WO2009142739A1 - Composition de couchage de papier présentant une nanocharge - Google Patents

Composition de couchage de papier présentant une nanocharge Download PDF

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Publication number
WO2009142739A1
WO2009142739A1 PCT/US2009/003137 US2009003137W WO2009142739A1 WO 2009142739 A1 WO2009142739 A1 WO 2009142739A1 US 2009003137 W US2009003137 W US 2009003137W WO 2009142739 A1 WO2009142739 A1 WO 2009142739A1
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WO
WIPO (PCT)
Prior art keywords
based substrate
paper based
coating composition
nanofiller
coating
Prior art date
Application number
PCT/US2009/003137
Other languages
English (en)
Inventor
Qichun Wan
Huiqing Zhang
Original Assignee
Dow Global Technologies Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Dow Global Technologies Inc. filed Critical Dow Global Technologies Inc.
Publication of WO2009142739A1 publication Critical patent/WO2009142739A1/fr

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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
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • 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
    • D21H19/46—Non-macromolecular organic compounds
    • D21H19/48—Diolefins, e.g. butadiene; Aromatic vinyl monomers, e.g. styrene; Polymerisable unsaturated acids or derivatives thereof, e.g. acrylic acid
    • 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
    • D21H19/64—Inorganic compounds
    • 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
    • D21H21/50—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 form
    • D21H21/52—Additives of definite length or shape

Definitions

  • the present disclosure generally relates to a coating composition, and particularly to a paper coating composition having a nanofiller for oil and grease resistance barrier and blocking resistance properties.
  • Oil and grease resistance is an important property for coated paper and paperboard intended for food packaging, such as pizza boxes, popcorn, and pet food bags.
  • fluorochemicals either by surface treatment or as a wet end additive in the paper making process, have been the dominant approach used to achieve OGR.
  • Recent environmental concerns surrounding fluorochemicals have prompted paper and paperboard manufacturers to search for alternative approaches to coating compositions that impart OGR to the coated paper.
  • Blocking resistance is the ability of the paper (coated and/or processed with the agents) to resist sticking due to one or more of the effects of temperature, pressure, or relative humidity. So, as the freshly coated paper is being wound under pressure in its hot and moist state the paper has a tendency to "stick" to itself, resulting in a product that is likely damaged and/or unusable.
  • inorganic pigments such as clay or calcium carbonate, and/or hard polymers, such as for example plastic pigments, have been added to coating compositions.
  • hard polymers such as for example plastic pigments.
  • the presence of the pigments and/or hard polymers can dilute the binder to such an extent that the OGR barrier properties of the resulting coating composition are greatly diminished.
  • the present disclosure addresses the above-identified issues.
  • the present disclosure provides embodiments of a coating composition, a coated paper based substrate in which a paper based substrate has a coating formed from the coating composition, a process for preparing the coating composition, a process for preparing the coated paper based substrate, and a method of coating a paper based substrate to form the coated paper based substrate.
  • the coating formed with the coating composition provides the coated paper based substrate with improved blocking resistance while maintaining and even enhancing the oil and grease resistant (OGR) barrier properties of the paper based substrates on which the coating composition is applied.
  • OGR oil and grease resistant
  • the coated paper based substrate displayed significantly better blocking resistance while maintaining and even improving OGR properties as compared to coatings formed with comparable coating compositions containing conventional fillers, instead of the nanofiller of the present disclosure, or without fillers.
  • the coated paper based substrates of the present disclosure also maintain their OGR barrier properties even when folded and/or creased, as illustrated by a folded Kit Rating Number of 11 or 12. This is in contrast to conventional methods of imparting OGR that have relied upon using relatively large amounts of filler materials, which leads to embrittled coatings that are not robust enough to maintain their OGR properties after folding and/or creasing the coated paper.
  • the coating composition includes a nanofiller, a crosslinking agent, and a binder.
  • the nanofiller used in the coating composition of the present disclosure can have a variety of aspect ratios, which include, but are not limited to, at least 25, and those that are at least 100. Other values for the aspect ratio of the nanofiller are also possible.
  • the nanofiller can also have undergone an exfoliation process to form an exfoliated nanofiller, as discussed herein.
  • the coating composition includes the nanofiller having an aspect ratio of at least 25 and in an amount from 2 to 50 percent by weight based on 100 dry weight percent of the nanofiller and the binder.
  • the coating composition further includes the binder present in an amount of 50 to 98 percent by weight based on 100 dry weight percent of the nanofiller and the binder, and the crosslinking agent in an amount from 0.1 to 40 parts per 100 weight parts of a total dry weight of the nanofiller and the binder.
  • the coating composition can have an amount of the nanof ⁇ ller from 5 to 25 percent by weight based on 100 dry weight percent of the nanofiller and the binder, an amount of the binder from 75 to 95 percent by weight based on 100 dry weight percent of the nanofiller and the binder, and an amount of the crosslinking agent from 2 to 20 parts per 100 weight parts of a total dry weight of the nanofiller and the binder.
  • the coating composition can have an amount of the nanofiller from 5 to 20 percent by weight based on 100 dry weight percent of the nanofiller and the binder, an amount of the binder from 80 to 95 percent by weight based on 100 dry weight percent of the nanofiller and the binder, and an amount of the crosslinking agent from 3 to 15 parts per 100 weight parts of a total dry weight of the nanofiller and the binder.
  • Embodiments of the present disclosure further include a process for preparing the coating composition.
  • the process includes preparing an aqueous dispersion of the nanofiller, mixing the binder with the aqueous dispersion of the nanofiller, mixing the crosslinking agent with the binder and the aqueous dispersion of the nanofiller, and aging the coating composition.
  • Embodiments of the present disclosure further include a coated paper based substrate in which a surface of the paper based substrate has a coating formed with the coating composition of the present disclosure.
  • Embodiments of the present disclosure also include a process for preparing the coated paper based substrate.
  • the process for preparing the coated paper based substrate includes providing the paper based substrate having a surface, providing the coating composition, and coating the surface of the paper based substrate with the coating composition to form the coated paper based substrate.
  • Embodiments of the present disclosure further include a method of coating the paper based substrate to form the coated paper based substrate.
  • the method includes providing the paper based substrate having the surface, and applying the coating composition on the surface of the paper based substrate.
  • the coating formed with the coating composition applied to the paper based substrate provides the coated paper based substrate with a Blocking Ranking Value of 3 or less for a blocking resistance and an oil/grease resistant barrier having a flat Kit Rating Number and a folded Kit Rating Number of 1 1 to 12.
  • a As used herein, "a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.
  • a coating composition that includes “a” binder can be interpreted to mean that the binder includes “one or more” binders.
  • dry means a substantial absence of liquids.
  • dry weight refers to a weight of a dry material.
  • the solids content of the nanofiller can be expressed as a dry weight, meaning that it is the weight of nanofiller remaining after essentially all volatile materials (e.g., water) have been removed.
  • room temperature refers to an ambient temperature of 20 0 C to 25 0 C.
  • parts refers to parts per 100 weight parts of a total dry weight of one or more solids of the coating composition.
  • an “aspect ratio” is a ratio of a longest dimension along a first axis of an individual piece of the nanofiller to a shortest dimension along a second axis of the nanofiller.
  • paper and paperboard refers to a paper based substrate of an amalgamation of fibers that can include, at least in part, vegetable and/or wood fibers, such as cellulose, hemicelluloses, lignin, and/or synthetic fibers.
  • fiberboard refers to a material made by compressing fibers (such as those discussed herein) into sheets that are stiffer than either paper and/or paperboard.
  • other components can be included in the paper based substrate of the paper and/or paperboard and/or the sheet of the fiberboard.
  • paper, paperboard and/or fiberboard differ in their thickness, stiffness, strength, and/or weight, but are intended to be modified by the embodiments of the coating compositions and methods provided herein to form the coated paper based substrate of the present disclosure.
  • the term “paper based substrate” encompasses and is interchangeable with the terms “paper,” “paperboard,” and “fiberboard” unless such a construction is clearly not intended as will be clear from the context in which this term is used.
  • aging refers to a process for preparing the coating composition of the present disclosure under a predetermined condition for a predetermined time interval, where the process allows for improvements in the blocking resistance of coatings formed from the coating composition as compared to coatings formed from the coating composition of the present disclosure that did not undergo the aging process.
  • blocking refers to the tendency of a coating on a first surface of a paper based substrate (e.g., the coating composition of the coated paper based substrate) to stick to a second surface of the paper based substrate opposite the first surface (i.e., a backside of the paper) when wound in a roll.
  • nano e.g. as used in “nanofiller” indicates that at least one linear dimension (e.g., a thickness) of the article has a size in the nanometer range from 0.1 nanometer to less than 1000 nanometers.
  • a “nano" filler material has a nano scale size in at least one of three dimensions.
  • composition or “coating composition” is interpreted to include true liquid solutions, as well as colloidal dispersions, suspensions, emulsions and latexes as they are conventionally defined.
  • exfoliation refers to a process of breaking up and separating layered fillers into individual layers of the original particle.
  • Figure 1 is a graph illustrating penetration of hot oleic acid into samples of coated paper based substrate as a function of time.
  • Embodiments of the present disclosure provide for a coating composition that provides for improved blocking resistance while maintaining and even enhancing the oil and grease resistant (OGR) barrier properties of a coated paper based substrates on which the coating composition is applied.
  • OGR oil and grease resistant
  • disclosure display significantly better blocking resistance as well as maintaining and even improving OGR barrier properties than those with comparable amounts of conventional clays or without clays.
  • the coating composition of the present disclosure includes a nanofiller, a binder, and a crosslinking agent. As discussed herein, embodiments of the coating composition provides for both good blocking resistance while maintaining and even enhancing the OGR barrier properties of the paper based substrates on which the coating composition is applied.
  • the nanofiller can be present in the coating composition in an amount from 2 to 50 weight percent based on 100 dry weight percent of the nanofiller and the binder. In an additional embodiment, the nanofiller can be present in the coating composition in an amount from 5 to 25 weight percent based on 100 dry weight percent of the nanofiller and the binder. In a more specific embodiment, the nanofiller can be present in the coating composition in an amount from 5 to 20 weight percent based on 100 dry weight percent of the nanofiller and the binder.
  • the nanofiller used in the coating compositions of the present disclosure has a high aspect ratio.
  • suitable aspect ratios for the nanofiller can include those that range from 25 to as high as 10,000. More specific examples of suitable aspect ratios include those that are at least 100, those that are at least 500, those that are at least 100 to as high as 10,000, and those that are at least 500 to as high as 10,000.
  • the aspect ratio for the nanofiller can have a range of 100 to 2000.
  • the aspect ratio for the nanofiller can have a range of 100 to 5000.
  • the nanofiller can be selected from a group consisting of an exfoliated natural layered silicate, a partially exfoliated natural layered silicate, an exfoliated synthetic layered silicate, a partially exfoliated synthetic layered silicate, and mixtures thereof.
  • nanof ⁇ llers examples include, but are not limited to, natural and/or synthetic layered silicates such as montmorillonite, bentonite, kaolinite, kaolin, mica, hectorite, sauconite, fluorohectorite, saponites, attapulgite, sepiolite, beidellite, ledikite, nontronite, volkonskoite, stevensite, vermiculite, halloysite, talc, pyrophillite, palygorskite, illite, phlogopite, biotite, chlorite, nacrite, dickite, suconite, magadiite, kenyaite, Laponite ® , tainiolite, synthetic fluoromica and combination thereof.
  • Such nanofillers may be hydrophilic or organophilic.
  • Organophilic nanofillers include those that may have surface chemistry modified through use of an agent such as a surfactant, a
  • nanofillers can also include, but are not limited to, inorganic fillers such as layered double hydroxides, calcium carbonate, wollastonite or metal oxides.
  • the nanofiller can have undergone an exfoliation process to form the exfoliated nanofillers.
  • the exfoliation process serves to break the agglomerates apart so that each resulting "nanofiller” has a thickness of 1 nanometer (for conventional clay the thickness is more than 500 nm).
  • the effectiveness of the nanofiller in the coating formed from the coating composition can depend upon the lateral size of the nanofillers, the degree of exfoliation in water, and the degree to which they reassemble to form larger particles during the coating and drying process.
  • the coatings formed from the coating compositions of the present disclosure retain the nanofiller in a well-dispersed form, resulting in an increase in surface area for the nanofiller as compared to the use of a conventional clay.
  • the higher surface area provided by the nanofiller also help to provide for improved OGR barrier property of the coating composition due to the highly tortuous path formed in the dried coating composition.
  • the highly tortuous path helps to slow the migration of oil and/or grease through the coating to the underlying paper based substrate.
  • Useful crosslinking agents for the present disclosure include, but are not limited to, those classified as multivalent metal oxides and/or metal salts, aldehydes and/or aldehyde- derivatives, and/or aminoplast resins.
  • multivalent metal oxides and/or metal salts such crosslinking agents can include, but are not limited to, zinc oxide, zinc ammonium carbonate, ammonium zirconium carbonate, zirconium oxide, and mixtures thereof in either complexes or dispersions.
  • the metal oxides and/or metal salts can have sizes in the nano-scale.
  • crosslinking agents can include, but are not limited to, formaldehyde, glyoxal (dialdehyde), and modified glyoxal resins.
  • modified glyoxal resins can include, but are not limited to, urea-formaldehyde and melamine-formaldehyde.
  • This type of crosslinker can effectively react with compounds or polymers having amino, hydroxyl, or carboxylic functional groups through covalent bonding.
  • the crosslinking agents can be selected from two or more crosslinking agents from the above classes of crosslinking agents and/or from a combination of crosslinking agents from two or more of the above identified classes of crosslinking agents.
  • the crosslinking agent can be present in the coating composition in an amount from 0.1 to 40 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • the TDCC# 65050A can be present in the coating composition in an amount from 0.1 to 40 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • crosslinking agent can be present in the coating composition in an amount from 2 to 20 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition. In a more specific embodiment, the crosslinking agent can be present in the coating composition in an amount from 3 to 15 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • the binder can be present in the coating composition in an amount of 50 to 98 percent by weight based on 100 dry weight percent of the nanofiller and the binder. In an additional embodiment, the binder can be present in the coating composition in an amount of 75 to 95 percent by weight based on 100 dry weight percent of the nanofiller and the binder. In a more specific embodiment, the binder can be present in the coating composition in an amount of 80 to 95 percent by weight based on 100 dry weight percent of the nanofiller and the binder.
  • a variety of binders can be used with the coating composition of the present disclosure.
  • binders can include, but are not limited to, natural binders, synthetic binders, latex binders or dispersions, and mixtures thereof.
  • Specific examples of binders include, but are not limited to, those selected from the group consisting of styrene-butadiene latexes, styrene-acrylate latexes, styrene-acrylic latexes, styrene maleic anhydrides, styrene-butadiene acrylonitrile latexes, styrene-acrylate-vinyl acrylonitrile latexes, vinyl acetate latexes, vinyl acetate-butyl acrylate latexes, vinyl acetate-ethylene latexes, acrylic latexes, vinyl acetate- acrylate latexes, acrylate copolymers, vinylidene-containing latexes, vinylidene chloride/vinyl chloride containing latexes and
  • Carboxylated versions of several of the above latexes are also possible, where the latexes are prepared by copolymerizing the monomers with a carboxylic acid such as, for example, acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid etc.
  • a carboxylic acid such as, for example, acrylic acid, methacrylic acid, itaconic acid, maleic acid, fumaric acid etc.
  • binders can also include starches, proteins, polyvinyl alcohols, carboxymethyl celluloses, silicones, waxes, neoprenes, polyhydroxy ethers, lacquers, polylactic acids, copolymers of polylactic acid, fiuorinated polymers, polyurethanes, epoxy resins, polyesters, polyolefins dispersions, and mixtures thereof may also be used with nanofillers.
  • binders can also include starches, proteins, polyvinyl alcohols, carboxymethyl celluloses, silicones, waxes, neoprenes, polyhydroxy ethers, lacquers, polylactic acids, copolymers of polylactic acid, fiuorinated polymers, polyurethanes, epoxy resins, polyesters, polyolefins dispersions, and mixtures thereof may also be used with nanofillers.
  • mixtures of two or more of the binders provided herein, or other known binders can be used in the coating composition of the present disclosure.
  • the binders can also have a structured form and/or an unstructured form.
  • particles of the binder can have a variety of morphological configurations such as, for example, core/shell, core/shell particles with shell phases incompletely encapsulating the core, core/shell particles with a multiplicity of cores, interpenetrating network particles, and the TDCC# 65050A
  • the particles of the binder may also be agglomerated, have a bimodal particle size distribution, and/or have a polymodal particle size distribution.
  • at least one of the binder(s) selected for use in the coating composition can have a minimum film formation temperature less than 50 0 C, preferably less than 30 0 C.
  • Specific embodiments of the coating composition of the present disclosure include those with the nanofiller having an aspect ratio of at least 25 and in an amount from 2 to 50 percent by weight based on 100 dry weight percent of the nanofiller and the binder; the binder in an amount of 50 to 98 percent by weight based on 100 dry weight percent of the nanofiller and the binder; and the crosslinking agent in an amount from 0.1 to 40 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • the coating composition of the present disclosure includes those where the amount of the nanofiller is from 5 to 25 percent by weight based on 100 dry weight percent of the nanofiller and the binder, the amount of the binder is from 75 to 95 percent by weight based on 100 dry weight percent of total solids of the nanofiller and the binder; and the amount of the crosslinking agent is from 2 to 20 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • the coating composition of the present disclosure includes those where the amount of the nanofiller is from 5 to 20 percent by weight based on 100 dry weight percent of the nanofiller and the binder; the amount of the binder is from 80 to 95 percent by weight based on 100 dry weight percent of total solids of the nanofiller and the binder; and the amount of the crosslinking agent is from 3 to 15 parts per 100 weight parts of a total dry weight of the nanofiller and the binder of the coating composition.
  • the present disclosure further includes a process for preparing the coating composition.
  • Embodiments of the process for preparing the coating composition include preparing an aqueous dispersion of the nanofiller.
  • the nanofiller can be dispersed in water and mixed with sufficient shearing forces to exfoliate and keep the nanofiller from clumping together.
  • Other organic carriers may also be used as a carrier liquid, either neat or in combination with water. Examples of suitable organic carriers include hexane, heptane, toluene, l-methyl-2-pyrrolidinone, cyclohexanone, ethanol, methanol, isopropanol, ethylene glycol, other hydrocarbon based carriers, and mixtures thereof. Selection of a suitable organic carrier to be used with or without water is within the skill of the art.
  • the binder and the crosslinking agent are both mixed with the aqueous dispersion of the nanofiller.
  • the coating composition can then be aged.
  • TDCC# 65050A In one TDCC# 65050A
  • the coating composition can be aged under a predetermined condition for a predetermined time interval. As discussed herein, this aging process allows for improvements in the blocking resistance of coatings formed from the coating composition as compared to coatings formed from the coating composition of the present disclosure that did not undergo the aging process.
  • the coating composition can be aged at room temperature for at least seven (7) days before its use.
  • the coating composition can be aged at 40 to 50 0 C for 1 to 2 hours before use.
  • aging the coating composition of the present disclosure as provided herein helps to improve the blocking resistance of the coated paper based substrate as compared to coatings formed from the coating composition of the present disclosure that did not undergo the aging process.
  • other aging processes can be performed on the coating composition of the present disclosure with the intention of improving the blocking resistance of the coating composition.
  • the process of preparing the coating composition can further include additional process steps.
  • a de-flocculent such as an electrolytic compound (e.g., an inorganic electrolytic compound), for helping to improve the dispersion of nanofiller within a dispersion, reduce viscosity, or both.
  • an electrolytic compound e.g., an inorganic electrolytic compound
  • one approach is to employ a sodium containing compound, such as tetra-sodium pyrophosphate, sodium carbonate, compound, or both.
  • Other de-flocculants e.g., alkali metal compounds, phosphates, organic compounds, or otherwise may also be employed.
  • the de-flocculant when employed, may be employed in a suitable concentration.
  • one approach is to add de-flocculant to a nanofiller dispersion, prior to incorporating the dispersion into the coating composition, in an amount of less than 5 percent (or more specifically less than 3 percent) by dry weight of the nanofiller within the dispersion.
  • the nanofiller may also be subjected to one or more treatment steps, such as one or more steps for reducing particle agglomerations, for segregating particles by size, for reducing impurities, or combinations thereof.
  • the nanofiller may be jet-milled, centrifuged, ultrasonically agitated, or combinations thereof.
  • the process for preparing the coating composition can further include adjusting a pH of the coating composition using a base such as NH 4 OH, NaOH and/or KOH provided that care is taken to avoid agglomeration of the nanofiller.
  • a base such as NH 4 OH, NaOH and/or KOH provided that care is taken to avoid agglomeration of the nanofiller.
  • the pH of the coating composition can be adjusted to a value of 8 to 8.8. Other pH values are also possible.
  • the coating composition has a solids level of 20 to 70 percent by weight based on a total weight of the coating composition. In an additional embodiment, the coating composition has a solids content of 30 to 60 percent by weight based on a total weight of the coating composition. In a specific embodiment, the solids level of the coating composition can be adjusted to 40 percent solids by weight based on a total weight of the coating composition.
  • the coating composition of the present disclosure can further include one or more of the following materials: a surfactant, an emulsifier, an anti-foaming agent, a defoaming agent, a dispersing agent, a wetting agent, a leveling agent, a thickener, and a pH control agent, among others, mixed into the coating composition.
  • the thickener is used for water retention and rheology control of the coating composition, where such thickeners can be selected from compounds of the group comprising, without limitation, alginates (e.g. guluronic acid salt or mannuronic acid salt), cellulosics (e.g. carboxymethylcelluloses, hydroxyethylcelluloses), and alkali-soluble or swellable polyacrylates, and combinations thereof.
  • the surfactants, wetting agents, anti-foaming agents, emulsif ⁇ ers, dispersing agents, and/or leveling agents can be anionic, cationic and/or nonionic.
  • the amount and number of surfactants, wetting agents, anti-foaming agents, emulsif ⁇ ers, dispersing agents, and/or leveling agents added to the coating composition will depend on the particular compound(s) selected, but should be limited to an amount that is necessary to achieve wetting of the substrate while not compromising the performance of the dried coating. For example, typical surfactant amounts can be less than or equal to 10 percent by weight of the dried coating composition.
  • the coating composition of the present disclosure can be used to provide a coating for an OGR barrier and blocking resistance on a paper based substrate selected from the group consisting of a paper, a paperboard, and a fiberboard.
  • the process for preparing the coated paper based substrate includes providing the paper based substrate having a surface. The coating composition is provided and is applied, or coated, over the surface of the paper based substrate and then dried to form the coated paper base substrate.
  • the method of coating the paper based substrate to form the coated paper based substrate includes applying the coating composition to one or more of a first and/or a second major surface of the paper based substrate.
  • the paper coating composition of the present disclosure may be used as one of a base coat, a top coat and/or one or more intermediate coats between a base coat and a top coat of a coated paper based TDCC# 65050A
  • the coating composition can also be used alone to provide at least one layer of the coating composition on the paper based substrate.
  • the coating composition can be applied to the paper based substrate to form a coating of a desired thickness and/or coat weight by using conventional paper or paper board coating techniques.
  • Such techniques include, but are not limited to, cast coating, pre-metered size press coating, flooded nip size press coating, Meyer rod coating in conventional coating equipments such as a pre-meter size coater, air knife coater, rod or roll coater, and curtain coater, and others.
  • the coating composition of the present disclosure can be applied on the paper based substrate as a single, double, or multi-layer coating, where for multi-layer coatings, the coating composition for each layer may or may not be the same.
  • the coating composition may be applied to the paper based substrate at a desired thickness, depending on the application and type of paper based substrate, the purpose for which the coating composition is being applied and the ultimate use of the coated paper based substrate.
  • the coating composition of the present invention may be applied to the paper based substrate by the methods described above at a coat weight of 2 to 20 lb/3300 ft 2 .
  • the coat weight can also include 3 to 12 lb/3300 ft 2 .
  • the coat weight can include 4 to 8 lb/3300 ft 2 .
  • the coated paper based substrate can be dried at a selected temperature, e.g., room temperature or greater than room temperature to form a dried coating of the coating composition.
  • a selected temperature e.g., room temperature or greater than room temperature.
  • the selection of the drying temperature, relative humidity, and convective air flow rates depends on the desired time for drying; that is, reduced drying times may be achieved at elevated air temperatures, lower relative humidity and higher rates of air circulation over the drying coating surface.
  • One of skill in the art can readily adjust the drying conditions as desired.
  • the coating compositions of the present disclosure can also be used for paper based substrates and non-paper coating applications that require barrier properties such as, for example, an oxygen barrier, a water barrier and/or a moisture barrier in food packaging.
  • barrier properties such as, for example, an oxygen barrier, a water barrier and/or a moisture barrier in food packaging.
  • the coated paper based substrates with the coating composition are repulpable and/or recyclable, which is not the case with coating compositions that include high levels of wax, or other non- recyclable materials to achieve grease and oil resistance.
  • the dried coatings of the coating composition of the present disclosure exhibit surprising good blocking resistance along with the OGR barrier properties for the coated paper based substrates.
  • the dried coating of the coating TDCC# 65050A exhibit surprising good blocking resistance along with the OGR barrier properties for the coated paper based substrates.
  • composition on the coated paper based substrate provides a Blocking Ranking Value of 3 or less for the blocking resistance.
  • Blocking Ranking Value is determined by simulating a pilot coater or paper mill conditions that are known to produce blocking tendencies in coated paper.
  • the dried coatings of the coating composition of the present disclosure also exhibit good OGR barrier properties for the coated paper based substrates.
  • the dried coatings of the coating composition on the coated paper based substrates provides an OGR barrier that has a flat Kit Rating Number and a folded Kit Rating Number of 11 to 12.
  • the Kit Rating Number is a metric given to indicate how well a surface (such as the surface of the dried coating of the coated paper based substrate) resists penetration by a series of reagents of increasing aggressiveness.
  • the coating composition provides a decrease in a Y- value brightness of less than 2 percent from an initial Y-value after exposing the dried coating of the coating composition to oleic acid at 60 0 C for 30 minutes.
  • the coated paper based substrate also had a decrease in a Y-value brightness of less than 59 percent from an initial Y-value brightness of the coated paper based substrate after exposing the dried coating of the coating composition on the surface of the coated paper based substrate to oleic acid at 60 0 C for 4 hours.
  • the coated paper based substrate also had a decrease in a Y-value brightness of 1 percent or less from an initial Y-value brightness of the coated paper based substrate after exposing a dried coating of the coating composition on the surface of the coated paper based substrate to corn oil at 60 0 C for 24 hours.
  • Binder RAP 810NA Latex (The Dow Chemical Company).
  • Unmodified smectic clays (Nanofiller): SOMASIF ME- 100 (Co-OP Chemical Company) and TOPY E3 Clay (TOPY Industry).
  • TDCC# 65050A Unmodified smectic clays (Nanofiller): SOMASIF ME- 100 (Co-OP Chemical Company) and TOPY E3 Clay (TOPY Industry).
  • Crosslinker AquaMix® 1162, a zinc oxide (ZnO) dispersion (approximately 60 weight percent solids, PolyOne Corporation).
  • Defoamer DREWPLUS L 140 (Ashland Chemical Company), having 71 to 81 weight percent white mineral oil, 3.8 to 14 weight percent silica, 3 to 13 weight percent aliphatic petroleum distillates, and small amount emulsif ⁇ er and polyethylene glycol 6000 dioleate.
  • Thickener ALCOGUM 1228 (National Starch and Chemical Company), an ammonium salt of an acrylate copolymer.
  • Oleic acid 85+%, neutralization value 192-206, freezing point 8-16°C made by TCI® of Tokyo Kasei) from VWR International.
  • Corn oil CRISCO brand pure corn oil.
  • a coating composition of the present disclosure that includes a mixture of 90 weight percent of RAP 810NA latex binder based on 100 dry weight percent of the nanofiller and the binder, 10 weight percent of a nanofiller prepared from SOMASIF M E- 100 based on 100 dry weight percent of the nanofiller and the binder, and 6 dry parts of AquaMix® 1162 based on 100 weight parts of the total dry weight of the nanofiller and the binder.
  • the tables herein refer to this coating composition as RAP 810/SOMASIF ME- 100 nanofiller/ZnO (90/10/6).
  • No. 3 qualitative filter paper Allow the filtrate to separate into two phases with time: a clear top phase and a turbid bottom phase.
  • the clear top phase has a weight percentage of 3.3 solids.
  • the coating composition of Example 2 includes 90 weight percent of RAP 810NA latex binder based on 100 dry weight percent of the nanofiller and the binder, 10 weight percent of a nanofiller prepared from TOPY E3 based on 100 dry weight percent of the nanofiller and the binder, and 6 dry parts of AquaMix® 1 162 based on 100 weight parts of the total dry weight of the nanofiller and the binder.
  • the tables herein refer to this coating composition as RAP 810/TOPY E3Clay /ZnO (90/10/6).
  • Comparative Example 1 Formulate the coating composition of Comparative Example 1 according to the same procedure discussed for Example 1, except that no nanofiller and no AquaMix® 1 162 are in the coating composition. So, Comparative Example 1 contains 100 weight percent of RAP 810NA latex. The tables herein refer to this coating composition as RAP 810. Comparative Example 2
  • Comparative Example 2 Formulate the coating composition of Comparative Example 2 according to the same procedure discussed for Example 1, except do not include a nanofiller in the coating composition. So, the Comparative Example 2 contains 100 weight percent of RAP 81 ONA latex binder and a 6 dry parts of AquaMix® 1 162 based on 100 weight parts of the total dry weight of the binder. The tables herein refer to this coating composition as RAP 810/ZnO (100/6). Comparative Example 3
  • Comparative Example 3 contains 92.5 weight percent of RAP 81 ONA latex binder based on 100 dry weight percent of the nanofiller and the binder, and 7.5 weight percent of a nanofiller prepared from SOMASIF ME- 100 based on 100 dry weight percent of the nanofiller and the binder.
  • the tables herein refer to this coating composition as RAP 810/SOMASIF ME-100 nanofiller (92.5/7.5).
  • METALCRAFT type 991 to the range of 40 0 C to 110 0 C.
  • the temperature where the strip of paper based substrate sticks to the coating composition is the paper surface tack temperature. If the coating composition sample does not cause the base paper strip to pick or tear, assign a hot stick temperature of greater than 110 0 C to that coating composition sample.
  • a tack temperature of 1 10 0 C is the highest temperature that the present test method can reach.
  • nanofiller improves the tack temperature to above 1 10 0 C, but only to 57 0 C for HYDRAFINE 90 clay.
  • a blocking resistance test for coatings of the coating compositions of the present disclosure simulates pilot coater or paper mill conditions that are known to produce blocking tendencies in coated paper. The following is a description of the blocking resistance test method.
  • the blocking resistance test helps to screen the different coating compositions of the present disclosure. If the coated base paper has a blocking ranking value of 5 with average percentage fiber tear higher than 20%, this formulation is not acceptable due to poor blocking resistance. If the coated base paper has a blocking ranking value of between 4 and 5 with average percentage fiber tear lower than 20%, the formulation is borderline acceptable. It is believed that a blocking ranking value of 4 is minimally acceptable for the performance of a coating composition.
  • Table 2 provides blocking resistance as relative blocking ranking, average blocking ranking values and percent fiber tear for coatings formed from the coating compositions provided herein.
  • the coating compositions having the binder, the nanofiller and ZnO aqueous dispersions have lower blocking numbers, indicating better blocking resistance than those coating compositions that contain only the binder and the nanofiller or only the binder and ZnO or the binder without the nanofiller or ZnO.
  • addition of the nanofiller aqueous dispersions to the coating composition also provides better blocking resistance improvement than traditional HYDRAFINE 90 clay at the same addition levels.
  • Kit Test is a procedure for testing the degree of repellency of paper or paperboard having a coating, such as the coated base paper of the present disclosure.
  • Kit Test as follows. Obtain five representative samples (5.08 cm by 5.08 cm) of each of the coated base papers. Drop one drop of the Kit Rating Number test reagent onto a flat surface of the coated base paper having a coating formed from the coating composition of the present disclosure from a height of 2.54 cm. After 15 seconds, wipe the excess Kit Rating Number test reagent away with a clean tissue or cotton swatch.
  • a "Folded Kit Test” was also developed to test the OGR properties of the coating compositions.
  • the Folded Kit Test applies the Kit Rating Number test reagent (provided in Table 3, above) to an inside crease of a folded sample of the coated base paper.
  • the hot corn oil resistance test evaluates the degree of oil penetration into the base paper by assessing the changes in the brightness value (from a Y- value measurement) of the coated base paper. The greater the oil and grease penetration through the coating of the coated base paper, the darker the coated base paper becomes and the lower the brightness value.
  • Table 5 shows the results of the Hot Corn Oil Resistance Test (corn oil at 60 0 C for 24 hours) on coatings formed from the coating compositions of Examples 1-3 and Comparative Examples 2-4 of the present disclosure.
  • the standard deviation of the Y-value for the corn oil stain test was 0.5.
  • Hot Oleic Acid Resistance Test Use a hot oleic acid resistance test to assess the hot-oil resistance of the coating compositions of the present disclosure.
  • the hot oleic acid resistance test can help to further evaluate the degree of oil penetration into the coatings formed from the coating compositions of the present disclosure by assessing changes in a brightness value (from a Y-value measurement) of the coated base paper. The greater the oil and grease penetration through the TDCC# 65050A
  • FIG. 1 shows the brightness (Y-value) of four tested coating compositions of the coated base paper after contact with 60 0 C oleic acid up to 4 hours. The standard deviation of the Y-value for the oleic acid stain test was 0.8. With increased oleic acid contact time, the oleic acid penetrated deeper into the coated base paper and the brightness further decreases.
  • the coating compositions of Examples 1 & 2 had a higher brightness as compared to Comparative Example #2 (without clay) and Comparative Example # 4 (those with conventional clay).
  • the coating compositions that include the combination RAP 810NA/Nanofiller/ZnO provide coatings have better hot oleic acid stain resistance than the comparative examples without all three of these components.

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Abstract

L’invention concerne une composition de couchage destinée à former un couchage pour une barrière résistant à l’huile et à la graisse et une résistance à l’adhérence sur un substrat à base de papier, la composition de couchage comportant une nanocharge présentant un rapport d’aspect d’au moins 25, un liant, et un agent de réticulation. Le couchage formé à partir de la composition de couchage peut fournir une barrière résistant à la fois à l’huile et à la graisse présentant un numéro d’évaluation de kit plat et un numéro d’évaluation de kit plié de 11 à 12, et un classement d’adhérence de 3 ou moins pour la résistance à l’adhérence du substrat à base de papier couché. La composition de couchage peut être utilisée sur un papier, un carton, ou un panneau de fibres.
PCT/US2009/003137 2008-05-23 2009-05-21 Composition de couchage de papier présentant une nanocharge WO2009142739A1 (fr)

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US9580867B2 (en) 2013-04-26 2017-02-28 Pacific Nano Products, Inc. Fibrous structured amorphous silica including precipitated calcium carbonate, compositions of matter made therewith, and methods of use thereof
US9670621B2 (en) 2015-02-11 2017-06-06 Westrock Mwv, Llc Compostable paperboard with oil, grease, and moisture resistance
WO2018116118A1 (fr) 2016-12-22 2018-06-28 Stora Enso Oyj Procédé de fabrication de matériau d'emballage et matériau d'emballage fabriqué par le procédé
EP3431283A1 (fr) 2017-07-21 2019-01-23 Dow Global Technologies Llc Formulation de latex avec ion métallique multivalent
US10253458B2 (en) 2015-02-11 2019-04-09 Westrock Mwv, Llc Printable compostable paperboard

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WO1997022669A1 (fr) * 1995-12-18 1997-06-26 Dry Branch Kaolin Company Pigments cationises et leur utilisation dans la fabrication du papier
EP0802214A1 (fr) * 1996-04-12 1997-10-22 Sumitomo Chemical Company Limited Résines solubles dans l'eau et leurs application pour le couchage du papier
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DE19957348A1 (de) * 1998-11-30 2000-05-31 Sumitomo Chemical Co Harzmasse für Papierbeschichtungen, Beschichtungszusammensetzung für Papier und beschichtetes Papier
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WO1997022669A1 (fr) * 1995-12-18 1997-06-26 Dry Branch Kaolin Company Pigments cationises et leur utilisation dans la fabrication du papier
EP0802214A1 (fr) * 1996-04-12 1997-10-22 Sumitomo Chemical Company Limited Résines solubles dans l'eau et leurs application pour le couchage du papier
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US9637864B2 (en) 2013-04-26 2017-05-02 Pacific Nano Products, Inc. Fibrous structured amorphous silica including precipitated calcium carbonate, compositions of matter made therewith, and methods of use thereof
US9708770B2 (en) 2013-04-26 2017-07-18 Pacific Nano Products, Inc. Paper, paperboard, or label stock coated with fibrous structured amorphous silica including precipitated calcium carbonate
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US11447641B2 (en) 2013-04-26 2022-09-20 Pacific Nano Products, Inc. Fibrous structured amorphous silica including precipitated calcium carbonate and compositions of matter made therewith
US11326308B2 (en) 2015-02-11 2022-05-10 Westrock Mwv, Llc Oil and grease resistant paperboard
US9670621B2 (en) 2015-02-11 2017-06-06 Westrock Mwv, Llc Compostable paperboard with oil, grease, and moisture resistance
US10253458B2 (en) 2015-02-11 2019-04-09 Westrock Mwv, Llc Printable compostable paperboard
US10519604B2 (en) 2015-02-11 2019-12-31 Westrock Mwv, Llc Oil and grease resistant paperboard
WO2018116118A1 (fr) 2016-12-22 2018-06-28 Stora Enso Oyj Procédé de fabrication de matériau d'emballage et matériau d'emballage fabriqué par le procédé
US11098452B2 (en) 2016-12-22 2021-08-24 Stora Enso Oyj Method for manufacturing a packaging material and a packaging material made by the method
EP3431283A1 (fr) 2017-07-21 2019-01-23 Dow Global Technologies Llc Formulation de latex avec ion métallique multivalent
US10683396B2 (en) 2017-07-21 2020-06-16 Dow Global Technologies Llc Latex formulation with a multivalent metal ion

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