Coating Composition, a Process of Producing a Coating Composition, a Coated Article, and a Method of Forming Such Articles

Patent metadata

Field	Value
Publication number	US-2016145451-A1
Application number	US-201514950070-A
Country	US
Kind code	A1
Filing date	Nov 24, 2015
Priority date	Dec 12, 2008
Publication date	May 26, 2016
Grant date	—

Abstract

The instant invention provides a coating composition, a process of making a coating composition, a coated article, and a method of forming such articles.
The coating composition according to the present invention comprises a dispersion comprising: (a) a core comprising a base polymer; (b) a shell at least partially surrounding said core, wherein said shell comprising a polar polymeric stabilizing agent; and (c) one or more hydrophobic particulate fillers embedded at least partially in said shell.
The process for making a coating composition according to the present invention comprises the steps of: (1) selecting a base polymer; (2) selecting a polar polymeric stabilizing agent; (3) selecting one or more hydrophobic particulate fillers; (4) melt-blending said base polymer, said polar polymeric stabilizing agent, and said one or more hydrophobic particulate fillers; (4) contacting said melt-blended base polymer, polar polymeric stabilizing agent and one or more hydrophobic particulate fillers with water and optionally in the presence of a neutralizing agent; (5) thereby forming said dispersion comprising: (a) a core comprising said base polymer; (b) a shell at least partially surrounding said core, wherein said shell comprising said polar polymeric stabilizing agent; and (c) said one or more hydrophobic particulate fillers embedded at least partially in said shell.
The coated article according to the present invention comprises: a substrate comprising cellulose base material; and a dispersion on at least one surface of said substrate, wherein said dispersion comprises: (a) a core comprising a base polymer; (b) a shell at least partially surrounding said core, wherein said shell comprising a polar polymeric stabilizing agent; and (c) one or more hydrophobic particulate fillers embedded at least partially in said shell.
The method of making a coated article according to the present invention comprises the steps of: (1) providing a substrate comprising cellulose base material (2) providing a coating composition comprising a dispersion comprising: (a) a core comprising a base polymer; (b) a shell at least partially surrounding said core, wherein said shell comprising a polar polymeric stabilizing agent; and (c) one or more hydrophobic particulate fillers embedded at least partially in said shell; (3) applying said coating composition to at least one surface of said substrate; and (4) thereby making said coated article.

First claim

1 .- 15 . (canceled)

16 . A packaging device comprising:
a substrate; and a coating layer disposed at least on a surface of said substrate, wherein said coating layer is derived from an aqueous polyolefin dispersion which comprises
a core comprising a base polymer, wherein said base polymer comprises a thermoplastic polymer;
a shell at least partially surrounding said core, wherein said shell comprises a polar polymeric stabilizing agent; and
one or more hydrophobic particulate fillers having a particle size diameter in the range of from 5 nm to 250 nm embedded at least partially in said shell,
wherein coating layer comprises a continuous base polymer phase with discrete stabilizing agent phase dispersed therein the continuous base polymer phase.

17 . A process for making a packaging device comprising:
selecting a substrate; and disposing an aqueous polyolefin dispersion on a surface of said substrate, wherein said aqueous polyolefin dispersion comprises
a core comprising a base polymer, wherein said base polymer comprises a thermoplastic polymer;
a shell at least partially surrounding said core, wherein said shell comprises a polar polymeric stabilizing agent; and
one or more hydrophobic particulate fillers having a particle size diameter in the range of from 5 nm to 250 nm embedded at least partially in said shell;
drying said aqueous dispersion disposed on a surface of said substrate at a temperature in the range of equal to or greater than the melting point temperature of the base polymer, thereby forming a coated substrate, wherein a coating layer is disposed at least on a surface of said substrate, wherein said coating layer comprises a continuous base polymer phase with discrete stabilizing agent phase dispersed therein the continuous base polymer phase; forming said coated substrate into a packaging device.

18 . The packaging device of claim 16 , wherein the base polymer is a thermoplastic polymer selected from the group consisting of an ethylene based polymer, a propylene based polymer, and combinations thereof.

19 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion comprises 20 to 90 percent by weight of the base polymer, based on the total solid weight of the aqueous polyolefin dispersion.

20 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion comprises 10 to 50 percent by weight the polar polymeric stabilizing agent, based on the total solid weight of the aqueous polyolefin dispersion.

21 . The packaging device of claim 16 , wherein the base polymer and polar polymeric stabilizing agent are the same type of polymeric material, provided each has a different acid number.

22 . The packaging device of claim 16 , wherein one or more hydrophobic particulate fillers are selected from the group consisting of an inorganic substance, an organic substance, and combinations thereof.

23 . The packaging device of claim 16 , wherein one or more hydrophobic particulate fillers are inorganic substances selected from the group consisting of aluminum hydroxide, aragonite, barium sulphate, calcite, calcium sulphate, dolomite, magnesium hydroxide, magnesium carbonate, magnesite, ground calcium carbonate, precipitated calcium carbonate, rutile titanium dioxide, anatase titanium dioxide, satin white, zinc oxide, silica, alumina trihydrate, mica, talc, clay, calcined clay, diatomaceous earth, vaterite, and combination thereof.

24 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion comprises 1 to 50 percent by weight of one or more hydrophobic particulate fillers, based on the total solid weight of the dispersion.

25 . The packaging device of claim 16 , wherein the polar polymeric stabilizing agent is selected from the group consisting of ethylene-acrylic acid (EAA), ethylene methyl methacrylate (EMMA), ethylene butyl acrylate (EBA), and combinations thereof.

26 . The packaging device of claim 16 , wherein the polar polymeric stabilizing agent is neutralized from 50 to 90 percent.

27 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion has a solid average particle size distribution in the range of from 0.2 to 2 μm.

28 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion has a pH in the range of from 8 to 12.

29 . The packaging device of claim 16 , wherein the aqueous polyolefin dispersion comprises from 40 to 55 percent by volume of a liquid media, based on the total volume of the aqueous polyolefin dispersion.

30 . The process for making a packaging device of claim 17 , wherein the base polymer is a thermoplastic polymer selected from the group consisting of an ethylene based polymer, a propylene based polymer, and combinations thereof.

31 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion comprises 20 to 90 percent by weight of the base polymer, based on the total solid weight of the aqueous polyolefin dispersion.

32 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion comprises 10 to 50 percent by weight the polar polymeric stabilizing agent, based on the total solid weight of the aqueous polyolefin dispersion.

33 . The process for making a packaging device of claim 17 , wherein the base polymer and polar polymeric stabilizing agent are the same type of polymeric material, provided each has a different acid number.

34 . The process for making a packaging device of claim 17 , wherein one or more hydrophobic particulate fillers are selected from the group consisting of an inorganic substance, an organic substance, and combinations thereof.

35 . The process for making a packaging device of claim 17 , wherein one or more hydrophobic particulate fillers are inorganic substances selected from the group consisting of aluminum hydroxide, aragonite, barium sulphate, calcite, calcium sulphate, dolomite, magnesium hydroxide, magnesium carbonate, magnesite, ground calcium carbonate, precipitated calcium carbonate, titanium dioxide (e.g. rutile and/or anatase), satin white, zinc oxide, silica, alumina trihydrate, mica, talc, clay, calcined clay, diatomaceous earth, vaterite, and combination thereof.

36 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion comprises 1 to 50 percent by weight of one or more hydrophobic particulate fillers, based on the total solid weight of the dispersion.

37 . The process for making a packaging device of claim 17 , wherein the polar polymeric stabilizing agent is selected from the group consisting of ethylene-acrylic acid (EAA), ethylene methyl methacrylate (EMMA), ethylene butyl acrylate (EBA), and combinations thereof.

38 . The process for making a packaging device of claim 17 , wherein the polar polymeric stabilizing agent is neutralized from 50 to 90 percent.

39 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion has a solid average particle size distribution in the range of from 0.2 to 2 μm.

40 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion has a pH in the range of from 8 to 12.

41 . The process for making a packaging device of claim 17 , wherein the aqueous polyolefin dispersion comprises from 40 to 55 percent by volume of a liquid media, based on

Assignees

• Dow Global Technologies Llc

Inventors

• Vyorykka Jouko
• Malotky David L
• Wevers Ronald

Classifications

• C08F255/00

  Macromolecular compounds obtained by polymerising monomers on to polymers of hydrocarbons as defined in group C08F10/00 · CPC title

• C08F285/00

  Macromolecular compounds obtained by polymerising monomers on to preformed graft polymers · CPC title

• C09D7/68

  Particle size between 100-1000 nm · CPC title

• C08F255/02

  on to polymers of olefins having two or three carbon atoms · CPC title

• C09D7/80

  Processes for incorporating ingredients · CPC title