Classifications

• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
  • C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
  • C09D123/16—Elastomeric ethene-propene or ethene-propene-diene copolymers, e.g. EPR and EPDM rubbers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/04—Homopolymers or copolymers of ethene
  • C08L23/08—Copolymers of ethene
  • C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing atoms other than carbon or hydrogen
  • C08L23/0853—Ethene vinyl acetate copolymers
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
  • C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
  • C08L23/04—Homopolymers or copolymers of ethene
  • C08L23/08—Copolymers of ethene
  • C08L23/0846—Copolymers of ethene with unsaturated hydrocarbons containing atoms other than carbon or hydrogen
  • C08L23/0869—Copolymers of ethene with unsaturated hydrocarbons containing atoms other than carbon or hydrogen with unsaturated acids, e.g. [meth]acrylic acid; with unsaturated esters, e.g. [meth]acrylic acid esters
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
  • C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
  • C09D123/04—Homopolymers or copolymers of ethene
  • C09D123/08—Copolymers of ethene
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
  • C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
  • C09D123/04—Homopolymers or copolymers of ethene
  • C09D123/08—Copolymers of ethene
  • C09D123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
  • C09D123/0869—Acids or derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
  • C09D123/00—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers
  • C09D123/02—Coating compositions based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Coating compositions based on derivatives of such polymers not modified by chemical after-treatment
  • C09D123/10—Homopolymers or copolymers of propene
  • C09D123/14—Copolymers of propene
  • C09D123/142—Copolymers of propene at least partially crystalline copolymers of propene with other olefins
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
  • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
  • C09J123/04—Homopolymers or copolymers of ethene
  • C09J123/08—Copolymers of ethene
  • C09J123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
  • C09J123/0853—Vinylacetate
• • C—CHEMISTRY; METALLURGY
  • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
  • C09J—ADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
  • C09J123/00—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
  • C09J123/02—Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
  • C09J123/04—Homopolymers or copolymers of ethene
  • C09J123/08—Copolymers of ethene
  • C09J123/0846—Copolymers of ethene with unsaturated hydrocarbons containing other atoms than carbon or hydrogen atoms
  • C09J123/0869—Acids or derivatives thereof
• • C—CHEMISTRY; METALLURGY
  • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
  • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
  • C08L2205/00—Polymer mixtures characterised by other features
  • C08L2205/02—Polymer mixtures characterised by other features containing two or more polymers of the same C08L -group
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
  • Y10T428/254—Polymeric or resinous material
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31855—Of addition polymer from unsaturated monomers

Definitions

• the instant invention relates to a coating composition, a film containing the same, and a method for forming a sealable film.
• Heat sealed biaxially oriented films and particularly biaxially oriented polypropylene (BOPP) films, are used as a preferred material for packaging various products.
• BOPP is a preferred material for packaging confectionary products due to its high gloss, good mechanics and very low shrinkage.
• the biaxially oriented films may be heat sealed.
• Ultra-fast packaging lines for confectionary products operate at more than 1500 pieces wrapped per minute. Such lines require ultra-low temperature sealing of the BOPP or other film to minimize packaging time. While BOPP films coextruded with sealing layers are known, such sealants require temperatures of at least about 70 °C to form a seal.
• the instant invention is a coating composition and a film containing the coating composition and a method for forming a sealable film.
• the instant invention provides a coating composition
• a coating composition comprising an aqueous dispersion which comprises the melt-kneading product of (A) from 60 to 95 wt% of a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based upon the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymer, maleic anhydride grafted polyolefins, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion at a rate of from 1 to 2 grams per square meter has two or more of the following properties: (a) a heat
• the instant invention is a coating composition, a film containing the same, and a method for forming a film.
• ethylene-based polymer refers to a polymer having more than 50 mole percent units derived from ethylene monomer (based on the total amount of polymerizable monomers), and, optionally, one or more comonomers.
• propylene-based polymer refers to a polymer having more than 50 mole percent units derived from propylene monomer (based on the total amount of polymerizable monomers), and, optionally, one or more comonomers.
• homopolymer is a polymer that is formed from only a single type of monomer, such as ethylene.
• interpolymer refers to polymers prepared by the copolymerization of at least two different types of monomers.
• the term interpolymer includes copolymers, usually employed to refer to polymers prepared from two different monomers, and polymers prepared from more than two different types of monomers, such as terpolymers.
• the coating composition according to the present invention comprises an aqueous dispersion which comprises the melt-kneading product of (A) from 60 to 95 wt% of a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based upon the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymer, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion at a rate of from 1 to 2 grams per square meter (gsm) has two or more of the following properties: (a) a heat seal strength
• the instant invention further provides a film comprising a first layer which comprises one or more biaxially oriented polyolefms; and at least one coating layer applied to the first layer and derived from a coating composition which comprises an aqueous dispersion comprising the melt-kneading product of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, maleic anhydride grafted polyolefms, and combinations of two or more thereof; (C) a neutralizing agent; and (D) water;
• a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, maleic anhydride grafted polyolef
• aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; and wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the coating composition at a rate of from 1 to 2 grams per square meter has two or more of the following properties: (a) a heat seal strength of greater than or equal to 0.6 N/15 mm at a sealing temperature from 60 to 70 °C; (b) blocking resistance up to at least 40 °C; and (c) a broader hot tack than observed for the biaxially oriented polypropylene film in the absence of the coating layer.
• the instant invention further provides a method for forming a sealable film comprising selecting a substrate formed from one or more biaxially oriented polyolefms; selecting a coating composition which comprises an aqueous dispersion derived from the melt kneading of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethic acid copolymers, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; applying the coating composition to at least one surface of the substrate; removing at least a portion of the water thereby forming a coating layer on the substrate and thereby forming a coated substrate.
• a coating composition which comprises an aqueous dis
• the instant invention provides a coating composition, a film, and a method for forming a sealable film in accordance with any of the embodiments disclosed herein, except that a biaxially oriented polypropylene film having a coating layer derived from the application of the coating composition at a rate of from 1 to 2 grams per square meter has a heat seal strength of greater than or equal to 2 N/15mm at a sealing temperature from 60 to 70 °C. All individual values and subranges from equal to or greater than 2 N/15 mm at a sealing temperature from 60 to 70 °C are included herein and disclosed herein.
• the seal strength at a sealing temperature from 60 to 70 °C may be equal to or greater than 2 N/15mm, or in the alternative, the seal strength at a sealing temperature from 60 to 70 °C may be equal to or greater than 2.2 N/15mm, or in the alternative, the seal strength at a sealing temperature from 60 to 70 °C may be equal to or greater than 2.3 N/15mm, or in the alternative, the seal strength at a sealing temperature from 60 to 70 °C may be equal to or greater than 2.5 N/15mm, or in the alternative, the seal strength at a sealing temperature from 60 to 70 °C may be equal to or greater than 2.7 N/15mm.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the neutralizing agent is dimethylethanolamine.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the first layer and/or substrate is not primed prior to application of the coating layer onto the first layer.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the coating layer exhibits a sealing window from 60 °C to 140 °C. All individual values and subranges from 60 °C to 140 °C are included herein and disclosed herein.
• the sealing window may be from a lower limit of 60, 62, 64, 66, 75, 80, 90, or 100 °C to an upper limit of 80, 90, 100, 110, 120, 130 or 140 °C.
• the sealing window may be from 60 °C to 140 °C, or in the alternative, the sealing window may be from 64 °C to 140 °C, or in the alternative, the sealing window may be from 60 °C to 80 °C, or in the alternative, the sealing window may be from 66 °C to 100 °C, or in the alternative, the sealing window may be from 70 °C to 140 °C.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the application of the coating composition onto the first layer and/or substrate exhibits no build-up on coating rolls in regular machine processing.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the film is suitable for use in contact with food.
• suitable for use in contact with food means compliant with current food contact EU regulation 10/2011.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the coating layer has a dry thickness of from 0.5 to 20 microns. All individual values and subranges from 0.5 to 20 microns are included herein and disclosed herein; for example, the coating layer dry thickness may be from a lower limit of 0.5, 2, 4, 6, 8, 10, 12, 14, 16, or 18 microns to an upper limit of 1, 3, 5, 7, 9, 11, 13, 15, 17, 19 or 20 microns.
• the dry coating layer thickness can be from 0.5 to 20 microns, or in the alternative, the dry coating layer thickness can be from 0.5 to 10 microns, or in the alternative, the dry coating layer thickness can be from 10 to 20 microns, or in the alternative, the dry coating layer thickness can be from 0.5 to 5 microns.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the applying the aqueous dispersion is accomplished by hand coating or machine coating.
• the instant invention provides a coating composition, a film comprising a layer derived from the application of the coating composition, and a method for forming a coated substrate in accordance with any of the embodiments disclosed herein, except that the dry weight of the coating layer is equal to or less than 5 g/m 2 .
• the weight of the coating layer may be equal to or less than 5 g/m 2 , or in the alternative, the weight of the coating layer may be equal to or less than 4 g/m 2 , or in the alternative, the weight of the coating layer may be equal to or less than 3 g/m 2 , or in the alternative, the weight of the coating layer may be equal to or less than 2 g/m 2 . In a specific embodiment, the weight of the coating layer is at least 0.01 g/m 2 .
• the coating composition consists essentially of an aqueous dispersion which comprises the melt-kneading product of (A) from 60 to 95 wt% of a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based upon the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene -methacrylic acid copolymer, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion at a rate of from 1 to 2 grams per square meter (gsm) has two or more of the following properties: (a)
• the coating composition comprises an aqueous dispersion which consists essentially of the melt-kneading product of (A) from 60 to 95 wt% of a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based upon the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene -methacrylic acid copolymer, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion at a rate of from 1 to 2 grams per square meter (gsm) has two or more of the following properties: (a)
• the coating composition comprises an aqueous dispersion which comprises the melt-kneading product of (A) from 60 to 95 wt% of a base polymer which consists essentially of one or more thermoplastic polymers; (B) from 5 to 40 wt%, based upon the total weight of (A) and (B), of a stabilizing agent which consists essentially of at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene- methacrylic acid copolymer, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; wherein a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion at a rate of from 1 to 2 grams per square meter (gsm) has two or more of the following properties: (A) from 60
• the instant invention further provides a film comprising a first layer which consists essentially of one or more biaxially oriented polyolefms; and at least one coating layer applied to the first layer and derived from a coating composition which consists essentially of an aqueous dispersion comprising the melt-kneading product of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene -methacrylic acid copolymers, maleic anhydride grafted polyolefms, and combinations of two or more thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; and
• the instant invention further provides a film comprising a first layer which comprises one or more biaxially oriented polyolefms; and at least one coating layer applied to the first layer and derived from a coating composition which consists essentially of an aqueous dispersion comprising the melt-kneading product of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, maleic anhydride grafted polyolefms, and combinations of two or more thereof; (C) a neutralizing agent; and (D) water;
• aqueous dispersion has a volume average particle size of less than about 5 ⁇ ;
• the instant invention further provides a method for forming a sealable film consisting essentially of selecting a substrate formed from one or more biaxially oriented polyolefms; selecting a coating composition which comprises an aqueous dispersion derived from the melt kneading of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethic acid copolymers, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; applying the coating composition to at least one surface of the substrate; removing at least a portion of the water thereby forming a coating layer on the substrate and thereby forming a coated substrate.
• a coating composition which comprises an a
• the instant invention further provides a method for forming a sealable film comprising selecting a substrate formed from one or more biaxially oriented polyolefms; selecting a coating composition which consists essentially of an aqueous dispersion derived from the melt kneading of (A) a base polymer which comprises one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which comprises at least one component selected from the group consisting of ethic acid
• aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; applying the coating composition to at least one surface of the substrate; removing at least a portion of the water thereby forming a coating layer on the substrate and thereby forming a coated substrate.
• the instant invention further provides a method for forming a sealable film comprising selecting a substrate formed from one or more biaxially oriented polyolefms; selecting a coating composition which comprises an aqueous dispersion derived from the melt kneading of (A) a base polymer which consists essentially of one or more thermoplastic polymers; (B) from 5 to 40 wt%, based on the total weight of (A) and (B), of a stabilizing agent which consists essentially of at least one component selected from the group consisting of ethic acid copolymers, maleic anhydride grafted polyolefms, and combinations thereof; (C) a neutralizing agent; and (D) water; wherein the aqueous dispersion has a volume average particle size of less than about 5 ⁇ ; applying the coating composition to at least one surface of the substrate; removing at least a portion of the water thereby forming a coating layer on the substrate and thereby forming a coated substrate.
• a coating composition
• Component A Base Polymer
• the coating composition comprises an aqueous dispersion which comprises the melt kneading product of a base polymer which comprises from 60 to 95 weight percent (wt %), based on the total weight of the base polymer and stabilizing agent ((A) plus (B)), of one or more
• thermoplastic polymers All individual values and subranges from 60 to 95 wt% are included herein and disclosed herein; for example, weight percent of the one or more thermoplastic polymers can be from a lower limit of 60, 65, 70, 75, 80, 85 or 90 weight percent to an upper limit of 63, 68, 73, 78, 82, 87, 92 or 95 weight percent.
• the aqueous dispersion may comprise the melt kneading product of from 60 to 95 wt% one or more thermoplastic polymers, or in the alternative, the aqueous dispersion may comprise the melt kneading product of from 60 to 80 wt% one or more thermoplastic polymers, or in the alternative, the aqueous dispersion may comprise the melt kneading product of from 80 to 95 wt% one or more thermoplastic polymers, or in the alternative, the aqueous dispersion may comprise the melt kneading product of from 80 to 90 wt% one or more thermoplastic polymers, or in the alternative, the aqueous dispersion may comprise the melt kneading product of from 60 to 70 wt% one or more thermoplastic polymers, or in the alternative, the aqueous dispersion may comprise the melt kneading product of from 70 to 80 wt% one or more thermoplastic polymers.
• the one or more thermoplastic polymers may comprise one or more olefin based polymers, one or more acrylic based polymers, one or more polyester based polymers, one or more
• thermoplastic polyurethane polymers or combinations thereof.
• thermoplastic materials include, but are not limited to, homopolymers and copolymers (including elastomers) of one or more ⁇ -olefms such as ethylene, propylene, 1-butene, 3 -methyl- 1-butene, 4-methyl-l-pentene, 3-methyl-l-pentene, 1-heptene, 1-hexene, 1-octene, 1- decene, and 1-dodecene, as typically represented by polyethylene, polypropylene, poly- 1-butene, poly-3 -methyl- 1-butene, poly-3 -methyl- 1-pentene, poly-4-methyl-l-pentene, ethylene-propylene copolymer, ethylene-l-butene copolymer, and propylene- 1-butene copolymer; copolymers (including elastomers) of an a-olefin with a conjugated or non-conjugated diene, as typically represented by ethylene -butad
• Exemplary (meth)acrylates as thermoplastic polymers, include, but are not limited to, methyl acrylate, ethyl acrylate, butyl acrylate, hexyl acrylate, 2-ethylhexyl acrylate, octyl acrylate and isooctyl acrylate, n-decyl acrylate, isodecyl acrylate, tert-butyl acrylate, methyl methacrylate, butyl methacrylate, hexyl methacrylate, isobutyl methacrylate, isopropyl methacrylate as well as 2- hydroxy ethyl acrylate and acrylamide.
• the preferred (meth)acrylates are methyl acrylate, ethyl acrylate, butyl acrylate, 2-ethylhexyl acrylate, octyl acrylate, isooctyl acrylate, methyl methacrylate and butyl methacrylate.
• Suitable (meth)acrylates that can be polymerized from monomers include lower alkyl acrylates and methacrylates including acrylic and methacrylic ester monomers: methyl acrylate, ethyl acrylate, n-butyl acrylate, t-butyl acrylate, 2-ethylhexyl acrylate, decyl acrylate, isobornyl acrylate, methyl methacrylate, ethyl methacrylate, n-propyl methacrylate, isopropyl methacrylate, n-butyl methacrylate, isobutyl methacrylate, sec-butyl methacrylate, cyclohexyl methacrylate, isodecyl methacrylate, isobornyl methacrylate, t-butylaminoethyl methacrylate, stearyl methacrylate, glycidyl methacrylate, dicyclopentenyl meth
• thermoplastic polymer may, for example, comprise one or more polyolefins selected from the group consisting of ethylene-a olefin copolymers, propylene-a olefin copolymers, and olefin block copolymers.
• the thermoplastic polymer may comprise one or more non-polar polyolefms.
• polyolefms such as polypropylene, polyethylene, copolymers thereof, and blends thereof, as well as ethylene-propylene-diene terpolymers
• exemplary olefmic polymers include homogeneous polymers, as described in U.S. Pat. No. 3,645,992; high density polyethylene (HDPE), as described in U.S. Pat. No.
• heterogeneously branched linear low density polyethylene LLCPE
• heterogeneously branched ultra-low linear density polyethylene ULDPE
• homogeneously branched, linear ethylene/a-olefm copolymers homogeneously branched, substantially linear ethylene/a-olefm polymers, which can be prepared, for example, by processes disclosed in U.S. Pat. Nos. 5,272,236 and 5,278,272, the disclosures of which are incorporated herein by reference
• high pressure, free radical polymerized ethylene polymers and copolymers such as low density polyethylene (LDPE) or ethylene vinyl acetate polymers (EVA).
• LDPE low density polyethylene
• EVA ethylene vinyl acetate polymers
• the thermoplastic polymer may, for example, be ethylene vinyl acetate (EVA) based polymers. In other embodiments, the thermoplastic polymer may, for example, be ethylene -methyl acrylate (EMA) based polymers. In other particular embodiments, the ethylene-a olefin copolymer may, for example, be ethylene-butene, ethylene-hexene, or ethylene- octene copolymers or interpolymers. In other particular embodiments, the propylene-a olefin copolymer may, for example, be a propylene-ethylene or a propylene-ethylene-butene copolymer or interpolymer.
• EVA ethylene vinyl acetate
• EMA ethylene -methyl acrylate
• the ethylene-a olefin copolymer may, for example, be ethylene-butene, ethylene-hexene, or ethylene- octene copolymers or interpolymers.
• the thermoplastic polymer may, for example, be a semi- crystalline polymer and may have a melting point of less than 110°C. In another embodiment, the melting point may be from 25 to 100°C. In another embodiment, the melting point may be between 40 and 85°C.
• the thermoplastic polymer is a propylene/a-olefm copolymer, which is characterized as having substantially isotactic propylene sequences.
• substantially isotactic propylene sequences means that the sequences have an isotactic triad (mm) measured by 13 C NMR of greater than about 0.85; in the alternative, greater than about 0.90; in another alternative, greater than about 0.92; and in another alternative, greater than about 0.93.
• Isotactic triads are well-known in the art and are described in, for example, U.S. Patent No. 5,504,172 and International Publication No. WO 00/01745, which refers to the isotactic sequence in terms of a triad unit in the copolymer molecular chain determined by 13 C NMR spectra.
• the propylene/a-olefm copolymer may have a melt flow rate in the range of from 0.1 to 25 g/10 minutes, measured in accordance with ASTM D-1238 (at 230° C / 2.16 Kg). All individual values and subranges from 0.1 to 25 g/10 minutes are included herein and disclosed herein; for example, the melt flow rate can be from a lower limit of 0.1 g/10 minutes, 0.2 g/10 minutes, 0.5 g/10 minutes, 2 g/10 minutes, 4 g/10 minutes, 5 g/10 minutes, 10 g/10 minutes, or 15 g/10 minutes to an upper limit of 25 g/10 minutes, 20 g/10 minutes, 18 g/10 minutes, 15 g/10 minutes, 10 g/10 minutes, 8 g/10 minutes, or 5 g/10 minutes.
• the propylene/a-olefm copolymer may have a melt flow rate in the range of from 0.1 to 20 g/10 minutes; or from 0.1 to 18 g/10 minutes; or from 0.1 to 15 g/10 minutes; or from 0.1 to 12 g/10 minutes; or from 0.1 to 10 g/10 minutes; or from 0.1 to 5 g/10 minutes.
• the propylene/a-olefm copolymer has a crystallinity in the range of from at least 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 30 percent by weight (a heat of fusion of less than 50 Joules/gram). All individual values and subranges from 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 30 percent by weight (a heat of fusion of less than 50 Joules/gram). All individual values and subranges from 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 30 percent by weight (a heat of fusion of less than 50
• Joules/gram are included herein and disclosed herein; for example, the crystallinity can be from a lower limit of 1 percent by weight (a heat of fusion of at least 2 Joules/gram), 2.5 percent (a heat of fusion of at least 4 Joules/gram), or 3 percent (a heat of fusion of at least 5 Joules/gram) to an upper limit of 30 percent by weight (a heat of fusion of less than 50 Joules/gram), 24 percent by weight (a heat of fusion of less than 40 Joules/gram), 15 percent by weight (a heat of fusion of less than 24.8 Joules/gram) or 7 percent by weight (a heat of fusion of less than 11 Joules/gram).
• the propylene/a-olefm copolymer may have a crystallinity in the range of from at least 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 24 percent by weight (a heat of fusion of less than 40 Joules/gram); or in the alternative, the propylene/a-olefm copolymer may have a
• crystallinity in the range of from at least 1 percent by weight (a heat of fusion of at least 2
• the propylene/a-olefm copolymer may have a crystallinity in the range of from at least 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 7 percent by weight (a heat of fusion of less than 11 Joules/gram); or in the alternative, the propylene/a-olefm copolymer may have a crystallinity in the range of from at least 1 percent by weight (a heat of fusion of at least 2 Joules/gram) to 5 percent by weight (a heat of fusion of less than 8.3 Joules/gram).
• the crystallinity is measured via Differential scanning calorimetry (DSC) method.
• the propylene/a-olefin copolymer comprises units derived from propylene and polymeric units derived from one or more a-olefin comonomers.
• Exemplary comonomers utilized to manufacture the propylene/a-olefm copolymer are C 2 , and C 4 to C 10 a-olefins; for example, C 2 , C 4 , C 6 and Cg a-olefins.
• the propylene/a-olefin copolymer comprises from 1 to 40 percent by weight of units derived from one or more a-olefin comonomers. All individual values and subranges from 1 to 40 weight percent are included herein and disclosed herein; for example, the weight percent of units derived from one or more ⁇ -olefin comonomers can be from a lower limit of 1 , 3, 4, 5, 7, or 9 weight percent to an upper limit of 40, 35, 30, 27, 20, 15, 12, or 9 weight percent.
• the propylene/a- olefin copolymer comprises from 1 to 35 percent by weight of units derived from one or more a- olefin comonomers; or in the alternative, the propylene/a-olefin copolymer comprises from 1 to 30 percent by weight of units derived from one or more a-olefin comonomers; or in the alternative, the propylene/a-olefin copolymer comprises from 3 to 27 percent by weight of units derived from one or more a-olefin comonomers; or in the alternative, the propylene/a-olefin copolymer comprises from 3 to 20 percent by weight of units derived from one or more a-olefin comonomers; or in the alternative, the propylene/a-olefin copolymer comprises from 3 to 15 percent by weight of units derived from one or more a-olefin comonomers.
• the propylene/a-olefin copolymer has a molecular weight distribution (MWD), defined as weight average molecular weight divided by number average molecular weight (M w /M n ) of 3.5 or less; in the alternative 3.0 or less; or in another alternative from 1.8 to 3.0.
• MWD molecular weight distribution
• propylene/a-olefin copolymers are further described in details in the U.S. Patent Nos. 6,960,635 and 6,525,157, incorporated herein by reference.
• Such propylene/a-olefin copolymers are commercially available from The Dow Chemical Company, under the tradename VERSIFYTM, or from ExxonMobil Chemical Company, under the tradename VISTAMAXXTM.
• the propylene/a-olefin copolymers are further characterized as comprising (A) between 60 and less than 100, preferably between 80 and 99 and more preferably between 85 and 99, weight percent units derived from propylene, and (B) between greater than zero and 40, preferably between 1 and 20, more preferably between 4 and 16 and even more preferably between 4 and 15, weight percent units derived from at least one of ethylene and/or a C 4 _io a-olefin; and containing an average of at least 0.001 , preferably an average of at least 0.005 and more preferably an average of at least 0.01, long chain branches/ 1000 total carbons, wherein the term long chain branch, as used herein, refers to a chain length of at least one (1) carbon more than a short chain branch, and short chain branch, as used herein, refers to a chain length of two (2) carbons less than the number of carbons in the comonomer.
• a propylene/ 1-octene interpolymer has backbones with long chain branches of at least seven (7) carbons in length, but these backbones also have short chain branches of only six (6) carbons in length.
• the maximum number of long chain branches typically it does not exceed 3 long chain branches/1000 total carbons.
• the thermoplastic polymer e.g. propylene/a-olefm copolymer
• the thermoplastic polymer may, for example, be a semi-crystalline polymer and may have a melting point of less than 110°C.
• the melting point may be from 25 to 100°C. In more preferred embodiments, the melting point may be between 40 and 85°C.
• olefin block copolymers e.g., ethylene multi-block copolymer, such as those described in the International Publication No. WO2005/090427 and U.S. Patent Application Publication No. US 2006/0199930, incorporated herein by reference to the extent describing such olefin block copolymers, may be used as the thermoplastic polymer.
• olefin block copolymer may be an ethylene/a-olefm interpolymer:
• (c) being characterized by an elastic recovery, Re, in percent at 300 percent strain and 1 cycle measured with a compression-molded film of the ethylene/a-olefm interpolymer, and having a density, d, in grams/cubic centimeter, wherein the numerical values of Re and d satisfying the following relationship when ethylene/a-olefm interpolymer being substantially free of a cross-linked phase:
• Such olefin block copolymer e.g. ethylene/a-olefm interpolymer may also:
• (a) have a molecular fraction which elutes between 40 °C and 130 °C when fractionated using TREF, characterized in that the fraction having a block index of at least 0.5 and up to about 1 and a molecular weight distribution, M w /M n , greater than about 1.3; or
• (b) have an average block index greater than zero and up to about 1.0 and a molecular weight distribution, M w /M n , greater than about 1.3.
• the thermoplastic polymer may, for example, comprise a polar polymer, having a polar group as either a comonomer or grafted monomer.
• the thermoplastic polymer may, for example, comprise one or more polar polyolefms, having a polar group as either a comonomer or grafted monomer.
• Exemplary polar polyolefms include, but are not limited to, ethylene-acrylic acid (EAA) and ethylene -methacrylic acid copolymers, such as those available under the trademarks PRIMACOR TM , commercially available from The Dow Chemical Company, NUCREL TM , commercially available from E.I.
• thermoplastic polymers include, but are not limited to, ethylene ethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA), and ethylene butyl acrylate (EBA).
• the thermoplastic polymer may, for example, comprise a polar polyolefm selected from the group consisting of ethylene-acrylic acid (EAA) copolymer, ethylene- methacrylic acid copolymer, and combinations thereof
• the stabilizing agent may, for example, comprise a polar polyolefm selected from the group consisting of ethylene-acrylic acid (EAA) copolymer, ethylene-methacrylic acid polymer, and combinations thereof; provided, however, that thermoplastic polymer may, for example, have a lower acid number, measured according to ASTM D-974, than the stabilizing agent.
• the thermoplastic polymer may, for example, comprise a polyester resin.
• Polyester resin refers to thermoplastic resins that may include polymers containing at least one ester bond.
• polyester polyols may be prepared via a conventional esterification process using a molar excess of an aliphatic diol or glycol with relation to an alkanedioic acid.
• glycols that can be employed to prepare the polyesters are ethylene glycol, diethylene glycol, propylene glycol, dipropylene glycol, 1,3-propanediol, 1,4-butanediol and other butanediols, 1,5-pentanediol and other pentane diols, hexanediols, decanediols, and dodecanediols.
• the aliphatic glycol may contain from 2 to about 8 carbon atoms.
• dioic acids that may be used to prepare the polyesters are maleic acid, malonic acid, succinic acid, glutaric acid, adipic acid, 2-methyl-l,6-hexanoic acid, pimelic acid, suberic acid, and dodecanedioic acids.
• the alkanedioic acids may contain from 4 to 12 carbon atoms.
• the polyester polyols are poly(hexanediol adipate), poly(butylene glycol adipate), poly(ethylene glycol adipate), poly(diethylene glycol adipate), poly(hexanediol oxalate), and poly(ethylene glycol sebecate.
• polyester resins containing aliphatic diols such as UNOXOL (a mixture of cis and trans 1,3- and 1,,4-cyclohexanedimethanol) available from The Dow Chemical Company (Midland, MI).
• the thermoplastic polymer comprises a thermoplastic polyurethane polymer.
• thermoplastic polyurethane polymers are generally know, and further described, for example, in the International Publication No. 2008/057878, incorporated herein by reference to the extent that it describes a thermoplastic polyurethane polymer.
• the thermoplastic polymer is selected from the group consisting of ethylene-based polymers, propylene-based polymers and combinations thereof.
• the thermoplastic polymer is an ethylene-based polymer having a melt index, I 2 , from 1 to 50 g/10 mins and a density from 0.85 to 0.90 g/cm 3 .
• the I 2 of the ethylene-based polymer can be from a lower limit of 1, 10, 20, 30 or 40 g/10 mins to an upper limit of 5, 15, 25, 35, 45 or 50 g/10 mins.
• the ethylene-based polymer may have an I 2 from 1 to 50 g/10 mins, or in the alternative, the ethylene-based polymer may have an I 2 from 5 to 30 g/10 mins, or in the alternative, the ethylene-based polymer may have an I 2 from 1 to 25 g/10 mins, or in the alternative, the ethylene-based polymer may have an I 2 from 15 to 50 g/ 10 mins.
• the density of the ethylene-based polymer may be from a lower limit of 0.85, 0.86, 0.87, 0.88 or 0.89 g/cm 3 to an upper limit of 0.86, 0.87, 0.88, 0.89, or 0.90 g/cm 3 .
• the thermoplastic polymer may be an ethylene-based polymer having a density from 0.85 to 0.90 g/cm 3 , or in the alternative, the thermoplastic polymer may be an ethylene-based polymer having a density from
• thermoplastic polymer may be an ethylene-based polymer having a density from 0.85 to 0.875 g/cm 3 , or in the alternative, the thermoplastic polymer may be an ethylene-based polymer having a density from 0.86 to 0.89 g/cm 3 .
• the thermoplastic polymer comprises a propylene-based polymer.
• the thermoplastic polymer comprises a propylene-based polymer having a melt flow rate, MFR from 1 to 150 g/10 mins and a density from 0.85 to 0.90 g/cm 3 . All individual values and subranges from 1 to 150 g/10 mins are included herein and disclosed herein; for example, the propylene-based polymer may have an MFR from a lower limit of
• the MFR of the propylene-based polymer may be from 1 to 150 g/10 mins, or in the alternative, the MFR of the propylene-based polymer may be from 1 to 150 g/10 mins, or in the alternative, the MFR of the propylene-based polymer may be from 1 to 75 g/10 mins, or in the alternative, the MFR of the propylene-based polymer may be from 75 to 150 g/10 mins, or in the alternative, the MFR of the propylene-based polymer may be from 5 to 110 g/10 mins.
• the base polymer consists essentially of one or more ethylene-based polymer having a melt index, I 2 , from 1 to 50 g/10 mins. and a density from 0.85 to 0.90 g/cm 3
• the base polymer consists essentially of one or more propylene- based polymer having a melt flow rate, MFR, from 1 to 150 g/10 mins and a density from 0.85 to 0.90 g/cm 3 .
• the base polymer consists essentially of one or more ethylene-based polymer having a melt index, I 2 , from 1 to 50 g/10 mins. and a density from 0.85 to 0.90 g/cm 3 and one or more propylene-based polymer having a melt flow rate, MFR, from 1 to 150 g/10 mins and a density from 0.85 to 0.90 g/cm 3 .
• Component B Stabilizing Agent
• the coating composition comprises an aqueous dispersion which comprises the melt kneading product of a base polymer which comprises from 5 to 40 weight percent (wt%), based on the total weight of the base polymer and stabilizing agent ((A) plus (B)), of a stabilizing agent which comprises at least one component selected from the group consisting of ethylene-acrylic acid (EAA) copolymers, ethylene -methacrylic acid (EMMA) copolymers, maleic anhydride grafted polyolefms, and combinations thereof.
• EAA ethylene-acrylic acid
• EMMA ethylene -methacrylic acid
• the amount of stabilizing agent may be from a lower limit of 5, 10, 15, 20, 25, 30 or 35 wt% to an upper limit of 8, 13, 18, 23, 28, 33, 38 or 40 wt%.
• the amount of stabilizing agent can be from 5 to 40 wt%, or in the alternative, the amount of stabilizing agent can be from 5 to 25 wt%, or in the alternative, the amount of stabilizing agent can be from 25 to 40 wt%, or in the alternative, the amount of stabilizing agent can be from 15 to 30 wt%, or in the alternative, the amount of stabilizing agent can be from 10 to 20 wt%, all based on the total weight of the base polymer plus the weight of the stabilizing agent.
• the stabilizing agent comprises at least one component selected from the group consisting of ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, maleic anhydride grafted polyolefms, and combinations thereof.
• Exemplary polymeric stabilizing agents include, but are not limited to, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, such as those available under the trademarks PRIMACOR TM , commercially available from The Dow Chemical Company, NUCREL TM , commercially available from E.I. DuPont de Nemours, and ESCORTM, commercially available from ExxonMobil Chemical Company and described in U.S. Patent Nos.
• Maleic anhydride grafted polyolefins may also be used. Such polymers are available under the name AMPLIFYTM TY Maleic Anhydride Grafted Polyolefins from The Dow Chemical Company. One suitable maleic anhydride grafted ethylene - propylene copolymer is commercially available from Baker Petrolite under the name BHX 10075.
• component B comprises an ethylene-acrylic acid copolymer
• the ethylene-acrylic acid copolymer comprises from 5 to 40 weight percent units derived from acrylic acid based on the total weight of the ethylene-acrylic acid copolymer. All individual values and subranges from 5 to 40 weight percent are included herein and disclosed herein; for example, the amount of units derived from acrylic acid may be from a lower limit of 5, 10, 15, 20, 25, 30 or 35 weight percent to an upper limit of 10, 15, 20, 25, 30, 35, or 40 weight percent.
• the amount of units derived from acrylic acid may range from 5 to 40 weight percent, or in the alternative, the amount of units derived from acrylic acid may range from 12 to 20 weight percent, or in the alternative, the amount of units derived from acrylic acid may range from 5 to 20 weight percent, or in the alternative, the amount of units derived from acrylic acid may range from 10 to 20 weight percent, or in the alternative, the amount of units derived from acrylic acid may range from 20 to 40 weight percent.
• component B comprises an ethylene -methacrylic acid copolymer
• the ethylene -methacrylic acid copolymer comprises from 5 to 40 weight percent units derived from methacrylic acid based on the total weight of the ethylene-methacrylic acid copolymer. All individual values and subranges from 5 to 40 weight percent are included herein and disclosed herein; for example, the amount of units derived from methacrylic acid may be from a lower limit of 5, 10, 15, 20, 25, 30 or 35 weight percent to an upper limit of 10, 15, 20, 25, 30, 35, or 40 weight percent.
• the amount of units derived from methacrylic acid may range from 5 to 40 weight percent, or in the alternative, the amount of units derived from methacrylic acid may range from 12 to 20 weight percent, or in the alternative, the amount of units derived from methacrylic acid may range from 5 to 20 weight percent, or in the alternative, the amount of units derived from methacrylic acid may range from 10 to 20 weight percent, or in the alternative, the amount of units derived from methacrylic acid may range from 20 to 40 weight percent.
• the stabilizing agent consists essentially of one or more EAA copolymers, EMAA copolymers or a combination of two or more thereof.
• the stabilizing agent consists essentially of one or more EAA copolymers.
• the stabilizing agent consists essentially of one or more EMMA copolymers.
• Component C Neutralizing Agent
• the neutralizing agent may be present in an amount to provide from 25 to 200 percent neutralization of Component B on a molar basis; or in the alternative, it may be from 50 to 110 percent on a molar basis.
• the neutralizing agent may be a base, such as ammonium hydroxide or potassium hydroxide, for example.
• Other neutralizing agents can include lithium hydroxide or sodium hydroxide, for example.
• the neutralizing agent may, for example, be a carbonate.
• the neutralizing agent may, for example, be any amine such as monoethanolamine, or 2-amino-2-methyl-l-propanol (AMP).
• Amines useful in embodiments disclosed herein may include monoethanolamine, diethanolamine, triethanolamine, and TRIS AMINO (each available from Angus), NEUTROL TE (available from BASF), as well as triisopropanolamine, diisopropanolamine, and ⁇ , ⁇ -dimethylethanolamine (DMEA) (each available from The Dow Chemical Company, Midland, MI).
• TRIS AMINO each available from Angus
• NEUTROL TE available from BASF
• DMEA ⁇ , ⁇ -dimethylethanolamine
• amines may include ammonia, monomethylamine, dimethylamine, trimethylamine, monoethylamine, diethylamine, triethylamine, mono-n-propylamine, dimethyl-n propylamine, N-methanol amine, N-aminoethylethanolamine, N- methyldiethanolamine, monoisopropanolamine, ⁇ , ⁇ -dimethyl propanolamine, 2-amino-2 -methyl- 1- propanol, tris(hydroxymethyl)-aminomethane, N,N,N'N'-tetrakis(2-hydroxylpropyl)
• ethylenediamine, 1.2-diaminopropane In some embodiments, mixtures of amines or mixtures of amines and surfactants may be used.
• an appropriate neutralizing agent depends on the specific composition formulated and the specific processing conditions, and that such a choice is within the knowledge of those of ordinary skill in the art.
• the aqueous dispersion may further comprise one or more optional stabilizing agents.
• the stabilizing agent may preferably be an external stabilizing agent.
• the dispersion of the instant invention comprises 1 to 50 percent by weight of one or more stabilizing agents, based on the total weight of the solid content of the dispersion. All individual values and subranges from 1 to 45 weight percent are included herein and disclosed herein; for example, the weight percent can be from a lower limit of 1, 3, 5, 10 weight percent to an upper limit of 15, 25, 35 , 45, or 50 weight percent.
• the dispersion may comprise from 1 to 25, or in the alternative from 1 to 35, or in the alternative from 1 to 40, or in the alternative from 1 to 45 percent by weight of one or more stabilizing agents, based on the total weight of the solid content of the dispersion.
• the stabilizing agent may be a surfactant, a polymer, or mixtures thereof.
• the stabilizing agent can be a polar polymer, having a polar group as either a comonomer or grafted monomer.
• the stabilizing agent comprises one or more polar polyolefms, having a polar group as either a comonomer or grafted monomer.
• Exemplary polymeric stabilizing agents include, but are not limited to, ethylene-acrylic acid (EAA) and ethylene-methacrylic acid copolymers, such as those available under the trademarks
• PRIMACOR commercially available from The Dow Chemical Company
• NUCREL commercially available from E.I. DuPont de Nemours
• ESCORTM commercially available from ExxonMobil Chemical Company and described in U.S. Patent Nos. 4,599,392, 4,988,781, and 5,938,437, each of which is incorporated herein by reference in its entirety.
• Other exemplary polymeric stabilizing agents include, but are not limited to, ethylene ethyl acrylate (EEA) copolymer, ethylene methyl methacrylate (EMMA), and ethylene butyl acrylate (EBA).
• EAA ethylene ethyl acrylate
• EMMA ethylene methyl methacrylate
• EBA ethylene butyl acrylate
• Other ethylene-carboxylic acid copolymer may also be used. Those having ordinary skill in the art will recognize that a number of other useful polymers may also be used.
• stabilizing agents include, but are not limited to, long chain fatty acids, fatty acid salts, or fatty acid alkyl esters having from 12 to 60 carbon atoms.
• the long chain fatty acid or fatty acid salt may have from 12 to 40 carbon atoms.
• Additional stabilizing agents that may be useful in the practice of the present invention include, but are not limited to, cationic surfactants, anionic surfactants, or non-ionic surfactants.
• anionic surfactants include, but are not limited to, sulfonates, carboxylates, and phosphates.
• cationic surfactants include, but are not limited to, quaternary amines.
• non-ionic surfactants include, but are not limited to, block copolymers containing ethylene oxide and silicone surfactants.
• Stabilizing agents useful in the practice of the present invention can be either external surfactants or internal surfactants. External surfactants are surfactants that do not become chemically reacted into the thermoplastic polymer during dispersion preparation.
• Examples of external surfactants useful herein include, but are not limited to, salts of dodecyl benzene sulfonic acid and lauryl sulfonic acid salt.
• Internal surfactants are surfactants that do become chemically reacted into the thermoplastic polymer during dispersion preparation.
• An example of an internal surfactant useful herein includes 2,2-dimethylol propionic acid and its salts.
• Additional surfactants that may be useful in the practice of the present invention include cationic surfactants, anionic surfactants, non-ionic surfactants, or combinations thereof.
• surfactants may be used in embodiments disclosed herein, including: OP- 100 (a sodium stearate), OPK-1000 (a potassium stearate), and OPK-181 (a potassium oleate), each available from RTD Hallstar; UNICID 350, available from Baker Petrolite; DISPONIL FES 77-IS and DISPONIL TA-430, each available from Cognis; RHODAPEX CO-436, SOPROPHOR 4D384, 3D-33, and 796/P, RHODACAL BX-78 and LDS-22, RHODAFAC RE-610, and RM-710, and SUPRAGIL MNS/90, each available from Rhodia; and TRITON QS-15, TRITON W-30, DOWFAX 2A1, DOWFAX 3B2, DOWFAX 8390, DOWFAX C6L, TRITON X-200, TRITON XN-45S, TRITON H-55, TRITON GR-5M, TRITON
• Component D Water
• the aqueous dispersion further comprises water.
• the dispersion of the instant invention comprises 35 to 80 percent by volume of water, based on the total volume of the dispersion.
• the water content may be in the range of from 35 to 75, or in the alternative from 35 to 70, or in the alternative from 45 to 60 percent by volume, based on the total volume of the dispersion.
• Water content of the dispersion may preferably be controlled so that the solids content (thermoplastic polymer plus stabilizing agent) is between about 1 percent to about 74 percent by volume.
• the solids range may be between about 10 percent to about 70 percent by volume.
• the solids range is between about 20 percent to about 65 percent by volume.
• the solids range is between about 25 percent to about 55 percent by volume.
• the dispersion according to the present invention may further comprise optionally one or more binder compositions such as acrylic latex, vinyl acrylic latex, styrene acrylic latex, vinyl acetate ethylene latex, and combinations thereof; optionally one or more fillers; optionally one or more additives; optionally one or more pigments, e.g. titanium dioxide, mica, calcium carbonate, silica, zinc oxide, milled glass, aluminum trihydrate, talc, antimony trioxide, fly ash, and clay;
• binder compositions such as acrylic latex, vinyl acrylic latex, styrene acrylic latex, vinyl acetate ethylene latex, and combinations thereof
• fillers optionally one or more additives
• optionally one or more pigments e.g. titanium dioxide, mica, calcium carbonate, silica, zinc oxide, milled glass, aluminum trihydrate, talc, antimony trioxide, fly ash, and clay;
• co-solvents e.g. glycols, glycol ether, 2,2,4-trimethyl-l,3-pentanediol monoisobutyrate, alcohols, mineral spirits, and benzoate esters; optionally one or more dispersants, e.g. aminoalcohols, and polycarboxylates; optionally one or more surfactants; optionally one or more defoamers; optionally one or more preservatives, e.g. biocides, mildewcides, fungicides, algaecides, and combinations thereof; optionally one or more thickeners, e.g.
• co-solvents e.g. glycols, glycol ether, 2,2,4-trimethyl-l,3-pentanediol monoisobutyrate, alcohols, mineral spirits, and benzoate esters
• dispersants e.g. aminoalcohols, and polycarboxylates
• surfactants e.g. aminoalcohol
• cellulosic based thickeners such as hydroxyethyl cellulose, hydrophobically modified alkali soluble emulsions (HASE thickeners such as UCAR POLYPHOBE TR-116) and hydrophobically modified ethoxylated urethane thickeners (HEUR); or optionally one or more additional neutralizing agents, e.g. hydroxides, amines, ammonia, and carbonates.
• HASE thickeners such as UCAR POLYPHOBE TR-116
• HEUR hydrophobically modified ethoxylated urethane thickeners
• additional neutralizing agents e.g. hydroxides, amines, ammonia, and carbonates.
• the dispersion according to the present invention can be formed by any number of methods recognized by those having skill in the art.
• Components A and B, and optionally one or more stabilizing agents are melt-kneaded in an extruder along with water and a neutralizing agent to form a dispersion.
• Components A and B are compounded, and then the compound is melt-kneaded in an extruder in the presence of an optional stabilizing agent, water, and one or more neutralizing agents thereby forming a dispersion.
• the dispersion is first diluted to contain about 1 to about 3% by weight water and then, subsequently, further diluted to comprise greater than about 25% by weight water.
• melt-kneading means known in the art may be used.
• a kneader, a BANBURY ® mixer, single -screw extruder, or a multi-screw extruder, e.g. a twin screw extruder is used.
• a process for producing the dispersions in accordance with the present invention is not particularly limited.
• an extruder in certain embodiments, for example, a twin screw extruder, is coupled to a back pressure regulator, melt pump, or gear pump.
• embodiments also provide a base reservoir and an initial water reservoir, each of which includes a pump. Desired amounts of base and initial water are provided from the base reservoir and the initial water reservoir, respectively.
• Any suitable pump may be used, but in some embodiments, for example, a pump that provides a flow of about 150 cc/min at a pressure of 240 bar is used to provide the base and the initial water to the extruder.
• a liquid injection pump provides a flow of 300 cc/min at 200 bar or 600 cc/min at 133 bar.
• the base and initial water are preheated in a preheater.
• thermoplastic polymers in the form of pellets, powder, or flakes, are fed from the feeder to an inlet of the extruder where the resin is melted or compounded.
• Component B is added to the base polymer comprising one or more thermoplastic polymers through and along with the resin and in other embodiments, Component B is provided separately to the twin screw extruder.
• the resin melt is then delivered from the mix and convey zone to an emulsification zone of the extruder where the initial amount of water and base from the water and base reservoirs are added through an inlet.
• Component B may be added additionally or exclusively to the water stream.
• further dilution water may be added via water inlet from water reservoir in a dilution and cooling zone of the extruder. Typically, the dispersion is diluted to at least 30 weight percent water in the cooling zone.
• the diluted mixture may be diluted any number of times until the desired dilution level is achieved.
• water is not added into the twin screw extruder but rather to a stream containing the resin melt after the melt has exited from the extruder. In this manner, steam pressure build-up in the extruder is eliminated and the dispersion is formed in a secondary mixing device such as a rotor stator mixer.
• the coating composition of the present invention may be used, for example, in different coating applications such as architectural coating applications, automotive coating applications, paper coating applications, seed coating applications, conductive coatings and industrial coating applications, adhesives applications, sealant applications, foam applications, toner applications, and controlled released coating applications.
• coating applications such as architectural coating applications, automotive coating applications, paper coating applications, seed coating applications, conductive coatings and industrial coating applications, adhesives applications, sealant applications, foam applications, toner applications, and controlled released coating applications.
• the coating composition may be used for coating biaxially oriented films.
• the coating composition may be used for coating biaxially oriented polypropylene films and/or biaxially oriented polyethylene films.
• the coating composition may be used for coating biaxially oriented polypropylene films used in food packaging, such as packaging for confectionary products.
• the coating composition may be applied to a substrate by use of any known technique, including for example, by hand coating or by use of a coating machine.
• a biaxially oriented polypropylene film having a coating layer derived from the application of the aqueous dispersion, according to any of the embodiments described herein, at a rate of from 1 to 2 grams per square meter has two or more of the following properties: (a) a heat seal strength of greater than or equal to 0.6 N/15 mm at a sealing temperature from 60 to 70 °C; (b) blocking resistance up to at least 40 °C; and (c) a broader hot tack than observed for the biaxially oriented polypropylene film in the absence of the coating layer. All individual values and subranges of a heat seal strength of greater than or equal to 0.6 N/15 mm at a sealing temperature from 60 to 70 °C are included herein and disclosed herein. For example, the heat seal strength at a sealing
• temperature from 60 to 70 °C may be greater than or equal to 0.6 N/15 mm, or in the alternative, greater than or equal to 0.8 N/15mm, or in the alternative, greater than or equal to 1 N/15mm, or in the alternative, greater than or equal to 1.3 N/15mm, or in the alternative, greater than or equal to 1.6 N/15mm, or in the alternative, greater than or equal to 2 N/15mm.
• a blocking resistance up to at least 40 °C are included herein and disclosed herein.
• the blocking resistance may be up to at least 42 °C, or in the alternative, the blocking resistance may be up to at least 44 °C, or in the alternative, the blocking resistance may be up to at least 46 °C.
• DMEA dimethyl ethanol amine, commercially available, CAS number 108-01-0.
• Aqueous dispersions were prepared according to the methods described in WO2005085331, the disclosure of which is incorporated herein in its entirety.
• aqueous dispersions of each of Inventive Examples 1-2 and Comparative Examples 1-5 were applied on a corona-treated surface of a BOPP film using a bar-coater, with a bar having 4 micron target coating weight to produce Inventive Film Examples 1-2 and Comparative Film
• Inventive example 2 was applied on a corona-treated surface of a biaxially oriented polypropylene (BOPP) film using a lab-scale laminator from Nordmeccanica S.p.A (Piacenza, Italy) to form Inventive Film Example 4.
• Experimental conditions such as e.g. pressure of coating roll, speed of primary web, setup of drying tunnel, were optimized and thickness of the applied coating was in the range of 1 micron.
• the pressure of the coating roll was varied between 2.5 and 3.5 bars
• web speed was varied from 35 to 50 m/min while oven profile was similar to the one a person skilled in the art would use for coating of water-based systems. Nevertheless, influence of processing conditions on performance was not relevant, i.e.
• inventive example 2 could be processed with a wide window of processing conditions with similar final performance.
• the pressure on the coating roll was varied between 2.5 and 3.5 bars and the web speed was varied between 35 and 50 m/min. .
• Table 4 provides the seal strength at several temperatures, hot tack range, haze and clarity of Inventive Film Example 2.
• Test methods include the following:
• Melt flow rate was measured in accordance with ASTM D-1238 at 230 °C with a 2.16 kg weight for propylene-based polymers.
• Haze % was measured according to ASTM D 1003-1 1.
• Clarity % was according to ASTM D 1003-11.
• Coating layer weight and thickness were determined gravimetrically. Coating layer weight was determined based on weight difference between coated and uncoated films. Ten disc-shaped pieces (each measuring 100 cm 2 ) of coated film samples were weighed individually on a high precision scale and the coating thickness was determined by subtracting the weight of the base BOPP substrate. The dry coating density is used for calculating the coating thickness based on the weight difference.
• Hot tack range was measured according to ASTM F1921 -98.
• Heat seal strength was measured according to ASTM F2029-00 (practice B, web scalability).
• Heat seal coated material on a given substrate was cut into a 1 inch by 12 inch strip.
• a sample of the uncoated substrate was also cut into a 1 inch by 12 inch strip.
• the two strips are placed on a glass plate in such a way that the coating on the coated strip is facing down on the uncoated strip.
• a metal square block weighing one pound (with exact dimension of 1 "square) is put on the strips at a 2.5 to 3" apart at a pressure of 1 pound per inch.
• the combined strips with the weight were then put in a forced air oven maintained at 120 °F for 24 hours. After 24 hours, the combined strips were pulled out from the oven and carefully pulled apart by hand.

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• Chemical & Material Sciences (AREA)
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• Life Sciences & Earth Sciences (AREA)
• Engineering & Computer Science (AREA)
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• Wood Science & Technology (AREA)
• Health & Medical Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
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• Polymers & Plastics (AREA)
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