ratio of inorganic particulate material to alcohol-based binder may, for example, be about 1:1.
- the second coating composition comprises a latex binder and a phyllosilicate.
- the second coating composition may consist essentially of or consist of a latex binder and a phyllosilicate, or may consist of a latex binder and a phyllosilicate.
- the second coating composition may, for example, be an aqueous suspension/dispersion.
- the solids content of the second coating composition may suitably be as high as possible whilst still giving a suitably fluid composition which may be used in coating a substrate.
- the solids content of the second coating composition may, for example, range from about 10% to about 90% by weight of the composition.
- the solids content of the second coating composition may range from about 10% to about 80%, for example from about 10% to about 70%, for example from about 10% to about 60% by weight of the composition.
- the coating composition may be allowed to dry.
- the second coating may be in the form of a dry residue comprising a latex binder and a phyllosilicate.
- latex is used herein to mean a dispersion/suspension (e.g. aqueous dispersion/suspension) of one or more polymer(s).
- the polymers may, for example, be natural or synthetic. Therefore, the term “latex binder” means any composition comprising, consisting essentially of or consisting of one or more polymers, which is capable of functioning as a binder in a coating composition, for example a barrier coating composition, which may be suitable for coating a paper product.
- the latex binder may, for example, be natural rubber latex obtained from, for example, rubber trees.
- the latex binder may, for example, be a synthetic latex.
- the latex binder may, for example, be a styrene polymer, for example copolymers including styrene monomers.
- the latex binder may be a copolymer comprising, consisting essentially of or consisting of alkene monomers (e.g. ethylene, propylene, butylene, butadiene) and styrene monomers.
- the latex binder may be styrene butadiene.
- the latex binder may, for example, be polyurethane, polyester and/or polyethyleneacrylate dispersions.
- the invention may tend to be discussed in terms of styrene butadiene. However, the invention should not be construed as being limited to such embodiments.
- the second coating composition may, for example, comprise at least about 20 % by weight latex binder, based on the total weight of the barrier coating composition, for example, at least about 25 % by weight latex binder, for example at least about 30 % by weight latex binder, for example at least about 35 % by weight latex binder, for example at least about 40% by weight latex binder, for example at least about 45 % by weight latex binder, for example at least about 50 % by weight latex binder, for example at least about 55 % by weight latex binder, for example at least about 60 % by weight latex binder, for example at least about 65 % by weight latex binder, for example at least about 70 % by weight latex binder or, for example at least about 75 % by weight latex binder.
- the second coating composition may, for example, comprise up to about 99 % by weight, for example up to about 98 % by weight, for example up to about 95 % by weight, for example up to about 90 % by weight, for example up to about 85 % by weight, for example up to about 80 % by weight latex binder.
- the phyllosilicate is talc.
- the phyllosilicate may be a combination of two or more phyllosilicates, for example a combination of talc and another phyllosilicate, for example talc and kaolin.
- the invention may tend to be discussed in terms of talc. However, the invention should not be construed as being limited to such embodiments.
- Talc may comprise, consist essentially of, or consist of natural talc particulate or synthetic talc particulate or a mixture of natural talc particulate and synthetic talc particulate.
- Natural talc means talc derived from a natural resource, i.e., natural talc deposits.
- Natural talc may be either the hydrated magnesium silicate of formula Si 4 Mg 3 O 10 (OH) 2 , which is arranged as a stack of laminae, or the mineral chlorite (hydrated magnesium aluminium silicate), or a mixture of the two, optionally associated with other minerals, for example, dolomite.
- Natural talc occurs as rock composed of talc crystals.
- synthetic talc means talc that has been synthesized using a man-made synthetic process.
- the talc used in the present invention may be a macrocrystalline talc or microcrystalline talc.
- the phyllosilicate mineral may, for example, be bleached with a reductive bleaching agent, such as sodium hydrosulfite. If sodium hydrosulfite is used, the bleached phyllosilicate mineral may optionally be dewatered, and optionally washed and again optionally dewatered, after the sodium hydrosulfite bleaching step.
- a reductive bleaching agent such as sodium hydrosulfite.
- the phyllosilicate mineral may be treated to remove impurities, e.g. by flocculation, flotation, or magnetic separation techniques well known in the art.
- the phyllosilicate mineral may be untreated in the form of a solid or as an aqueous suspension.
- the process for preparing the phyllosilicate may include one or more comminution steps, e.g., grinding or milling.
- Light comminution of a coarse phyllosilicate is used to give suitable delamination thereof.
- the comminution may use beads or granules of a plastic (e.g. nylon), sand or ceramic grinding or milling aid.
- the coarse phyllosilicate may be refined to remove impurities and improve physical properties using well known procedures.
- the phyllosilicate may be treated by a known particle size classification procedure, e.g., screening and centrifuging (or both), to obtain particles having a desired particle size distribution.
- the phyllosilicate may be calcined or non-calcined.
- the phyllosilicate may be calcined talc or non-calcined talc.
- the phyllosilicate material used in embodiments of the present invention will contain less than 5% by weight, preferably less than 1% by weight of other mineral impurities.
- the first coating composition may, for example, comprise at least about 20 % by weight phyllosilicate, based on the total weight of the barrier coating composition, for example, at least about 25 % by weight phyllosilicate, for example at least about 30 % by weight phyllosilicate, for example at least about 35 % by weight phyllosilicate, for example at least about 40% by weight phyllosilicate, for example at least about 45 % by weight phyllosilicate, for example at least about 50 % by weight phyllosilicate, for example at least about 55 % by weight phyllosilicate, for example at least about 60 % by weight phyllosilicate, for example at least about 65 % by weight phyllosilicate, for example at least about 70 % by weight phyllosilicate or, for example at least about 75 % by weight phyllosilicate.
- the first coating composition may, for example, comprise no more than about 99 % by weight, for example no more than about 98 % by weight, for example no more than about 95 % by weight, for example no more than about 90 % by weight, for example no more than about 80 % by weight, for example no more than about 70 % by weight, for example no more than about 60 % by weight, for example no more than about 50 % by weight phyllosilicate.
- the second coating composition may, for example, be applied as a single layer.
- the weight ratio of the latex binder and phyllosilicate may be chosen so that the maximum weight of phyllosilicate particles is obtained in the coating without creating pores in the coating. This may, for example, depend on the particle size of the phyllosilicate.
- the weight ratio of phyllosilicate to latex binder may, for example, range from about 5:1 to about 1:10, for example, from about 5:1 to about 1:9, for example, from about 5:1 to about 1:7, for example, from about 5:1 to about 1:5, for example, from about 4:1 to about 1:4, for example, from about 3:1 to about 1:3, for example, from about 2:1 to about 1:2.
- the weight ratio of phyllosilicate to latex binder may be from about 2:1 about 1:1.
- the phyllosilicate may, for example, have a high shape factor.
- the phyllosilicate may be considered to be more "platey” than a phyllosilicate product of low shape factor.
- Shape factor as used herein, is as described above in relation to the first coating composition.
- the shape factor of the phyllosilicate may suitably be equal to or greater than about 10.
- the shape factor may be equal to or greater than about 20, or equal to or greater than about 30, or equal to or greater than about 40, or equal to or greater than about 50, or equal to or greater than about 60 or equal to or greater than about 70.
- the shape factor may be equal to or greater than about 80, for example equal to or greater than about 90 or equal to or greater than about 100.
- the shape factor of the phyllosilicate e.g. talc
- the shape factor may lie in one or more of the following ranges: 20 to 150; 20 to 110; 20 to 100; 30 to 150; 30 to 110; 30 to 100; 40 to 150; 40 to 110; 40 to 100; 50 to 150; 50 to 110; 50 to 100; 60 to 150; 60 to 110; 60 to 100; 70 to 150; 70 to 110; 70 to 100; 80 to 150; 80 to 110; 80 to 100; 90 to 150; 90 to 110; 90 to 100.
- the phyllosilicate (e.g. talc) may, for example, have a mean equivalent particle diameter (d 50 ) less than or equal to about 10 microns ( ⁇ m) (by Sedigraph), e.g. less than or equal to about 8 ⁇ m, or less than or equal to about 6 ⁇ m, or less than or equal to about 4 ⁇ m.
- d 50 mean equivalent particle diameter
- the phyllosilicate may have a d 50 of less than or equal to about 2 ⁇ m, for example equal to or less than about 1.5 ⁇ m.
- the phyllosilicate may, for example, have a d 50 ranging from about 0.1 ⁇ m to about 10 ⁇ m, for example from about 0.1 ⁇ m to about 5 ⁇ m, for example from about 0.1 ⁇ m to about 2 ⁇ m, for example from about 0.1 ⁇ m to about 1.5 ⁇ m, for example from about 0.5 ⁇ m to about 2 ⁇ m or from about 0.5 ⁇ m to about 1.5 ⁇ m.
- the phyllosilicate may, for example, have a d 90 of less than or equal to about 20 ⁇ m, for example less than or equal to about 15 ⁇ m, for example less than or equal to about 10 ⁇ m.
- the phyllosilicate may have a d 90 of less than or equal to about 9 ⁇ m, for example less than or equal to about 8 ⁇ m, for example less than or equal to about 7 ⁇ m, for example less than or equal to about 6 ⁇ m.
- the value of d 90 may, for example, be in the range of about 1 ⁇ m to about 10 ⁇ m, for example about 1 ⁇ m to about 8 ⁇ m or, for example, about 1 ⁇ m to 6 ⁇ m.
- the range of fine content of phyllosilicate particles i.e. the wt% less than 0.25 ⁇ m may lie in the range of about 5 wt% to about 95 wt%, for example about 40wt% to about 90 wt% or about 5 wt% to about 20 wt%.
- the phyllosilicate (e.g. talc) may, for example, have a shape factor of greater than about 30 and a d 50 equal to or less than about 2 ⁇ m.
- the first and/or second coating compositions may contain one or more optional additional components, if desired.
- the first and/or second coating compositions may optionally comprise one or more further additive components, as discussed below.
- the first and/or second coating compositions may be in the form of an aqueous suspension of the binder and inorganic particulate material components defined above, and optionally one or more further additive components, as discussed below.
- Such additional components may suitably be selected from known additives for coating compositions (e.g. paper coating compositions). Some of these optional additives may provide more than one function in the coating composition. Examples of known classes of optional additives are as follows:
- any of the above additives and additive types may be used alone or in admixture with each other and with other additives, if desired.
- first and/or second coating compositions may further comprise one or more crosslinker(s).
- first coating composition may further comprise one or more crosslinker(s).
- first or second coating compositions may further comprise one or more surfactant(s).
- both the first and second coating compositions may further comprise one or more surfactant(s).
- the use of one or more surfactant(s) in the first and/or second coating compositions may, for example, improve the application of one coating on another (e.g. the recoatability of the coatings).
- the use of one or more surfactant(s) may, for example, improve the interaction between the two coatings.
- Surfactants include, without limitation, ionic (e.g. anionic and/or cationic) and non-ionic surfactants.
- Anionic surfactants include, for example, sulphate, sulphonate and phosphate esters (e.g. ammonium lauryl sulphate, sodium lauryl sulphate, sodium lauryl ether sulphate) and carboxylates (e.g. alkyl carboxylates such as sodium stearate).
- Cationic surfactants include, for example, primary, secondary, tertiary and quaternary amines and quaternary ammonium species.
- Non-ionic surfactants include, for example, fatty alcohols, cetyl alcohol, stearyl alcohol, cetostearyl alcohol, oleyl alcohol, polyoxyethylene glycol alkyl ethers, polyoxypropylene glycol alkyl ethers, glucoside alkyl ethers, polyoxyethylene glycol octylphenol ethers, polyoxylene glycol alkylphenol ethers, glycerol alkyl ethers, sorbitan alkyl esters, dodecyldimethylamine oxide and block copolymers of polyethylene glycol and polypropylene glycol.
- the total amount of the one or more surfactant(s) in the first or second coating composition may, for example, be from about 0.01 wt% to about 5.0 wt%.
- the total amount of surfactant in the first or second coating composition may range from about 0.1 wt% to about 3.0 wt% or from about 0.1 wt% to about 2.0 wt% or from about 0.1 wt% to about 1.0 wt%.
- the total amount of surfactant in the first or second coating composition may range from about 0.5 wt% to about 3.0 wt% or from about 0.5 wt% to about 2.0 wt% or from about 0.5 wt% to about 1.0 wt%.
- the total amount of surfactant in the first or second coating composition may be about 0.5 wt%.
- the percentages by weight (based on the dry weight of inorganic particulate material (100%) present in the composition) can vary as understood by those skilled in the art.
- the minimum amount may be about 0.01% by weight based on the dry weight of the inorganic particulate material.
- the maximum amount of any one or more of the above additives may, for example, be about 5.0% by weight based on the dry weight of the inorganic particulate material.
- the maximum amount may be about 3.0% or 2.0% by weight based on the dry weight of the inorganic particulate material.
- a substrate may, for example, be coated with the first and second coating compositions described above, including all embodiments thereof in all possible combinations.
- a substrate provided with a first coating comprising an alcohol-based binder and an inorganic particulate material, and a second coating comprising a latex binder and a phyllosilicate.
- the substrate may, for example, be any material, for example selected from plastics (e.g. low density polyethylene, polypropylene, polyamides and the like), metals (e.g foils such as aluminium foil), textiles and paper.
- the material may, for example, be coloured, treated (e.g. varnished or laminated) or both.
- the coating of the substrates may, for example, comprise a dry residue of the first and/or second coating compositions described herein.
- the invention may be defined in terms of paper substrates. However, the invention should not be construed as being limited to such embodiments.
- paper substrate should be understood to mean all forms of paper, including board, such as, for example, white-lined board and linerboard, cardboard, paperboard, coated board, and the like.
- board such as, for example, white-lined board and linerboard, cardboard, paperboard, coated board, and the like.
- paper coated or uncoated, which may be coated using the compositions disclosed herein, including paper suitable for food packaging, perishable goods other than food, e.g., pharmaceutical products and compositions, books, magazines, newspapers and the like, and office papers.
- the paper may be calendered or super calendared as appropriate; for example super calendered magazine paper for rotogravure and offset printing may be made according to the present methods.
- Paper suitable for light weight coating (LWC), medium weight coating (MWC) or machine finished pigmentisation (MFP) may also be coated using the present compositions.
- the first coating is in direct contact with the substrate and the second coating is in direct contact with the first coating.
- the first coating on the substrate may, for example, have a coating weight between about 2 gsm and about 30 gsm (grams per m 2 ), for example between about 3 gsm and about 28 gsm.
- the first coating may, for example, have a coating weight of less than about 15 gsm.
- the first coating may have a coating weight of less than about 12 gsm, for example less than about 10 gsm.
- the first coating may, for example, have a coating weight of less than about 8 gsm, for example less than about 6 gsm, for example less than about 5 gsm.
- the second coating on the substrate may, for example, have a coating weight between about 3 gsm and about 30 gsm (grams per m 2 ), for example between about 2 gsm and about 28 gsm.
- the second coating may, for example, have a coating weight of less than about 15 gsm.
- the second coating may have a coating weight of less than about 12 gsm, for example less than about 10 gsm.
- the second coating may, for example, have a coating weight of less than about 8 gsm, for example less than about 6 gsm, for example less than about 5 gsm.
- the total coating weight of the first and second coatings on the substrate may, for example, range between about 2 gsm and about 50 gsm (grams per m 2 ).
- the total coating weight of the first and second coatings may range from about 2 gsm to about 40 gsm, for example from about 2 gsm to about 30 gsm.
- the total coating weight of the first and second coatings on the substrate may be less than about 30 gsm, for example less than about 25 gsm, for example less than about 20 gsm.
- the total coating weight of the first and second coatings on the substrate may be less than about 15 gsm.
- the first and second coating compositions used to coat the substrate may be barrier coating compositions.
- the first and second coating compositions may reduce or prevent the permeation of gases and/or vapours and/or liquids through the coated substrate.
- the coating compositions may reduce or prevent the permeation of water and/or organic oils through the coated product (i.e. reduce the moisture vapour and/or oil vapour transmission rate of the coated product).
- the coated substrate may, for example, have a moisture vapour transmission rate (MVTR) which is equal to or less than about 200 gsm (g/m 2 ) per day.
- MVTR moisture vapour transmission rate
- the coated substrate may have a MVTR which is equal to or less than about 150 gsm per day, for example equal to or less than about 100 gsm per day, for example equal to or less than about 50 gsm per day, for example equal to or less than about 30 gsm per day, for example equal to or less than about 20 gsm per day, for example equal to or less than about 10 gsm per day.
- the coated substrate may have a MVTR of equal to or less than about 8 gsm per day, for example equal to or less than about 5 gsm per day, for example equal to or less than about 4 gsm per day, for example equal to or less than about 3 gsm per day, for example equal to or less than about 2 gsm per day, for example equal to or less than about 1 gsm per day.
- the coated substrate may have a MVTR of equal to or less than about 0.9 gsm per day, for example equal to or less than about 0.8 gsm per day, for example equal to or less than about 0.7 gsm per day, for example equal to or less than about 0.6 gsm per day, for example equal to or less than about 0.5 gsm per day, for example equal to or less than about 0.4 gsm per day, for example equal to or less than about 0.3 gsm per day, for example equal to or less than about 0.2 gsm per day, for example equal to or less than about 0.1 gsm per day.
- the coated substrate may have a MVTR ranging from about 0.01 gsm per day to about 200 gsm per day, for example from about 0.1 gsm per day to about 50 gsm per day, for example from about 0.2 gsm per day to about 5 gsm per day, for example from about 0.5 gsm per day to about 1 gsm per day.
- the MVTR may be measured according to TAPPI T448.
- the opening of a pot containing silica gel or calcium chloride is covered with the coated substrate and the pot is weighed periodically over several hours or days depending on the expected MVTR level.
- the amount of water entering the pot is determined by measuring the change in weight of the silica gel or calcium chloride.
- the experiment is carried out at 23°C and 50% humidity.
- Each coating composition may be present at a coatweight equal to or less than about 10 gsm (e.g. total coatweight equal to or less than about 20 gsm).
- the substrate used may be a woodfree base paper.
- the base paper may be pre-coated with a pre-coating composition to improve smoothness of the paper.
- the coated substrate may, for example, have an oil vapour transmission rate (OVTR) which is equal to or less than about 200 gsm (g/m 2 ) per day.
- OVTR oil vapour transmission rate
- the coated substrate may have an OVTR which is equal to or less than about 150 gsm per day, for example equal to or less than about 100 gsm per day, for example equal to or less than about 50 gsm per day, for example equal to or less than about 30 gsm per day, for example equal to or less than about 20 gsm per day, for example equal to or less than about 20 gsm per day, for example equal to or less than about 10 gsm per day.
- OVTR oil vapour transmission rate
- the coated substrate may have a OVTR of equal to or less than about 8 gsm per day, for example equal to or less than about 5 gsm per day, for example equal to or less than about 4 gsm per day, for example equal to or less than about 3 gsm per day, for example equal to or less than about 2 gsm per day, for example equal to or less than about 1 gsm per day.
- the coated substrate may have a OVTR of equal to or less than about 0.9 gsm per day, for example equal to or less than about 0.8 gsm per day, for example equal to or less than about 0.7 gsm per day, for example equal to or less than about 0.6 gsm per day, for example equal to or less than about 0.5 gsm per day, for example equal to or less than about 0.4 gsm per day, for example equal to or less than about 0.3 gsm per day, for example equal to or less than about 0.2 gsm per day, for example equal to or less than about 0.1 gsm per day.
- the coated substrate may have an OVTR ranging from about 0.01 gsm per day to about 200 gsm per day, for example from about 0.1 gsm per day to about 50 gsm per day, for example from about 0.2 gsm per day to about 5 gsm per day, for example from about 0.5 gsm per day to about 1 gsm per day.
- the OVTR may be measured a method corresponding to that used to measure MVTR.
- the opening of a pot containing decane or heptane is covered with the coated substrate and the pot is weighed periodically over several hours or days depending on the expected OVTR level.
- the amount of decane or heptane leaving the pot is determined by measuring the change in weight of the pot.
- the experiment is carried out at 23°C and 50% humidity.
- Each coating composition may be present at a coatweight equal to or less than about 10 gsm (e.g. total coatweight equal to or less than about 20 gsm).
- the substrate used may be a woodfree base paper.
- the base paper may be pre-coated with a pre-coating composition to improve smoothness of the paper
- One advantage of using two different coating compositions may be that the barrier can be improved for both organic and water transmission. This may not be possible in the same way if only one type of coating is used (e.g. the one coating will only be optimized for either organic or water transmission but not both).
- another advantage may be that the lower or inner layer may be protected from the detrimental influence of the substance which is blocked by the upper or outer layer.
- an inner organic barrier layer may be protected from the detrimental effect of water by using an upper water barrier layer. Therefore, the inner layer (e.g. organic barrier layer) may perform better over time because it is not deteriorated (e.g. by water).
- the coating compositions disclosed herein may be used to coat various materials and substrates to form coated substrate.
- first and second coatings described above to coat a substrate (to make a coated substrate) and a method of coating a substrate.
- the first and second coatings (first and second coating compositions) may be as described above, including all embodiments thereof and all possible combinations thereof.
- the first and second coating compositions may be prepared by combining (e.g. mixing) the binder (e.g. alcohol-based binder or latex binder) and inorganic particulate material (e.g. kaolin or phyllosilicate such as talc) and other optional additives in appropriate amounts into an aqueous liquid to prepare a suspension of said components.
- the coating compositions may suitably be prepared by conventional mixing techniques, as will be known in the art.
- the inorganic particulate material may, for example, be an aqueous slurry. This may, for example, be prepared using a suitable mixer, following which the slurry is blended with a solution of the binder. The resulting mixture may be screened prior to coating.
- Slurry make-down process may, for example, include the addition of one or more additives, for example which may be selected from one or more dispersants, one or more wetting agents, one or more pH-adjusting agents.
- the slurry make-down process may, for example, involve dispersing the inorganic particulate material in the aqueous medium at high shear, for example between 2000 and 3000 rpm.
- the final viscosity of the phyllosilicate slurry may, for example, range from about 200 cP (200 mPa.s) to about 400 cP (400 mPa.s).
- the final viscosity of the phyllosilicate slurry may range from about 250 cP (250 mPa.s) to about 350 cP (350 mPa.s).
- the method of coating a substrate may, for example, comprise coating the substrate with a first coating composition comprising an alcohol-based binder and an inorganic particulate material and a second coating composition comprising a latex binder and a phyllosilicate.
- the coating process may be carried out using standard techniques which are known to the skilled person.
- the coating process may also involve calendaring or super-calendaring the coated substrate.
- the methods of coating may be performed using an apparatus comprising (i) an application for applying the coating composition to the material to be coated and (ii) a metering device for ensuring that a correct level of coating composition is applied.
- the metering device is downstream of it.
- the correct amount of coating composition may be applied to the applicator by the metering device, e.g., as a film press.
- the paper web support ranges from a backing roll, e.g. via one or two applicators, to nothing (i.e. just tension).
- the time the coating is in contact with the paper before the excess is finally removed is the dwell time - and this may be short, long or variable.
- the coating may added by a coating head at a coating station.
- paper grades are uncoated, single-coated, double-coated and even triple-coated.
- the initial coat may have a cheaper formulation and optionally coarser pigment in the coating composition.
- a coater that is applying coating on each side of the paper will have two or four coating heads, depending on the number of coating layers applied on each side. Most coating heads coat only one side at a time, but some roll coaters (e.g., film presses, gate rolls, and size presses) coat both sides in one pass.
- coaters examples include, without limitation, air knife coaters, blade coaters, rod coaters, bar coaters, multi-head coaters, roll coaters, roll or blade coaters, cast coaters, laboratory coaters, gravure coaters, kisscoaters, liquid application systems, reverse roll coaters, curtain coaters, spray coaters and extrusion coaters.
- Water may be added to the solids comprising the coating composition to give a concentration of solids which is preferably such that, when the composition is coated onto a sheet to a desired target coating weight, the composition has a rheology which is suitable to enable the composition to be coated with a pressure (i.e., a blade pressure) of between 1 and 1.5 bar.
- a pressure i.e., a blade pressure
- the barrier coating is printed on the paper product, e.g., printed on a surface of the fibrous substrate of the paper product.
- the printing may utilize a technique selected from offset printing, flexographic printing or rotogravure printing, thereby allowing the coating composition to be applied to areas where it is required.
- Offset printing is a widely used printing technique, as will be well understood by a person of ordinary skill in the art.
- the coating composition is transferred (or "offset") from a plate to a rubber blanket, then to the surface of the substrate (e.g., paper substrate).
- the substrate may be sheet-fed or web-fed.
- the web-fed process may be heatset or coldset.
- Flexographic printing is a widely used printing technique, as will be well understood by a person of ordinary skill in the art. Using this technique, the coating composition is transferred from a first roll which is partially immersed in a tank comprising the coating composition.
- the coating composition is then transferred to the anilox roll (or meter roll) whose texture holds a specific amount of the coating composition since it is covered with thousands of small wells or cups that enable it to meter the coating composition to the printing plate in a uniform thickness evenly and quickly.
- the substrate is finally sandwiched between the plate and the impression cylinder to transfer the barrier coating.
- the coated substrate is then fed through a dryer, which allows the coating to dry.
- flexographic printing enables the coating composition to be applied in a series of thin layers (e.g., a series of fiver layers with a total coat weight of about 5 gsm) which has sufficient hold out to maintain good barrier properties (to liquid and/or vapour mineral oil transmission) for coating compositions comprising greater than about 60 % by weight, for example, greater than about 65 % by weight of inorganic particulate, based on the total dry weight of the composition.
- Rotogravure printing is a widely used printing technique, as will be well understood by a person of ordinary skill in the art.
- the substrate e.g. paper
- the substrate may be formable or formed into a three-dimensional product, which may be suitable as food grade or pharmaceutical grade packaging, at least a portion of a first interior facing surface of the paper substrate is coated with the first and second coatings, and a second exterior facing surface of the paper substrate may be coated or printed with an ink-based product.
- the substrate e.g. paper
- the substrate may be derived from recycled pulp containing mineral oil and/or the ink-based product may comprise mineral oil.
- Coated products include brown corrugated boxes, flexible packaging including retail and shopping bags, food and hygiene bags and sacks, milk and beverage cartons, boxes suitable for cereals and the like, self adhesive labels, disposable cups and containers, envelopes, cigarette paper and bible paper.
- the fibrous substrate may comprise virgin pulp (i.e., pulp which is not derived from a recycled material).
- the fibrous substrate may comprise a mixture of recycled pulp and virgin pulp.
- a further aspect of the present invention is directed to packaged foodstuffs, pharmaceutical products or other perishable goods which are formed from the coated substrates (e.g. coated paper substrates) of the present invention.
- Foodstuffs are many and various and include, for example, grain based products such as breakfast cereals (e.g., oats, cornflakes and the like), flours (e.g., wheat flour and the like) and bakery products (e.g., breads, pastries and the like).
- Pharmaceutical products include, for example, tablets, powders suspensions and liquid-based products.
- the non-porous substrate may be a transparent paper, a translucent paper, a plastic film, such as polyethylene, polypropylene and the like, or a metal foil, such as aluminium foil.
- the substrate may be coloured, treated (e.g., varnished or laminated), or both.
- a porous polyolefin substrate e.g., polyethylene or polypropylene coated with the coating compositions described herein.
- base paper 1 and base paper 2 Two different base papers (herein referred to as base paper 1 and base paper 2) were coated as shown in Table 1 below.
- the first and second coating compositions were prepared by high shear mixing of the components.
- the first and second coatings were applied to the base papers a hand draw down rod coater.
- the first and second coatings, where present, were each applied at a coat weight of 10 gsm.
- Table 1 Coating First Coating Second Coating 1 None None 2 100 parts kaolin 100 parts kaolin 100 parts polyvinyl alcohol binder (88% hydrolysis) 100 parts polyvinyl alcohol binder (88% hydrolysis) 3 65 parts talc 100 parts kaolin 35 parts styrene butadiene binder 100 parts polyvinyl alcohol binder (88% hydrolysis) 4 100 parts kaolin 65 parts talc 100 parts polyvinyl alcohol binder (98% hydrolysis) 35 parts styrene butadiene binder 14 parts crosslinker 5 100 parts kaolin 65 parts talc 100 parts polyvinyl alcohol binder (88% hydrolysis) 35 parts styrene butadiene binder 6 65 parts talc 65 parts talc 35 parts styrene butadiene binder 35 parts st
- Base paper 1 is a wood free paper, pre-coated on its back side on a paper machine online using a filmpress (Speedcoater).
- Base paper 2 is a wood free paper, pre-coated on both sides on a paper machine online using a filmpress (Speedcoater).
- the pre-coat is not considered as a barrier coating but only smoothens the paper surface for the following barrier coatings.
- the kaolin used in the first and second coatings had a shape factor of 100, a GE brightness of 86 and an average particle size, d 50 of 1.535 ⁇ m.
- the talc used in the first and second coatings had a shape factor of 100, a talc/chlorite content of 98% and a d 50 of 2 ⁇ m.
- the polyvinyl alcohol used in the first and second coatings was either:
- ester value referred to above denotes the number of mg of KOH needed to neutralize the acid released from the ester by saponification in 1 g of substance.
- the residual acetyl content is calculated from the ester value as follows: EV x 0.0767.
- the styrene butadiene used was Styron DL1066.
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- Mechanical Treatment Of Semiconductor (AREA)
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PCT/EP2015/078501 WO2016087578A1 (en) | 2014-12-03 | 2015-12-03 | Coated substrate |
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GB202011616D0 (en) * | 2020-07-27 | 2020-09-09 | Nicoventures Trading Ltd | A Package |
US11549216B2 (en) | 2020-11-11 | 2023-01-10 | Sappi North America, Inc. | Oil/grease resistant paper products |
WO2023072628A1 (de) | 2021-10-25 | 2023-05-04 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e. V. | Gasbarriereschicht, nanokomposit-lack zur erzeugung der gasbarriereschicht sowie verfahren zur herstellung des lacks |
GB202200806D0 (en) * | 2022-01-21 | 2022-03-09 | British American Tobacco Investments Ltd | A package |
CN114725622A (zh) * | 2022-04-14 | 2022-07-08 | 中材锂膜(常德)有限公司 | 隔离膜、隔离膜制备方法及电化学装置 |
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JPH11279996A (ja) * | 1998-03-30 | 1999-10-12 | Oji Paper Co Ltd | 遮光性を有する易離解性防湿紙 |
FI117717B (fi) * | 1999-07-09 | 2007-01-31 | Ciba Sc Holding Ag | Pintaliimakoostumus |
FI107815B (fi) * | 2000-02-11 | 2001-10-15 | Raisio Chem Oy | Päällystyspastakoostumus, sen käyttö ja menetelmä sen valmistamiseksi |
EP1249533A1 (en) * | 2001-04-14 | 2002-10-16 | The Dow Chemical Company | Process for making multilayer coated paper or paperboard |
US20060257593A1 (en) * | 2002-10-01 | 2006-11-16 | J P Haenen | Coated printing sheet and process for making same |
US20070232743A1 (en) * | 2006-03-30 | 2007-10-04 | Mario Laviolette | Method of forming a vapor impermeable, repulpable coating for a cellulosic substrate and a coating composition for the same |
EP2473672B1 (en) * | 2009-08-31 | 2023-06-07 | Verso Paper Holding LLC | Inkjet recording medium |
FI126350B (fi) * | 2009-09-18 | 2016-10-14 | Upm Kymmene Corp | Menetelmä paperituotteen valmistamiseksi, paperituote ja hybridipäällyste |
GB201207860D0 (en) * | 2012-05-04 | 2012-06-20 | Imerys Minerals Ltd | Fibre based material |
GB201218125D0 (en) * | 2012-10-10 | 2012-11-21 | Imerys Minerals Ltd | Method for grinding a particulate inorganic material |
JP2014173201A (ja) * | 2013-03-08 | 2014-09-22 | Nippon Paper Industries Co Ltd | 紙製バリア包装材料 |
-
2015
- 2015-12-03 EP EP15804500.5A patent/EP3227493B1/en active Active
- 2015-12-03 US US15/532,661 patent/US20170356135A1/en not_active Abandoned
- 2015-12-03 ES ES15804500T patent/ES2923901T3/es active Active
- 2015-12-03 WO PCT/EP2015/078501 patent/WO2016087578A1/en active Application Filing
- 2015-12-03 CA CA2969559A patent/CA2969559C/en active Active
- 2015-12-03 JP JP2017529998A patent/JP6944370B2/ja active Active
- 2015-12-03 BR BR112017011468-2A patent/BR112017011468B1/pt active IP Right Grant
-
2023
- 2023-12-29 US US18/400,308 patent/US20240133119A1/en active Pending
Also Published As
Publication number | Publication date |
---|---|
JP6944370B2 (ja) | 2021-10-06 |
BR112017011468B1 (pt) | 2022-03-03 |
BR112017011468A2 (pt) | 2018-04-03 |
ES2923901T3 (es) | 2022-10-03 |
CA2969559A1 (en) | 2016-06-09 |
CA2969559C (en) | 2023-08-29 |
WO2016087578A1 (en) | 2016-06-09 |
EP3227493A1 (en) | 2017-10-11 |
US20240133119A1 (en) | 2024-04-25 |
JP2018507532A (ja) | 2018-03-15 |
US20170356135A1 (en) | 2017-12-14 |
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