U.S. patent application number 13/407927 was filed with the patent office on 2013-08-29 for highly viscous ionomer-poly(vinylalcohol) coatings.
This patent application is currently assigned to E.I. DU PONT DE NEMOURS AND COMPANY. The applicant listed for this patent is Elliott Echt, Richard Allen Hayes. Invention is credited to Elliott Echt, Richard Allen Hayes.
Application Number | 20130225021 13/407927 |
Document ID | / |
Family ID | 49003346 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130225021 |
Kind Code |
A1 |
Echt; Elliott ; et
al. |
August 29, 2013 |
HIGHLY VISCOUS IONOMER-POLY(VINYLALCOHOL) COATINGS
Abstract
Disclosed are methods to form coatings on a substrate, the
coatings comprising a blend of a poly(vinyl alcohol) composition
comprising a poly(vinyl alcohol) characterized by a hydrolysis
level of from about 85 to about 93 mole % and a 4 weight % aqueous
viscosity at 20.degree. C. of about 16 to about 75 centipoise; and
an ionomer comprising a parent acid copolymer that comprises
ethylene and about 18 to about 30 weight % of acrylic acid or
methacrylic acid, the acid copolymer having a melt flow rate from
about 200 to about 1000 g/10 min., wherein about 50% to about 70%
of the carboxylic acid groups of the copolymer are neutralized to
carboxylic acid salts comprising potassium cations, sodium cations
or combinations thereof. Multilayer structures comprising the blend
composition on a substrate are also disclosed.
Inventors: |
Echt; Elliott; (Wilmington,
DE) ; Hayes; Richard Allen; (Beaumont, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Echt; Elliott
Hayes; Richard Allen |
Wilmington
Beaumont |
DE
TX |
US
US |
|
|
Assignee: |
E.I. DU PONT DE NEMOURS AND
COMPANY
Wilmington
DE
|
Family ID: |
49003346 |
Appl. No.: |
13/407927 |
Filed: |
February 29, 2012 |
Current U.S.
Class: |
442/59 ; 156/60;
427/385.5; 428/314.4; 428/319.3; 428/461; 428/511; 524/503 |
Current CPC
Class: |
Y10T 442/20 20150401;
Y10T 428/31692 20150401; C09D 129/04 20130101; Y10T 428/31895
20150401; B32B 27/306 20130101; C09D 129/04 20130101; Y10T
428/249991 20150401; B32B 27/308 20130101; Y10T 428/249976
20150401; C08L 23/0876 20130101; Y10T 156/10 20150115; B32B 2270/00
20130101 |
Class at
Publication: |
442/59 ; 524/503;
428/511; 428/319.3; 428/461; 428/314.4; 427/385.5; 156/60 |
International
Class: |
B32B 27/30 20060101
B32B027/30; B32B 5/02 20060101 B32B005/02; B32B 3/26 20060101
B32B003/26; B32B 15/082 20060101 B32B015/082; B32B 37/14 20060101
B32B037/14; B05D 3/00 20060101 B05D003/00; B32B 37/06 20060101
B32B037/06; B32B 37/08 20060101 B32B037/08; B32B 37/10 20060101
B32B037/10; C09D 129/04 20060101 C09D129/04; B05D 7/00 20060101
B05D007/00 |
Claims
1. A method to form a coating comprising a blend of ionomer and
poly(vinyl alcohol) on a substrate, the method comprising (1)
providing a blend composition comprising (a) about 99 to about 1
weight %, based on the combination of (a) and (b), of a poly(vinyl
alcohol) composition comprising a poly(vinyl alcohol) characterized
by a hydrolysis level of from about 85 to about 93 mol % and a 4
weight % aqueous viscosity at 20.degree. C. of from 16 to about 75
centipoise (cp); and (b) about 1 to about 99 weight %, based on the
combination of (a) and (b), of an ionomer composition comprising a
parent acid copolymer that comprises copolymerized units of
ethylene and about 18 to about 30 weight % of copolymerized units
of acrylic acid or methacrylic acid, based on the total weight of
the parent acid copolymer, the acid copolymer having a melt flow
rate (MFR) from about 200 to about 1000 g/10 min., measured
according to ASTM D1238 at 190.degree. C. with a 2160 g load,
wherein about 50% to about 70% of the carboxylic acid groups of the
copolymer, based on the total carboxylic acid content of the parent
acid copolymer as calculated for the non-neutralized parent acid
copolymer, are neutralized to carboxylic acid salts comprising
potassium cations, sodium cations or combinations thereof; (2)
providing a substrate; and (3) coating the blend composition onto
the substrate.
2. The method of claim 1 comprising an ionomer wherein the cations
of the carboxylate salts consist essentially of sodium cations.
3. The method of claim 1 comprising an ionomer wherein the cations
of the carboxylate salts consist essentially of potassium
cations.
4. The method of claim 1 wherein (b) is present in the combination
of (a) and (b) in an amount from about 10 to about 95 weight %, (a)
being present in a complementary amount.
5. The method of claim 1 wherein (b) is present in the combination
of (a) and (b) in an amount from about 60 to about 95 weight %, (a)
being present in a complementary amount.
6. The blend composition of claim 1 wherein the poly(vinyl alcohol)
is characterized by a 4 weight % aqueous viscosity at 20.degree. C.
of about 20 to about 75 cp.
7. The blend composition of claim 6 wherein the poly(vinyl alcohol)
is characterized by a 4 weight % aqueous viscosity at 20.degree. C.
of about 20 to about 60 cp.
8. The method of claim 1 wherein the acid copolymer has a MFR from
about 250 to about 400 g/10 min.
9. The method of claim 1 wherein the acid copolymer is an ethylene
methacrylic acid dipolymer having about 18 to about 25 weight % of
copolymerized units of methacrylic acid.
10. The method of claim 1 wherein the ionomer composition has a MFR
from about 1 to about 20 g/10 min.
11. The method of claim 1 wherein the ionomer composition comprises
at least 11 weight % methacrylic acid salt and has a MFR of at
least 1 g/10 min.
12. The method of claim 1 wherein the substrate is paper,
paperboard, cardboard, pulp-molded shape, textile, material made
from a synthetic fiber spun fabric, film, open-cell foam,
closed-cell foam, or metallic foil.
13. The method of claim 12 wherein the substrate is paper,
paperboard, cardboard, or pulp-molded shape.
14. The method of claim 1 wherein the blend composition is provided
in the form of an aqueous dispersion comprising water and about
0.001 to about 50 weight % of the combination of (a) and (b); the
blend composition is coated onto the substrate as the aqueous
dispersion and the method further comprises (4) drying the coated
substrate at a temperature of about 20 to about 150.degree. C.
15. The method of claim 14 wherein providing the blend composition
comprises (1a) providing an aqueous poly(vinyl alcohol) solution
comprising water and the poly(vinyl alcohol) composition of (a);
(1b) providing an ionomer composition comprising the ionomer
composition of (b); (1c) mixing the ionomer composition with the
aqueous poly(vinyl alcohol) composition solution optionally with
heating; and (1d) optionally cooling the heated aqueous blend
dispersion to a temperature of about 20 to 30.degree. C., wherein
the combination remains dispersed in the liquid phase.
16. The method of claim 15 wherein (1a) comprises heating a mixture
of water and the poly(vinyl alcohol) composition to provide the
aqueous poly(vinyl alcohol) solution, optionally followed by
cooling to a temperature of about 20 to about 30.degree. C.; and
(1b) comprises providing an aqueous ionomer composition by mixing a
solid ionomer composition with water heated to a temperature from
about 80 to about 100.degree. C. to provide a heated aqueous
ionomer composition dispersion; optionally followed by cooling to a
temperature of about 20 to about 30.degree. C., wherein the ionomer
remains dispersed in the aqueous phase.
17. The method of claim 14 wherein providing the blend composition
comprises (1a) heating a mixture of water and a poly(vinyl alcohol)
composition described above to provide an aqueous poly(vinyl
alcohol) solution optionally followed by cooling to a temperature
of about 20 to about 30.degree. C.; (1b) providing the ionomer
composition comprising or consisting essentially of the ionomer in
solid form; (1c) heating the aqueous poly(vinyl alcohol) solution
to a temperature from about 80 to about 100.degree. C. (under low
shear conditions); (1d) contacting the solid ionomer composition
with the heated aqueous poly(vinyl alcohol) solution; (1e)
continuing heating at a temperature from about 80 to about
100.degree. C. until the solid ionomer composition has completely
dispersed; and (1f) optionally cooling to a temperature of about 20
to 30.degree. C.
18. The method of claim 14 wherein providing the blend composition
comprises (1a) heating a combination of the poly(vinyl alcohol)
with water to provide an aqueous poly(vinyl alcohol) composition
solution; (1b) providing the ionomer composition comprising the
ionomer in solid form; (1c) contacting the solid ionomer
composition with the aqueous poly(vinyl alcohol) solution to
provide a mixture; (1d) heating the mixture to a temperature from
about 80 to about 100.degree. C. until the solid ionomer
composition has completely dispersed; and (1e) optionally cooling
to a temperature of about 20 to 30.degree. C.
19. The method of claim 1 wherein the blend composition is provided
in the form of a preformed ionomer-PVOH film comprising the
combination of (a) and (b); (3) comprises (3a) producing a
prelaminate structure comprising the ionomer-PVOH film layer
adjacent to the substrate; and (3b) laminating the ionomer-PVOH
film layer to the substrate at a temperature from about 50 to about
150.degree. C., optionally with applied pressure; and the method
further comprises (4) cooling the coated substrate to a temperature
of about 20 to about 30.degree. C.
20. A multilayer structure comprising a coated substrate comprising
a surface layer on the substrate and the surface layer comprises a
blend composition comprising (a) about 99 to about 1 weight %,
based on the combination of (a) and (b), of a poly(vinyl alcohol)
composition comprising a poly(vinyl alcohol) characterized by a
hydrolysis level of from about 85 to about 93 mol % and a 4 weight
% aqueous viscosity at 20.degree. C. of from 8 to about 75
centipoise (cp); and (b) about 1 to about 99 weight %, based on the
combination of (a) and (b), of an ionomer composition comprising a
parent acid copolymer that comprises copolymerized units of
ethylene and about 18 to about 30 weight % of copolymerized units
of acrylic acid or methacrylic acid, based on the total weight of
the parent acid copolymer, the acid copolymer having a melt flow
rate (MFR) from about 200 to about 1000 g/10 min., measured
according to ASTM D1238 at 190.degree. C. with a 2160 g load,
wherein about 50% to about 70% of the carboxylic acid groups of the
copolymer, based on the total carboxylic acid content of the parent
acid copolymer as calculated for the non-neutralized parent acid
copolymer, are neutralized to carboxylic acid salts comprising
potassium cations, sodium cations or combinations thereof.
21. The multilayer structure of claim 20 wherein the ionomer
composition has a MFR from about 1 to about 20 g/10 min.
22. The multilayer structure of claim 20 wherein the acid copolymer
has a MFR from about 250 to about 400 g/10 min.
23. The multilayer structure of claim 20 wherein the acid copolymer
is an ethylene methacrylic acid dipolymer having about 18 to about
25 weight % of copolymerized units of methacrylic acid.
24. The multilayer structure of claim 20 wherein the ionomer
composition comprises at least 11 weight % methacrylic acid salt
and has a MFR of at least 1 g/10 min.
25. The multilayer structure of claim 20 wherein about 55% to about
60% of the total carboxylic acid groups of the copolymer are
neutralized to carboxylic acid salts.
26. The multilayer structure of claim 20 wherein the substrate is
paper, paperboard, cardboard, pulp-molded shape, textile, material
made from a synthetic fiber spun fabric, film, open-cell foam,
closed-cell foam, or metallic foil.
27. The multilayer structure of claim 20 wherein the substrate is
paper, paperboard, cardboard, or pulp-molded shape.
28. An article comprising the multilayer structure of claim 20.
29. The multilayer structure of claim 20 wherein (b) is present in
the combination of (a) and (b) in an amount from about 50 to about
70 weight %, (a) being present in a complementary amount.
Description
FIELD OF THE INVENTION
[0001] The present invention is directed to methods to form
coatings comprising highly viscous blends of ionomers and
poly(vinyl alcohol)s on a substrate and multilayer articles
comprising the blends.
BACKGROUND OF THE INVENTION
[0002] Ionomers of ethylene copolymers with
alpha,beta-ethylenically unsaturated carboxylic acids are known in
the art, wherein at least a portion of the carboxylic acid groups
of the copolymer are neutralized to form carboxylate salts
comprising alkali metal, alkaline earth metal or transition metal
cations. See for example U.S. Pat. Nos. 3,264,272; 3,338,739;
3,355,319; 5,155,157; 5,244,969; 5,304,608; 5,542,677; 5,591,803;
5,688,869; 6,100,336; 6,245,858; 6,518,365; and U.S. Patent
Application Publication 2009/0297747.
[0003] Aqueous dispersions of ionomers are also known in the art.
See for example U.S. Pat. Nos. 3,896,065; 3,904,569; 4,136,069;
4,508,804; 5,409,765; and Japanese Patent Applications JP01009338
and JP05075769. They have been produced by dissolving the acid
copolymer precursors in a solvent, neutralization of the acid
functionalities with generally ammonia, amines or alkali metal
ions, and dilution of the solution into water followed by partial
or complete removal of the solvent. See for example U.S. Pat. Nos.
2,313,144; 3,296,172; 3,389,109; 3,562,196; 5,430,111; 5,591,806;
British Patent GB1243303; Japanese Patent Applications JP50084687
and JP2009091426.
[0004] Aqueous ionomer dispersions have also been produced by
heating acid copolymer precursors or ionomers in hot aqueous
ammonia and other neutralizing agents. See for example U.S. Pat.
Nos. 3,644,258; 3,674,896; 3,823,108; 3,970,626; 4,540,736;
5,330,788; 5,550,177; U.S. Patent Application Publication
2007/0117916; Japanese Patent Application JP06000872; and PCT
Patent Application Publication WO2000/044801.
[0005] Aqueous ionomer dispersions have also been produced by
dispersing the acid copolymer precursor in aqueous solutions of
neutralizing agents at temperatures under high shear process
conditions above the boiling point of water, necessitating the use
of pressure vessels such as autoclaves and extruders. See for
example U.S. Pat. Nos. 4,775,713; 4,970,258; 4,978,707; 5,374,687;
5,445,893; 7,279,513; 7,528,080; U.S. Patent Application
Publications 2005/0100754; 2006/0124554; 2007/0141323;
2007/0144697; 2007/0292705; 2007/0295464; 2007/0295465;
2008/0000598; 2008/0000602; 2008/0041543; 2008/0073045;
2008/0073046; 2008/0118728; 2008/0135195; 2008/0176968;
2008/0182040; 2008/0216977; 2008/0230195; 2008/0292833;
2008/0295985; 2009/0194450; 2009/0253321; European Patent
Application EP1163276; PCT Patent Application WO 2011/058119; WO
2011/058121; WO 2011/068525; and Japanese Patent Applications
JP2958120; JP10006640; and JP50135141.
[0006] Aqueous ionomer dispersions have also been produced by
dispersing the ionomer in aqueous solutions under high shear
process conditions at temperatures above the boiling point of
water, necessitating the use of pressure vessels such as autoclaves
and extruders. See for example U.S. Pat. Nos. 4,173,669; 4,329,305;
4,410,655; 4,440,908; 6,458,897; Japanese Applications JP11158332;
JP2000328046; JP2005075878; and PCT Patent Application Publication
WO1999/10276.
[0007] Aqueous ionomer dispersions have also been produced by
dispersing highly neutralized, low melt index (MI) ionomers in hot
water. See for example U.S. Pat. Nos. 3,321,819; 3,472,825; and
4,181,566.
[0008] Ammonia-neutralized ionomer aqueous dispersions have been
used to coat certain substrates. See for example U.S. Pat. Nos.
3,872,039; 3,899,389; 3,983,268; 4,340,659; 4,400,440; 4,714,728;
5,336,528; and 6,852,792. As is well known in the art,
ammonia-neutralized ionomers liberate the ammonia upon drying to
reform the parent acid copolymer and are not redispersible in hot
water.
[0009] Low molecular weight ionomer waxes have been used as
temporary coatings removable with hot water. See for example U.S.
Pat. No. 5,292,794.
[0010] Certain ionomer articles have been dispersed in aqueous
caustic solutions. See for example U.S. Pat. No. 6,162,852.
[0011] Certain ionomer dispersions have been used as primer
coatings for substrates, such as PET, biaxially oriented
polypropylene (BOPP) and aluminum foil films. See for example U.S.
Pat. Nos. 5,419,960; 6,013,353; 7,364,800; 7,470,736; and U.S.
Patent Application Publication 2005/0271888.
[0012] Highly neutralized ionomer dispersions have been used as
fabric or paper treatments. See for example U.S. Pat. Nos.
5,082,697; 5,206,279; and 5,387,635.
[0013] Ionomer dispersions, produced through autoclave or extrusion
processes, have been used as internal and external paper sizing or
paper additives. See for example U.S. Pat. Nos. 5,993,604;
6,482,886; 7,588,662; U.S. Patent Application Publications
2007/0137808; 2007/0137809; 2007/0137810; 2007/0137811;
2007/0137813; 2007/0141936; 2007/0243331; and 2007/0284069.
[0014] Certain ionomer dispersions have been used in repulpable
paper compositions. See for example U.S. Pat. No. 5,160,484.
[0015] Blends of aqueous ionomer dispersions with poly(vinyl
alcohol) solutions are known in the art. See for example U.S. Pat.
Nos. 3,674,896; 3,896,065; 4,547,456; 4,575,532; 4,600,746;
5,192,620; 5,358,790; 6,821,373; European Patent Application EP
868363; Japanese Applications JPH09124975; JP2003049035; and
JP60072973. The blends suffer the shortcoming of a complicated
ionomer dispersion process, as disclosed above.
[0016] Ammonia-neutralized ionomer aqueous dispersions have been
used to coat certain substrates. See for example U.S. Pat. Nos.
3,872,039; 3,899,389; 3,983,268; 4,340,659; 4,400,440; 4,714,728;
5,336,528; and 6,852,792. As is well known in the art,
ammonia-neutralized ionomers liberate the ammonia upon drying to
reform the parent acid copolymer and are not redispersible in hot
water.
[0017] Low molecular weight ionomer waxes have been used as
temporary coatings removable with hot water. See for example U.S.
Pat. No. 5,292,794.
[0018] Certain ionomer articles have been dispersed in aqueous
caustic solutions. See for example U.S. Pat. No. 6,162,852.
[0019] Certain ionomer dispersions have been used as primer
coatings for substrates, such as PET, biaxially oriented
polypropylene (BOPP) and aluminum foil films. See for example U.S.
Pat. Nos. 5,419,960; 6,013,353; 7,364,800; 7,470,736; and U.S.
Patent Application Publication 2005/0271888.
[0020] Highly neutralized ionomer dispersions have been used as
fabric or paper treatments. See for example U.S. Pat. Nos.
5,082,697; 5,206,279; and 5,387,635.
[0021] Ionomer dispersions produced through autoclave or extrusion
processes have been used as internal and external paper sizing or
paper additives. See for example U.S. Pat. Nos. 5,993,604;
6,482,886; 7,588,662; U.S. Patent Application Publications
2007/0137808; 2007/0137809; 2007/0137810; 2007/0137811;
2007/0137813; 2007/0141936; 2007/0243331; and 2007/0284069.
[0022] Certain ionomer dispersions have been used in repulpable
paper compositions. See for example U.S. Pat. No. 5,160,484.
SUMMARY OF THE INVENTION
[0023] The invention provides a method to form a coating comprising
a blend of ionomer and poly(vinyl alcohol) on a substrate, the
method comprising or consisting essentially of
[0024] (1) providing a blend composition comprising or consisting
essentially of
[0025] (a) about 99 to about 1 weight %, based on the combination
of (a) and (b), of a poly(vinyl alcohol) composition comprising or
consisting essentially of a poly(vinyl alcohol) characterized by a
hydrolysis level of from about 85 to about 93 mol % and a 4 weight
% aqueous viscosity at 20.degree. C. of from 16 to about 75
centipoise (cp); and
[0026] (b) about 1 to about 99 weight %, based on the combination
of (a) and (b), of an ionomer composition comprising or consisting
essentially of a parent acid copolymer that comprises copolymerized
units of ethylene and about 18 to about 30 weight % of
copolymerized units of acrylic acid or methacrylic acid, based on
the total weight of the parent acid copolymer, the acid copolymer
having a melt flow rate (MFR) from about 200 to about 1000 g/10
min., measured according to ASTM D1238 at 190.degree. C. with a
2160 g load, wherein about 50% to about 70% of the carboxylic acid
groups of the copolymer, based on the total carboxylic acid content
of the parent acid copolymer as calculated for the non-neutralized
parent acid copolymer, are neutralized to carboxylic acid salts
comprising potassium cations, sodium cations or combinations
thereof;
[0027] (2) providing a substrate; and
[0028] (3) coating the blend composition onto the substrate.
[0029] In one embodiment, the blend composition is provided in the
form of an aqueous dispersion comprising or consisting essentially
of water and about 0.001 to about 50 weight % of the combination of
(a) and (b); the blend composition is coated onto the substrate as
the aqueous dispersion and the method further comprises (4) drying
the coated substrate at a temperature of about 20 to about
150.degree. C.
[0030] In another embodiment, the blend composition is provided in
the form of a preformed film comprising or consisting essentially
of the combination of (a) and (b); (3) comprises (3a) producing a
prelaminate structure comprising the ionomer-polyolefin film layer
adjacent to the substrate; and (3b) laminating the
ionomer-polyolefin film layer to the substrate at a temperature
from about 50 to about 150.degree. C., optionally with applied
pressure; and the method further comprises (4) cooling the coated
substrate to a temperature of about 20 to about 30.degree. C.
[0031] The invention also provides an article or multilayer
structure comprising the coated substrate as described above.
DETAILED DESCRIPTION OF THE INVENTION
[0032] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. In case
of conflict, the specification, including definitions, will
control.
[0033] Although methods and materials similar or equivalent to
those described herein can be used in the practice or testing of
the invention, suitable methods and materials are described
herein.
[0034] Unless stated otherwise, all percentages, parts, ratios,
etc., are by weight.
[0035] When an amount, concentration, or other value or parameter
is given as either a range, preferred range or a list of lower
preferable values and upper preferable values, this is to be
understood as specifically disclosing all ranges formed from any
pair of any lower range limit or preferred value and any upper
range limit or preferred value, regardless of whether ranges are
separately disclosed. Where a range of numerical values is recited
herein, unless otherwise stated, the range is intended to include
the endpoints thereof, and all integers and fractions within the
range. It is not intended that the scope of the invention be
limited to the specific values recited when defining a range.
[0036] When the term "about" is used in describing a value or an
end-point of a range, the disclosure should be understood to
include the specific value or end-point referred to.
[0037] As used herein, the terms "comprises," "comprising,"
"includes," "including," "containing," "characterized by," "has,"
"having" or any other variation thereof, are intended to cover a
non-exclusive inclusion. For example, a process, method, article,
or apparatus that comprises a list of elements is not necessarily
limited to only those elements but may include other elements not
expressly listed or inherent to such process, method, article, or
apparatus. Further, unless expressly stated to the contrary, "or"
refers to an inclusive or and not to an exclusive or.
[0038] The transitional phrase "consisting essentially of" limits
the scope of a claim to the specified materials or steps and those
that do not materially affect the basic and novel characteristic(s)
of the claimed invention. Where applicants have defined an
invention or a portion thereof with an open-ended term such as
"comprising," unless otherwise stated the description should be
interpreted to also describe such an invention using the term
"consisting essentially of".
[0039] Use of "a" or "an" are employed to describe elements and
components of the invention. This is merely for convenience and to
give a general sense of the invention. This description should be
read to include one or at least one and the singular also includes
the plural unless it is obvious that it is meant otherwise.
[0040] In describing certain polymers it should be understood that
sometimes applicants are referring to the polymers by the monomers
used to produce them or the amounts of the monomers used to produce
the polymers. While such a description may not include the specific
nomenclature used to describe the final polymer or may not contain
product-by-process terminology, any such reference to monomers and
amounts should be interpreted to mean that the polymer comprises
copolymerized units of those monomers or that amount of the
monomers, and the corresponding polymers and compositions
thereof.
[0041] The term "copolymer" is used to refer to polymers formed by
copolymerization of two or more monomers. Such copolymers include
dipolymers consisting essentially of two copolymerized
comonomers.
[0042] As used herein, "disperse," "dispersing" and related terms
refer to a process in which solid articles such as pellets of
polymer are mixed with water and over a brief period of time
disappear into the liquid phase. The terms "aqueous dispersion" and
"dispersion" describe a free-flowing liquid with no solids visible
to the human eye. No characterization is made regarding the
interaction of the polymer molecules with the water molecules in
such aqueous dispersions. "Self-dispersible" means that the
material disperses readily in hot (80 to 100.degree. C.) water
without need for additional dispersants or reagents.
[0043] Viscosity is a measure of the resistance of a fluid to being
deformed by either shear or tensile stress. In everyday terms for
fluids only, viscosity may be thought of as "thickness" or
"internal friction". For example, water is "thin", having a lower
viscosity, while honey is "thick", having a higher viscosity. The
less viscous a fluid is, the greater its ease of movement
(fluidity). As used herein, viscosity refers to dynamic or absolute
viscosity.
[0044] As used herein, the terms "poly(vinyl alcohol)" and "PVOH"
refer generally to poly(vinyl alcohol) homopolymers or copolymers
unless specified with more particularity.
[0045] The coating methods described herein provides coated
substrates using blend compositions comprising ionomers and certain
poly(vinyl alcohol)s. The ionomer-poly(vinylalcohol) coating on the
substrate as disclosed herein can be in the form of a monolithic
membrane that functions as a barrier to penetration of fluids into
or through the substrate. Monolithic membranes have high
water-entry pressure and are waterproof and liquidproof. The
coating also allows for providing a heat-sealable surface on a
substrate that is not heat-sealable. Printing properties may be
improved by altering the surface of the paper to make it more
hydrophobic by the coating.
[0046] Articles comprising the coated substrate provide easily
recyclable articles of commerce, for example, through repulping of
the coated paper, paperboard and the like.
[0047] Blend compositions comprising certain ionomer-poly(vinyl
alcohol) combinations are disclosed in co-pending U.S. application
Ser. No. 13/407,896, incorporated by reference herein. Methods to
produce high viscosity aqueous dispersions comprising certain
ionomer-poly(vinyl alcohol) combinations are disclosed therein. In
contrast, previous methods required significantly more rigorous
conditions to form dispersions. The dispersion methods provide
process simplifications that require less energy and are inherently
safer than disclosed in the prior art dispersion methods, such as
high pressure, high shear, autoclave processes or extrusion
processes. Surprisingly, ionomer-poly(vinyl alcohol) combinations
described therein readily form high viscosity aqueous dispersions
when mixed with hot water under low shear conditions.
[0048] Poly(Vinyl Alcohol) Composition
[0049] The blends and aqueous dispersions contain poly(vinyl
alcohol) compositions comprising or consisting essentially of a
poly(vinyl alcohol) wherein the poly(vinyl alcohol) is
characterized by a hydrolysis level of from about 85 to about 93
mol % and a 4 weight % aqueous viscosity at 20.degree. C. of from 8
to about 75 centipoise (cp).
[0050] The combination of the hydrolysis level and the 4 weight %
aqueous viscosity at 20.degree. C. of the poly(vinyl alcohol)
composition provides the desirable solubility/dispersibility
attributes needed to form aqueous dispersions when blended with
ionomers.
[0051] Poly(vinyl alcohol) compositions can be obtained by known
and conventional methods. Poly(vinyl alcohol) compositions are
typically obtained through polymerization of vinyl acetate monomer,
followed by conversion of the as-made poly(vinyl acetate)
composition to the poly(vinyl alcohol) composition through
alcoholysis or hydrolysis processes. The poly(vinyl alcohol)
products are typically referred to as "hydrolyzed" or
"saponified".
[0052] It is common to use the term "partially hydrolyzed" or
"partially saponified" when not all the acetate groups are
completely converted to alcohol groups, such as those with
hydrolysis levels of about 85 to about 93 mol %. When poly(vinyl
acetate) homopolymer is only partially hydrolyzed, the resulting
poly(vinyl alcohol) is actually a vinyl alcohol/vinyl acetate
copolymer. However, as noted, such polymers are generally referred
to as partially hydrolyzed poly(vinyl alcohol) homopolymers.
[0053] Surprisingly, some partially hydrolyzed poly(vinyl alcohol)
compositions when combined with the ionomers described above
provide high viscosity aqueous dispersions. The degree of
hydrolysis of the poly(vinyl alcohol) composition useful in
preparing high viscosity aqueous dispersions may be from about 85
to about 93 mol %, preferably from about 86 to about 90 mol %.
[0054] The viscosity of poly(vinyl alcohol) as a 4 weight % aqueous
solution at 20.degree. C. serves as an industrial standard relating
to the degree of polymerization and average molecular weight of the
poly(vinyl alcohol) composition.
[0055] The 4 weight % aqueous viscosity at 20.degree. C. of the
poly(vinyl alcohol) composition useful for preparing high viscosity
aqueous dispersions with ionomers may be from 8 to about 75
centipoise (cp), preferably from about 20 to about 75 cp, more
preferably from about 20 to about 60 cp. Of note are PVOH
compositions with 4 weight % aqueous viscosity at 20.degree. C. of
8 to 10 cp, 10 to 20 cp, 20 to 30 cp, 20 to 50 cp, 25 to 40 cp, or
40 to 55 cp.
[0056] Specific partially hydrolyzed poly(vinyl alcohol)s useful
herein have hydrolysis level of 87 to 89% and 4 weight % aqueous
viscosity at 20.degree. C. of 8 to 10 cp, 11 to 14 cp, 23 to 27 cp
or 44 to 50 cp.
[0057] Aqueous solutions comprising about 5 to 20 weight % of such
poly(vinyl alcohol) compositions may have viscosity at 20.degree.
C. of about 20 to about 50,000 cp or higher. For example, a
poly(vinyl alcohol) having a hydrolysis level of 86-89% and 4
weight % aqueous viscosity at 20.degree. C. of 50-58 cp has an
aqueous viscosity of about 50,000 cp at 16 weight % at 20.degree.
C.
[0058] Optionally, poly(vinyl alcohol) copolymers are also useful
for forming aqueous dispersions with ionomers, provided they have
the hydrolysis and viscosity attributes described above. The term
"copolymer" in this regard is used herein for materials which
result from hydrolysis of a vinyl acetate copolymer also containing
units derived from a monomer other than vinyl acetate, such an
alkyl acrylate, including for example methyl acrylate or methyl
methacrylate.
[0059] The PVOH materials are described in greater detail in U.S.
application Ser. No. 13/407,896.
Ionomer Composition
[0060] The ionomer used herein is derived from certain parent acid
copolymers comprising copolymerized units of ethylene and about 18
to about 30 weight % of copolymerized units of an alpha,
beta-ethylenically unsaturated carboxylic acid such as acrylic acid
or methacrylic acid. Preferably, the parent acid copolymer used
herein comprises about 19 to about 25 weight %, or more preferably
about 19 to about 23 weight %, of the alpha, beta-ethylenically
unsaturated carboxylic acid, based on the total weight of the
copolymer.
[0061] Preferably, the alpha, beta-ethylenically unsaturated
carboxylic acid is methacrylic acid. Of note are acid copolymers
consisting essentially of copolymerized units of ethylene and
copolymerized units of the alpha, beta-ethylenically unsaturated
carboxylic acid and 0 weight % of additional comonomers; that is,
dipolymers of ethylene and the alpha, beta-ethylenically
unsaturated carboxylic acid. Preferred acid copolymers are ethylene
methacrylic acid dipolymers.
[0062] The parent acid copolymers used herein preferably have a
melt flow rate (MFR) of about 200 to about 1000 grams/10 min as
measured by ASTM D1238 at 190.degree. C. using a 2160 g load.
Alternatively, the parent acid copolymers have MFR from a lower
limit of 200, 250 or 300 to an upper limit of 400, 500, 600 or
1000. The preferred melt flow rate of the parent acid copolymer
provides ionomers that allow for rapid self-dispersion in hot
water. Ionomers derived from parent acid copolymers with melt flow
rates below about 200 grams/10 minutes have minimal hot water
self-dispersibility, while ionomers derived from parent acid
copolymer melt flow rates of greater than about 1000 grams/10
minutes may reduce the physical properties in the intended
enduse.
[0063] In some embodiments, blends of two or more ethylene acid
copolymers may be used, provided that the aggregate components and
properties of the blend fall within the limits described above for
the ethylene acid copolymers. For example, two ethylene methacrylic
acid dipolymers may be used such that the total weight % of
methacrylic acid is about 18 to about 30 weight % of the total
polymeric material and the melt flow rate of the blend is about 200
to about 1000 grams/10 min.
[0064] The ionomers disclosed herein are produced from the parent
acid copolymers, wherein from about 50 to about 70%, or preferably
from about 55 to about 60%, such as about 60%, of the total
carboxylic acid groups of the parent acid copolymers, as calculated
for the non-neutralized parent acid copolymers, are neutralized to
form carboxylic acid salts with sodium ions, potassium ions or
mixtures thereof. Preferably, the ionomers disclosed herein are
produced from the parent acid copolymers wherein the carboxylic
acid groups of the parent acid copolymers are neutralized to form
carboxylic acid salts with sodium ions.
[0065] Importantly, the ionomer compositions combine the properties
of being self-dispersible in hot water along with being
thermoplastic. Preferably, the ionomers used herein have a melt
flow rate (MFR) of at least 1 gram/10 min, such as about 1 to about
20 grams/10 min as measured by ASTM D1238 at 190.degree. C. using a
2160 g load. More preferably, the ionomer composition has a MFR of
about 1 to about 10 grams/10 min, and most preferably a MFR of
about 1 to about 5 grams/10 min. The combination of the above
described parent acid copolymer melt flow rates and the
neutralization levels provides ionomers that combine the properties
of being easily self-dispersible in hot water and easily melt
fabricated. Preferably, the ionomer composition comprises at least
11 weight % methacrylic acid salt and has a MFR of at least 1 g/10
min.
[0066] In some embodiments, blends of two or more ionomers may be
used, provided that the aggregate components and properties of the
blend fall within the limits described above for the ionomers.
[0067] The ionomer materials are described in greater detail in
U.S. application Ser. No. 13/407,896.
[0068] The PVOH and ionomer can be combined into blend
compositions, including aqueous dispersions, by methods described
in U.S. application Ser. No. 13/407,896. The blend composition
comprises or consists essentially of a combination of about 1 to
about 99 weight % of a poly(vinyl alcohol) composition and about 99
to about 1 weight % of an ionomer composition, wherein the ionomer
and poly(vinyl alcohol) are as described above.
[0069] Of note are compositions wherein the ionomer is present in
the combination in an amount from a lower limit of about 10, 20,
30, 40 or 50 weight % to an upper limit of about 60, 70, 80, 90, or
95 weight %, the poly(vinyl alcohol) being present in a
complementary amount. Also of note are compositions wherein the
ionomer is present in the combination in an amount from a lower
limit of about 60, 70, or 75 weight % to an upper limit of about
80, 85, 90 or 95 weight %, the poly(vinyl alcohol) being present in
a complementary amount.
[0070] In some embodiments, the dispersion method comprises
providing a preformed aqueous solution of a poly(vinyl alcohol)
composition and mixing it with a preformed aqueous dispersion of an
ionomer composition.
[0071] The ionomer-PVOH composition may also contain other
additives known in the art. The additives may include, but are not
limited to, processing aids, flow enhancing additives, lubricants,
pigments, dyes, flame retardants, impact modifiers, nucleating
agents, anti-blocking agents such as silica, thermal stabilizers,
UV absorbers, UV stabilizers, surfactants, chelating agents, and
coupling agents.
[0072] These high viscosity dispersions are particularly
advantageous for coating substrates of porous materials such as
paper or fabric as described more fully below. The high viscosity
reduces penetration into the pores of the substrate without the
need for additional thickeners such as acrylates, alginates,
cellulose gums, associative thickeners, etc., thereby allowing more
of the dispersion to remain on the surface of the substrate. This
makes theses dispersions more suitable to coating methods requiring
higher viscosity, providing better coating performance with reduced
amounts of coating dispersions.
[0073] Substrate Materials
[0074] The substrate may be any material providing support, shape,
esthetic effect, protection, surface texture, bulk volume, weight,
or combinations of two or more thereof to enhance the functionality
and handability of the structure. Essentially any substrate
material known in the art may be used.
[0075] Any support or substrate meeting these desired
characteristics may be used with the ionomer-PVOH composition.
Cellulosic materials such as paper webs (for example Kraft or rice
paper), materials made from synthetic fiber spun fabrics, films,
open-cell foams, closed-cell foams, microporous films, nonwoven
fabrics, or even perforated films having large percentages of open
areas such as perforated PE films, may be used as materials for the
substrate(s), for example. Metallic foils such as aluminum foil may
also be used as substrates.
[0076] Cellulosic materials include paper, paperboard, cardboard,
and pulp-molded shapes. Paper, paperboard, cardboard and the like
refer to physical forms derived from cellulose or its derivatives
that have been processed as a pulp and formed by heat and/or
pressure into sheets. Paper describes thin sheets made from
cellulose pulp that are somewhat flexible or semi-rigid. In
general, paperboard and cardboard are thicker, rigid sheets or
structures based on paper. Typically, a paperboard is defined as a
paper with a basis weight above 224 g/m.sup.2. In accordance with
the present disclosure, the paper layer or paperboard layer used in
the substrate may have a thickness of about 30-600 .mu.m and a
basis weight of about 25-500 g/m.sup.2, or 100-300 g/m.sup.2.
Cardboard can be a monolithic sheet or can have a more complex
structure, such as corrugation. Corrugated cardboard comprises a
sheet of corrugated paper adhesively sandwiched between two flat
sheets of paper. A coating of the ionomer-PVOH blend may be useful
as an adhesive for producing corrugated cardboard. Pulp-molded
shapes are typically nonplanar shapes in which the cellulosic pulp
is molded into a rigid shape by application of pressure and/or
heat. An example pulp-molded shape is an egg carton.
[0077] Example substrates also include a textile or porous sheet
material. A textile may also include nonwoven textiles prepared
from polypropylene, polyethene, polyesters such as polyethylene
terephthalate or mixtures thereof, and other spun bonded polymer
fabrics. Sheets made from synthetic fiber spun fabrics, such as
nonwoven textiles, may be used as a textile substrate. Cloth that
is woven, knitted or the like is also suitable as a textile
substrate. Natural fibers alone or in combination with man-made
fibers can also be used in textile substrates. A fabric may
comprise flame retardant(s), filler(s), or additive(s) disclosed
above.
[0078] The substrate material may be in the form of a film, sheet,
woven fabric, nonwoven fabric and the like. The substrate material
may be unoriented or oriented, such monoaxially- or
biaxially-oriented. The substrate material may comprise a polymeric
or a metal composition. The substrate may be treated to enhance,
for example, adhesion with the coating. The treatment may take any
form known in the art such as for example, adhesive, primer or
coupling agent treatments or surface treatments, such as chlorine
treatments, flame treatments (see, e.g., U.S. Pat. Nos. 2,632,921;
2,648,097; 2,683,894; and 2,704,382), plasma treatments (see e.g.,
U.S. Pat. No. 4,732,814), electron beam treatments, oxidation
treatments, chemical treatments, chromic acid treatments, hot air
treatments, ozone treatments, ultraviolet light treatments, sand
blast treatments, solvent treatments or corona treatments and
combinations of the above.
[0079] Specific examples of substrate materials include
poly(ethylene terephthalate) (PET) films, biaxially-oriented
poly(propylene) (BOPP) films, polyamide films, aluminum foil,
paper, paperboard, and the like. Preferably, the substrate material
is paper, paperboard and the like to allow for repulpability after
use.
[0080] The substrate material may be any thickness, but generally
range from about 0.1 to about 20 mils thick, more generally from
about 0.5 to about 10 mils thick.
[0081] Methods to form a coating comprising a blend of ionomer and
poly(vinyl alcohol) on a substrate comprise or consist essentially
of (1) providing a blend composition comprising or consisting
essentially of the PVOH and ionomers described above; (2) providing
a substrate described above; and (3) coating the blend composition
onto the substrate.
[0082] Coating methods include embodiments where the blend
combination is in the form of an aqueous dispersion or lamination
methods wherein the blend combination is in the form of a preformed
film.
[0083] Dispersion Coating Method
[0084] One embodiment of the coating method is wherein the blend
composition is in the form of an aqueous ionomer-poly(vinyl
alcohol) dispersion comprising or consisting essentially of water
and about 0.001 to about 50 weight % of the combination of (a) and
(b) described above. In this embodiment, providing the blend
composition may comprise or consist essentially of (1a) providing
an aqueous poly(vinyl alcohol) solution comprising or consisting
essentially of water and the poly(vinyl alcohol) composition
described in (a) above; (1b) providing an ionomer composition
comprising or consisting essentially of the ionomer composition
described in (b) above; (1c) mixing the ionomer composition with
the aqueous poly(vinyl alcohol) composition solution optionally
with heating; and (1d) optionally cooling the heated aqueous blend
dispersion to a temperature of about 20 to 30.degree. C., wherein
the combination remains dispersed in the liquid phase. This
embodiment further comprises (4) drying the coated substrate at a
temperature of about 20 to about 150.degree. C.
[0085] Methods to produce aqueous dispersions comprising certain
ionomer-poly(vinyl alcohol) combinations are disclosed in greater
detail in copending application U.S. application Ser. No.
13/407,896. In contrast, previous methods required significantly
more rigorous conditions to form dispersions. The dispersion
methods provide process simplifications that require less energy
and are inherently safer than disclosed in the prior art dispersion
methods, such as high pressure, high shear, autoclave processes or
extrusion processes.
[0086] The methods include providing the blend composition by (1a)
providing an aqueous poly(vinyl alcohol) solution comprising water
and the poly(vinyl alcohol); (1b) providing an ionomer composition
comprising the ionomer; (1c) mixing the ionomer composition with
the aqueous poly(vinyl alcohol) composition solution optionally
with heating; and (1d) optionally cooling the heated aqueous blend
dispersion to a temperature of about 20 to 30.degree. C., wherein
the combination remains dispersed in the liquid phase.
[0087] In some embodiments, the dispersion method comprises or
consists essentially of providing a preformed aqueous solution of a
poly(vinyl alcohol) composition and mixing it with a preformed
aqueous dispersion of an ionomer composition. For example, (1a)
comprises heating a mixture of water and the poly(vinyl alcohol)
composition to provide the aqueous poly(vinyl alcohol) solution,
optionally followed by cooling to a temperature of about 20 to
about 30.degree. C.; and (1b) comprises providing an aqueous
ionomer composition by mixing a solid ionomer composition with
water heated to a temperature from about 80 to about 100.degree. C.
to provide a heated aqueous ionomer composition dispersion;
optionally followed by cooling to a temperature of about 20 to
about 30.degree. C., wherein the ionomer remains dispersed in the
aqueous phase.
[0088] In other embodiments, the ionomer in solid form, such as
melt cut pellets, may be mixed with the aqueous poly(vinyl alcohol)
solution with heating to prepare the blend dispersion.
[0089] In one such embodiment, the method comprises or consists
essentially of (1a) heating a mixture of water and a poly(vinyl
alcohol) composition described above to provide an aqueous
poly(vinyl alcohol) solution optionally followed by cooling to a
temperature of about 20 to about 30.degree. C.; (1b) providing the
ionomer composition comprising or consisting essentially of the
ionomer in solid form; (1c) heating the aqueous poly(vinyl alcohol)
solution to a temperature from about 80 to about 100.degree. C.
(under low shear conditions); (1d) contacting the solid ionomer
composition with the heated aqueous poly(vinyl alcohol) solution;
(1e) continuing heating at a temperature from about 80 to about
100.degree. C. (under low shear conditions) until the solid ionomer
composition has completely dispersed; and (1f) optionally cooling
to a temperature of about 20 to 30.degree. C.
[0090] In another such embodiment, the method comprises or consists
essentially of (1a) heating a combination of a poly(vinyl alcohol)
composition described above with water to provide an aqueous
poly(vinyl alcohol) composition solution; (1b) providing the
ionomer composition comprising or consisting essentially of the
ionomer described above in solid form; (1c) contacting the solid
ionomer composition with the aqueous poly(vinyl alcohol) solution
to provide a mixture; (1d) heating the mixture to a temperature
from about 80 to about 100.degree. C. (under low shear conditions)
until the solid ionomer composition has completely dispersed; and
(1e) optionally cooling to a temperature of about 20 to 30.degree.
C.
[0091] The dispersion coating composition may include other
additives known in the art. For example, the compositions may
include a wax additive, such as a microcrystalline wax or a
polyethylene wax, which serves as an anti-blocking agent as well as
to improve the coefficient of friction of the final coated
substrate. Other types of additives include fumed silica, which
reduces the tack of the coating at room temperature, fillers,
cross-linking agents, anti-static agents, defoamers, dyes,
brighteners, processing aids, flow enhancing additives, lubricants,
dyes, pigments, flame retardants, impact modifiers, nucleating
agents, anti-blocking agents, thermal stabilizers, UV absorbers, UV
stabilizers, surfactants, chelating agents, and coupling agents and
the like.
[0092] Inorganic fillers include calcium carbonate, titanium
dioxide, silica, talc, barium sulfate, carbon black, ceramics,
chalk or mixtures thereof. Organic fillers include natural starch,
modified starch, chemically modified starch, rice starch, corn
starch, wood flour, cellulose, and mixtures thereof.
[0093] Starch is a natural product composed of various amounts of
amylose and amylopectin. As used herein "starch" unless specified
refers generally to starch, starch derivatives, modified starch,
thermoplastic starch, cationic starch, anionic starch, starch
esters, such as starch acetate, starch hydroxyethyl ether, alkyl
starches, amine starches, phosphate starches and dialdehyde
starches. Important plant source of starch used in the paper
industry are potato, barley, wheat corn, waxy maize (corn with no
amylose in the starch), and tapioca.
[0094] Starch can be modified in a number of ways. The viscosity of
the starch can be reduced by use of enzymes, thermal treatment,
ammonium persulfate, hypochlorite, or acid. In addition, the starch
can be chemically modified, for example via hydroxyethylation,
carboxymethylation, acetylation, or phosphatizing. Thermoplastic
starch may be produced, for example, as disclosed in U.S. Pat. No.
5,362,777, which discloses mixing and heating of native or modified
starch with high boiling plasticizers, such as glycerin or
sorbitol, in such a way that the starch has little or no
crystallinity, a low glass transition temperature and a low water
content.
[0095] Once prepared, the ionomer-PVOH composition is coated onto a
substrate as described below.
[0096] In some embodiments the ionomer-PVOH composition can be
coated directly on a substrate using impregnation and coating
techniques. For example, the ionomer-PVOH composition is a coating
applied directly on the substrate (via spraying, painting or other
appropriate application methods). Such coating can be applied using
spreading methods known in the art such as with a rubber doctor
blade.
[0097] The composition can be applied to one side or both sides of
a substrate. In the case where the substrate is coated or laminated
on one side, the composition may be applied to the side that is
directly exposed to the environment to provide a liquid-impermeable
outer surface. Alternatively, in applications where mechanical wear
or abrasion is likely, the composition may be applied to the side
of the substrate opposite the side exposed to the mechanical wear
to afford protection of the polymeric composition.
[0098] In other embodiments the composition can be impregnated in a
substrate or the substrate can be impregnated in the polymer.
[0099] The ionomer-PVOH composition may be formed at least
partially in the substrate by impregnating the substrate with the
coating composition as an aqueous dispersion and then drying the
composition while it is in contact with the pores of the
substrate.
[0100] The composition can be dispersed throughout the substrate
such as a loosely woven fabric where the composition fills gaps in
the substrate and does not just adhere on the surface of a
substrate. The substrate can be impregnated inside the ionomer-PVOH
composition through coating processes to have the ionomer-PVOH
compositions on both sides of the substrate.
[0101] The coating as an aqueous dispersion can be applied to the
substrate in any suitable manner known in the art, including
gravure coating, roll coating, wire rod coating, dip coating,
flexographic printing, spray coating and the like. Excess aqueous
dispersion coating composition can be removed by squeeze rolls,
doctor knives and the like, if desired.
[0102] For the preferred paper and paperboard substrates, the
substrates may be applied to the preformed paper or paperboard
substrate, as described above, or during the manufacture of the
paper or paperboard substrates using, for example, size presses,
such as a puddle size press, a metering size press, a vertical size
press, an inclined size press and a horizontal size press, roll
coaters, gate-roll coaters, blade coaters, bill blade coaters, and
sprayers to coat the coating composition onto the paper or
paperboard substrate.
[0103] After coating the substrate, the aqueous dispersion is dried
to provide a solid coating of the ionomer-PVOH blend on the
substrate. As used herein, "drying" means removal of water from the
aqueous dispersion, such as by evaporation, freeze drying, or the
like. Drying may include allowing the dispersion to dry under
ambient conditions (temperatures of 20 to 30.degree. C. and
atmospheric pressure). Alternatively, drying may include
application of elevated temperatures (such as up to 100.degree. C.
in an oven or heating tunnel) and/or reduced pressure. Freeze
drying involves rapid freezing and drying in a high vacuum.
[0104] Non-Dispersion Coating Methods
[0105] Another embodiment is wherein the blend composition is in
the form of a preformed film. In this embodiment, the invention
provides a method to form a coating comprising an ionomer and PVOH
on a substrate, the method comprising or consisting essentially
of
[0106] (a) providing a preformed film of an ionomer-PVOH
composition as described above;
[0107] (b) producing a prelaminate structure comprising the
ionomer-PVOH film layer adjacent to a substrate layer;
[0108] (c) laminating the ionomer film layer to the substrate layer
at a temperature from about 50 to about 150.degree. C. and
optionally with applied pressure;
[0109] (d) cooling the coated substrate to a temperature of about
20 to about 30.degree. C.
[0110] The preformed film of the ionomer-PVOH composition may be
produced by any known art method. For example, thin films can be
formed by dipcoating; by providing a thin layer of an aqueous
ionomer-PVOH dispersion followed by drying; or any other processes
known to those skilled in the art.
[0111] In the film lamination method, the ionomer-PVOH coating
layer can be included in a multilayer structure with one or more
layers of additional material(s) to provide a multilayer coating.
In such processes, the ionomer-PVOH coating layer may be applied so
it is in direct contact with the substrate, or it may be applied so
it is in contact with a layer intervening between the substrate and
the ionomer-PVOH layer.
[0112] The actual making of the multilayer film and corresponding
film structures can generally be by any such method as practiced in
the art. As such, film and film structures used as a substrate for
the ionomer-PVOH composition can be typically cast, extruded,
co-extruded and the like including orientation (either axially or
biaxially) by various methodologies (e.g., blown film, bubble
techniques, mechanical stretching or the like, or lamination). It
should be appreciated that various additives as generally practiced
in the art can be present in the respective film layers including
the presence of tie layers and the like, provided their presence
does not substantially alter the properties of the film or film
structure. Thus, it is contemplated that various additives such as
antioxidants and thermal stabilizers, ultraviolet (UV) light
stabilizers, pigments and dyes, fillers, anti-slip agents,
plasticizers, other processing aids, and the like may be
advantageously employed.
[0113] The preformed film of the ionomer-PVOH composition can be
applied to one or both sides of the substrate. Preferably, the
ionomer-PVOH composition layer has a thickness from about 0.1 mils
to about 20 mils, more preferably a thickness from about 0.3 mils
to about 10 mils and most preferably a thickness from about 0.5
mils to about 5 mils.
[0114] The laminate structures may be produced by any known art
method. For example, the prelaminate structure can be produced by
plying the preformed film of the ionomer-PVOH composition with the
substrate followed by passing through heated nip rolls or through
an oven to form the laminate.
[0115] In these lamination coating methods, after coating the
substrate, the coated substrate is cooled to provide a solid
ionomer-PVOH coating on the substrate. As used herein, "cooling"
includes allowing the ionomer-PVOH coating to cool under ambient
conditions (temperatures of 20 to 30.degree. C. and atmospheric
pressure) and/or by application of reduced temperatures such as by
use of chill rolls or the like.
[0116] Additional layers may be applied to the coated substrate
following coating. For example, additional aqueous or solvent-based
dispersions not comprising an ionomer-PVOH combination may be
applied to the coated substrate. Alternatively, multilayer
structures may comprise additional thermoplastic materials applied
over the ionomer-PVOH layer by extrusion coating, lamination or the
like. In such cases, the ionomer-PVOH coating becomes an inner
layer in a multilayer structure.
[0117] The ionomer-PVOH coating composition can also be
accommodated between two layers of substrate in a sandwich-like
manner. Several layer assemblies can also be assembled one above
the other. For example, the configuration can comprise the
ionomer-PVOH layer, a substrate layer, another ionomer-PVOH layer,
another substrate layer, and so on, depending upon desired
applications of the structure. Other configurations can comprise
variations of the aforementioned sandwich configuration, including
a plurality of ionomer-PVOH layers, a plurality of substrate
layers, and so forth, including mixtures thereof.
[0118] In such cases, in aqueous dispersion coating methods the
ionomer coating may be maintained in an aqueous state during
assembly of the layered structure, followed by drying. In the
resulting layered structures, the ionomer-PVOH coating may function
as an adhesive layer to bond substrate layers together.
[0119] The coated substrates described herein may be used as film
or sheet goods for various end uses. Alternatively, the initially
prepared coated substrate may be further treated to provide more
finished articles.
[0120] For example, the coated substrate may be part of a package
comprising the coated substrate. The packages may comprise films or
sheets of the coated substrate wrapped around the packaged product
and optionally comprising other packaging materials. Packages may
also be formed of one or more portions of the coated substrate
bonded together, for example by heat sealing. The ionomer-PVOH
coating is readily heat sealable, allowing for production of
packages comprising a coated paper substrate that does not need
additional adhesive for sealing. Such packages or containers may be
in the form of pouches, bags, boxes, cartons, cups, packets, and
the like.
[0121] A film or sheet comprising the coated substrate could be
further processed by thermoforming into a shaped article. For
example, a film or sheet comprising the coated substrate as
described herein could be formed into a shaped piece that could be
included in packaging. Thermoformed articles typically have a shape
in which a sheet of material forms a concave surface such as a
tray, cup, can, bucket, tub, box or bowl. The thermoformed article
may also comprise a film or sheet with a cup-like depression formed
therein. In some cases, the thermoformed film or sheet is shaped to
match the shape of the material to be packaged therein. Flexible
films when thermoformed as described retain some flexibility in the
resulting shaped article. Thicker thermoformed sheets may provide
semi-rigid or rigid articles. Thermoformed articles may be combined
with additional elements, such as a generally planar film that
serves as a lid sealed to the thermoformed article.
[0122] Preferably, the container is suitable for containing,
transporting or storing food that may contain grease or oil,
including snack foods such as chips, crackers, cookies, cereal or
nuts; dry noodles, soup mix, coffee, French fries, sandwiches, pet
foods and the like. Frozen or chilled foods such as ice cream,
vegetables, waffles and the like may also be packaged in packages
comprising the coated substrate. Non-food items such as detergents
and soaps may also be packaged in packages comprising the coated
substrate. Products for serving foods may also be prepared from the
coated substrate such as cold drink cups, plates, bowls and the
like.
[0123] Pouches are formed from coated web stock by cutting and heat
sealing separate pieces of coated web stock and/or by a combination
of folding and heat sealing with cutting. Coated substrates may be
formed into pouches by overlaying and heat sealing the edges of the
substrate to form a seal and then sealing across the lengthwise
direction of the tube (transverse seal). Other packages include
containers, optionally further comprising lidding films such as
cups or tubs prepared from coated substrates as described herein
and flexible packages made by laminating the coated substrate to
another webstock to improve characteristics such as stiffness and
appearance.
[0124] Preferred packages comprise one or more of the preferred or
notable or structures as described herein. Preferred packaged
products comprise one or more of the preferred or notable
compositions, films, structures or packages as described
herein.
[0125] After preparation, the coated substrates can then take
advantage of the ready dispersibility of the ionomer-PVOH
composition in water, for example to allow for recyclability.
[0126] Once used for its intended purpose such as for packaging or
serving food, the coated substrate is easily recyclable by
treatment with hot water. The ionomer-PVOH coating is readily
dispersed in hot water, allowing it to be removed from the
substrate.
[0127] The process for separating the ionomer-PVOH coating from the
substrate materials comprised in containers disclosed herein may
include contacting the container with water at a temperature as low
as about 80.degree. C. In some embodiments, the temperature is in
the range from about 80 to 90.degree. C., or about 80 to 85.degree.
C., or about 85 to 90.degree. C. However, one can appreciate that
if the water-dispersable ionomer-PVOH compositions can disperse in
such temperatures, they can also be dispersed at temperatures above
90.degree. C. Also, in some embodiments, the container may be cut
into pieces before being contacted with water.
[0128] In normal circumstances, the water-dispersable compositions
could be dispersed in warm water in about 1 hour or less, such as
in about 30 minutes or less or in about 20 minutes or less. Once
the water-dispersible ionomer composition is fully dispersed in the
water, the substrate materials can be separated from the aqueous
ionomer-PVOH dispersion, such as by filtration. Then the non-water
dispersible materials comprised in the container, such as
paperboard base material or aluminum foil, could then be separated
from the aqueous phase by, for example filtration, for recycling.
In some cases, it may not be necessary to separate completely
dispersed ionomer-PVOH composition from paper pulp. The fiber can
be reused because recycled paper typically contains some small
fraction of dispersed "plastic", waxes, hot melt components, etc.,
and minimal amounts can be tolerated if the particle size is
small.
[0129] Removing the coating from the substrate materials may
involve one of the following embodiments:
[0130] The container (preferably after use) disclosed herein is
first mixed with water under low shear conditions at room
temperature (about 20 to 25.degree. C.) and then the temperature or
the mixture is raised to about 80-90.degree. C.
[0131] The container (preferably after use) disclosed herein is
mixed with water under low shear conditions at room temperature and
then the temperature of the mixture is raised to about
85-90.degree. C.
[0132] The container (preferably after use) disclosed herein is
mixed with water that is preheated to a temperature of about
80-90.degree. C. under low shear conditions.
[0133] The container (preferably after use) disclosed herein is
mixed with water that is preheated to a temperature of about
85-90.degree. C. under low shear conditions.
[0134] Following treatment with hot water to remove the coating,
the substrate materials can be collected and recycled into new
articles. For example, paper and paperboard materials can be
repulped by methods known in the art and processed into new
articles.
[0135] The aqueous ionomer-PVOH dispersion can also be further
processed to recover the ionomer-PVOH composition. For example,
excess water can be removed by distillation, evaporation, freeze
drying, or the like to provide the composition in solid form.
Alternatively, the ionomer can be purified from other water-soluble
materials by subjecting the aqueous dispersion to acid treatment,
providing the base ethylene acid copolymer that is insoluble in
water. The solid acid copolymer can be re-neutralized according to
methods disclosed herein to provide the ionomer.
EXAMPLES
[0136] Table 1 summarizes the ethylene methacrylic acid dipolymers
with copolymerized units of methacrylic acid at the indicated
weight % of the total acid copolymer used to prepare the ionomers
in Table 2. Ionomers were prepared from the acid copolymers using
standard conditions. Melt flow rate (MFR) was measured according to
ASTM D1238 at 190.degree. C. using a 2160 g load. A similar ISO
test is ISO 1133.
TABLE-US-00001 TABLE 1 Methacrylic acid (weight %) MFR (g/10 min)
ACR-1 19 400 ACR-2 19 250 ACR-3 23 270
Ionomers
[0137] Table 2 summarizes the ionomers derived from the ethylene
methacrylic acid dipolymers, with the indicated percentage of the
carboxylic acid groups neutralized with sodium hydroxide to form
sodium salts or potassium carbonate to form potassium salts. The
water dispersibility was determined according to the following
procedure, which illustrates addition of the non-neutralized acid
copolymer or ionomer to heated water. The procedure produced a
mixture of water and 10 weight % solid loading (as weighed prior to
addition to the water). Into a 1 quart (946.4 ml) metal can placed
into a heating mantle element was added 500 ml of distilled water.
An overhead paddle stirrer (3-paddle propeller type stirrer) was
positioned into the center of the metal can and turned on to
provide slow mixing. A thermocouple was positioned below the water
surface between the paddle stirrer and the metal can surface. The
paddle stirrer was typically set at a speed of about 170 rpm at the
beginning of the process and generally raised to about 300 to 470
rpm as the viscosity built during dispersion formation. The
distilled water was then heated with an Omega temperature
controller to a temperature of 90 C. The ionomer (55.5 grams, in
the form of melt cut pellets) indicated in Table 2 was then added
in one portion and the resulting mixture was stirred for a total of
20 minutes. The resulting mixture was then allowed to cool to room
temperature. For those materials that formed a dispersion at a
given temperature (denoted as "Yes" in Table 2), the dispersion was
generally formed in less than 10 minutes and was stable even after
being cooled to room temperature. As used herein, "stable" means
that the dispersion, a liquid with no visible solids, did not
exhibit any visual change after the initial cooling or on storage
at room temperature. The sample dispersions remained as liquids
with no settling after storing at room temperature for periods of
several weeks or longer.
TABLE-US-00002 TABLE 2 Water Dispersibility Base Neutralization MFR
at at Ionomer Copolymer Ion Level (%) (g/10 min.) 80.degree. C.
90.degree. C. ION-1 ACR-1 Na 50 5.3 No Yes ION-2 ACR-1 Na 60 1.4
Yes Yes ION-3 ACR-1 Na 70 1 -- Yes ION-4 ACR-3 Na 55 1.4 -- Yes
ION-5 ACR-2 K 50 3.9 -- Yes ION-6 ACR-1 K 50 5.4 -- Yes ION-7 ACR-2
Na 60 1.5 Yes Yes ION-8 ACR-1 Na 65 1.4 No Yes ION-9 ACR-2 Na 65
1.1 No Yes
[0138] ION-2 and ION-7 demonstrate a surprisingly preferred
embodiment of forming dispersions at the lower temperature of
80.degree. C., even though equivalent compositions based on the
same parent ethylene acid copolymers with higher neutralization
levels (ION-9 and ION-8, respectively) did not demonstrate the same
advantage.
[0139] Samples of poly(vinyl alcohol) (PVOH) compositions are
commercially available from DuPont under the Elvanol.RTM.
tradename. Aqueous solutions of the PVOH materials in Table 3 were
prepared by suspending the solid material in cool water and then
heating to 90 to 95.degree. C. with stirring until all solid
material disappeared. The poly(vinyl alcohol) solutions were clear,
transparent solutions.
TABLE-US-00003 TABLE 3 Hydrolysis Level 4 weight % Aqueous Solids
Level PVOH (%) Viscosity at 20.degree. C. (cp) (weight %) PVOH-1
99+ 27-33 11.5 PVOH-2 95-97 25-30 10.6 PVOH-3 90-93 27-33 11.2
PVOH-4 87-89 5-6 12.6 PVOH-5 87-89 44-50 12 PVOH-6 87-89 23-27 10
PVOH-7 87-89 11-14 10
Preparative Samples 1-12 and Comparative Samples C2-C19
[0140] These samples show the method of mixing preformed aqueous
PVOH solutions with a preformed aqueous ionomer dispersion. An 11.6
weight % aqueous dispersion of ION-2 was prepared by suspending the
solid material in hot (90 to 95.degree. C.) water and stirring
until all solid material disappeared. The ionomer dispersion was a
translucent milky liquid.
[0141] Blends of the aqueous ionomer dispersion with the aqueous
poly(vinyl alcohol) solutions were prepared by mixing them together
at room temperature to prepare the blend compositions summarized in
Table 4. Specifically, each of the aqueous poly(vinyl alcohol)
solutions were mixed with the aqueous ionomer dispersion in ratios
of 80:20; 60:40; 40:60 and 20:80 (weight:weight).
[0142] The viscosities were measured using a TA Instruments AR 2000
controlled-stress rheometer equipped with narrow-gap (1 mm)
concentric cylinder geometry. The concentric cylinder geometry
consists of a temperature controlled jacket, a cup (or stator), and
a DIN rotor (or bob). When a test was performed, the sample was
placed in the cup and then the rotor was inserted. A more
cylindrical rotor and often higher rpm is used for very low
viscosity fluids such as the ionomer dispersions. Higher viscosity
fluids such as the PVOH solutions or the ionomer-PVOH blend
dispersions require rotors consisting of a narrow shaft with a
disc, run at lower rpm. Since the drag of the fluid on the rotor is
proportional to the surface area, the contribution to the measured
torque from the shaft of the rotor was small relative to the fat
part of the rotor. As a result, the height of the fluid on the
shaft was not critical and the cup was filled so that the height of
the fluid in the cup was above the thick part of the rotor when the
rotor was inserted. A solvent cover was placed over the top of the
cup. This helped to minimize the effects of solvent evaporation or
moisture absorption on the measured properties.
[0143] Instrument bias was checked using a nominal 10 cP (actual
viscosity 9.5 cP) and a nominal 10,000 cP (actual viscosity 9860
cP) viscosity standard. The bias was 4% or less for both standards
at shear rates from 0.1 to 100 sec.sup.-1.
[0144] The viscosity of the test samples was measured at 25.degree.
C. The concentric cylinder geometry was set at the desired test
temperature. Proportional amounts of each material for a total of
20 mL were loaded into the cup using a syringe, the solutions were
mixed using a spatula for 10 seconds, the DIN was lowered to a gap
of 5920 .mu.m between the bottom of the rotor and the cup, a cover
was placed over the geometry, and the test was started. A time
sweep was performed at a shear rate of 20 sec.sup.-1. The viscosity
for each sample was monitored as a function of time by taking data
points every 10 seconds up to 1800 seconds. The measurement was
performed at least in duplicate with a fresh sample loading each
time and the average values are reported in Table 4 at
representative time points. The column entry "Viscosity Ratio"
denotes the ratio of the viscosity of the ionomer-PVOH blend
dispersion to the viscosity of the PVOH dispersion without ionomer,
each measured at 1800 seconds.
TABLE-US-00004 TABLE 4 Composition Viscosity (cp) after time
(seconds) Viscosity Example (weight % in water) 10 100 500 1000
1500 1800 Ratio C1 ION-2 (11.6) 3 3 2 2 2 2 -- C2 PVOH-1 (11.5) 792
773 767 767 766 766 -- C3 PVOH-1 (9.2) 368 373 399 423 448 463 0.6
ION-2 (2.3) C4 PVOH-1 (6.9) 152 156 172 187 201 211 0.28 ION-2
(4.6) C5 PVOH-1 (4.6) 51 52 58 63 67 70 0.09 ION-2 (7.0) C6 PVOH-1
(2.3) 15 15 16 17 18 19 0.03 ION-2 (9.3) C7 PVOH-2 (10.6) 484 478
476 476 476 476 -- C8 PVOH-2 (8.5) 415 423 455 492 534 562 1.18
ION-2 (2.3) C9 PVOH-2 (6.4) 328 338 386 440 510 560 1.17 ION-2
(4.6) C10 PVOH-2 (4.2) 247 260 319 382 455 510 1.07 ION-2 (7.0) C11
PVOH-2 (2.1) 118 124 156 185 215 236 0.49 ION-2 (9.3) C12 PVOH-3
(11.2) 740 733 730 731 731 731 -- 1 PVOH-3 (9.0) 741 754 815 890
970 1030 1.41 ION-2 (2.3) 2 PVOH-3 (6.7) 847 887 1065 1267 1526
1724 2.36 ION-2 (4.6) 3 PVOH-3 (4.5) 1030 1120 1530 1970 2520 2960
4.05 ION-2 (7.0) 4 PVOH-3 (2.2) 980 1090 1440 1860 2500 3000 4.1
ION-2 (9.3) C13 PVOH-4 (12.6) 32 31 31 31 31 31 -- C14 PVOH-4
(10.1) 28 27 27 28 28 28 0.91 ION-2 (2.3) C15 PVOH-4 (7.6) 27 27 28
29 29 30 0.96 ION-2 (4.6) C16 PVOH-4 (5.0) 30 30 31 33 35 37 1.19
ION-2 (7.0) C17 PVOH-4 (2.5) 23 22 23 25 26 27 0.87 ION-2 (9.3) C18
PVOH-5 (12) 1716 1701 1694 1694 1695 1696 -- 5 PVOH-5 (9.6) 1760
1800 1903 2045 2209 2322 1.37 ION-2 (2.3) 6 PVOH-5 (7.2) 2370 2760
3320 4010 4800 5400 3.18 ION-2 (4.6) 7 PVOH-5 (4.8) 3700 6600 8800
10700 13000 14600 8.61 ION-2 (7.0) 8 PVOH-5 (2.4) 12800 14800 17100
19900 22400 23400 13.8 ION-2 (9.3) C19 PVOH-6 (10) 583 583 583 583
583 583 -- 9 PVOH-6 (8) 709 714 744 791 841 877 1.50 ION-2 (2) 10
PVOH-6 (6) 1270 1400 1580 1810 2090 2280 3.91 ION-2 (4) 11 PVOH-6
(4) 2590 3310 4360 5120 5960 6490 11.13 ION-2 (6) 12 PVOH-6 (2)
6050 8200 9370 1040 11370 11970 20.53 ION-2 (8)
[0145] The data in Table 4 show that the viscosity of the ionomer
dispersion (Comparative Example C1) declined slightly and then
stabilized at about 2 cp over the course of measurement until 1800
seconds when the measurement was stopped. The viscosity of each of
the poly(vinyl alcohol) dispersions (Comparative Examples C2, C7,
C12, C13, C18 and C19) showed similar behavior, stabilizing at
various levels ranging from 31 cp (C13) to 1696 cp (C18).
[0146] When aqueous suspensions of fully hydrolyzed PVOH-1 with the
ionomer ION-2 were prepared (Comparative Examples C3-C6), the
viscosity declined compared to the viscosity of Comparative Example
C2 and decreased as the ratio of ionomer to PVOH increased.
[0147] When aqueous suspensions of highly hydrolyzed PVOH-2 with
the ionomer ION-2 were prepared (Comparative Samples C8-C11), the
viscosity compared to the viscosity of Comparative Sample C7
increased somewhat with low amounts of ionomer and then decreased
as the ratio of ionomer to PVOH increased.
[0148] There was little effect on the viscosity of aqueous
dispersions comprising PVOH-4 and ION-2 (Comparative Samples
C14-C17) compared to the viscosity of Comparative Sample C13. Table
5 summarizes a similar comparison using a 10 weight % aqueous
solution of PVOH-7 blended with a 10 weight % aqueous dispersion of
ION-2. Viscosity measurements on ION-2 were run at 100 rpm and
20.degree. C. using a cylindrical rotor and the PVOH and blends at
60 rpm and 20.degree. C. using a rotor consisting of a shaft with a
disc.
TABLE-US-00005 TABLE 5 Composition Viscosity (cp) after time
(seconds) Viscosity Example (weight % in water) 0 300 600 900 1200
1500 1800 Ratio C20 ION-8 (10) -- -- -- -- -- -- 5.2 -- C21 PVOH-7
(10) -- -- -- -- -- -- 236 -- C22 PVOH-7 (6) 229 209 211 229 214
205 206 0.87 ION-8 (4)
[0149] The viscosity behavior for the 60:40 blend of PVOH-7 and
ION-2 (Table 5) was similar to the behavior of the other
Comparative Samples.
[0150] However, when PVOH-3, PVOH-5 and PVOH-6 were combined with
ION-2, the viscosity of Samples 1 to 12 exhibited surprising
behavior compared to the solutions of PVOH-3, PVOH-5 and PVOH-6
without ionomer (Comparative Samples C12, C18 and C19,
respectively). Those dispersions demonstrated a dramatic increase
in viscosity with the combination of ionomer and PVOH, with
increases in viscosity of greater than 25% at a 1:4 ratio of
ionomer to PVOH. The viscosity further increased as the proportion
of ionomer increased, with increases of about 4 to about 20 times
that of the respective PVOH solution without ionomer when the
ionomer was present in a 4:1 ratio to the PVOH.
Examples
[0151] These examples demonstrate coating paperboard with aqueous
dispersions. Aqueous ionomer-PVOH dispersions were prepared by
mixing 10 weight % of aqueous solutions of PVOH-6 with 10 weight %
aqueous dispersions of ION-2 in ratios of 80:20; 60:40; 40:60 and
20:80 (weight:weight). Comparative Examples were prepared similarly
using PVOH-
[0152] The substrate was a 0.22-inch caliper paperboard with
nominal basis weight of 381 grams/meter.sup.2, treated on one side
with clay for printability, commercially available as
CartonMate.RTM. Bleached Board from RockTenn Converting Company,
Demopolis Ala. An 8-inch by 11-inch sample of the substrate was
coated on the side opposite to the clay coating in the following
manner: The sample was weighed and then attached to a flat piece of
plywood with a spring loaded clip at one end. Approximately 80 ml
of each of the ionomer-PVOH dispersions prepared as above was
applied to the clipped end and the dispersion spread and smoothed
with a wire-wound 0036 Meyer rod in one motion to cover the
remaining portion of the paper sample. The excess dispersion was
removed in the spreading operation. Because of the difficulty in
drying to constant weight, the dry coating weight pickup was
estimated by immediately reweighing the sample to determine the wet
coating weight and calculating the amount of polymer present from
the weight % of the dispersion. Depending on the diameter of the
wire wound around the rod, the coating weight may be about 4 to
about 12 grams per square meter. In these examples, the coating
weight was about 6 to about 12 grams per square meter.
[0153] The wet coated sample was dried in a forced air oven set at
100.degree. C. for five minutes. After drying the sample was
allowed to cool at room temperature and then further conditioned as
required for additional testing. The ionomer-PVOH coatings appeared
colorless, uniform and slightly glossier than an uncoated control.
Results are summarized in Tables 6 and 7. Comparative Example C1
was prepared using a more concentrated, more viscous dispersion,
leading to a higher coating weight. Example 9 was also obtained
with a higher coating weight than the other examples.
TABLE-US-00006 TABLE 6 Weight ratio Dry Pickup Example PVOH-6 ION-2
Dry Weight Wet Weight g % g/m.sup.2 C1 0 100 (13% dispersion) 24.71
30.88 0.802 3.25 12.37 C2 0 100 (10% dispersion) 29.69 24.29 0.540
2.22 8.47 C3 100 0 25.0 30.01 0.501 2.00 7.64 1 80 20 24.76 28.21
0.345 1.39 5.3 2 80 20 24.44 28.29 0.385 1.58 6.0 3 60 40 24.44
27.57 0.313 1.28 4.9 4 60 40 25.51 28.18 0.267 1.05 4.0 5 40 60
25.41 28.26 0.285 1.12 4.3 6 40 60 25.04 28.21 0.317 1.27 4.8 7 20
80 24.76 29.09 0.433 1.75 6.7 8 20 80 23.62 26.77 0.315 1.33 5.1 9
20 80 27.81 37.48 0.967 3.48 13.2
[0154] The Moisture Vapor Transmission Rate (MVTR) is a measure of
the permeability of a material to water vapor. MVTR of the uncoated
and coated substrates were measured on a Mocon Permatran-W.RTM. 101
K instrument according to ASTM D6701-01 at 37.8.degree. C. Coated
substrates were tested with the coated side toward the higher
moisture. Both the clay-treated side and the untreated side of the
uncoated substrate were tested facing the higher moisture.
Transmission rate units are grams per square meter per day.
[0155] The coated samples were tested in the Kit test (TAPPI T 559)
for grease resistance. The Kit test uses a series of mixed
solvents, combinations of castor oil, n-heptane and toluene,
numbered from 1 (100% castor oil) to 12 (45/55 ratio of
toluene/n-heptane), in order of decreasing viscosity and surface
tension. The reported number is the highest number solvent that
shows no sign of staining the tested material after 15 seconds of
contact.
[0156] The coated samples were also tested in the Cobb test (TAPPI
T 441) for water resistance. This test measures the weight gain due
to water absorption under standard conditions. The Cobb test time
can be varied according to the paper type. The test used herein
used was conducted by pouring 100 ml of water onto a paper sample
clamped under a ring enclosing 100 square centimeters and pouring
off the water after two minutes exposure. The weight gain is
multiplied by 100 to report the results in grams/square meter.
[0157] The results of MVTR, Kit and Cobb tests are summarized in
Table 7.
TABLE-US-00007 TABLE 7 2 minute Cobb Test, MVTR, water absorbed
average of 2 or 3 samples Example Kit Test (g/m.sup.2)
(g/m.sup.2/day) Uncoated 0 36 2324 (treated side) substrate 2394
(untreated side) C1 4 4.2 C2 6 5 C3 11 35.8 1 and 2 11+ 56 1811.9 3
and 4 11+ 46 1722.5 5and 6 11+ 25 1567.4 7 and 8 7 6 9 1008.7
[0158] The uncoated substrate had very poor results in the Kit test
for grease resistance and relatively high water absorption in the
Cobb test. The substrates coated with aqueous dispersions of ION-2
alone (Comparative Examples C1 and C2) showed improvement over the
uncoated substrate in both Kit and Cobb tests. Substrates coated
with PVOH-6 alone (Comparative Example C3) had better results in
the Kit test than those coated with the ionomer, but absorbed more
water. Examples 1-9, coated with aqueous dispersions of ionomer and
PVOH-6 provided excellent grease resistance, as indicated by the
high scores in the Kit test. The Kit test results are surprisingly
superior to that expected from a weighted average of the substrates
coated with ionomer or PVOH-6 alone. Water absorption resistance as
demonstrated by the Cobb test showed improvement as the amount of
ionomer increased. In general, excellent grease resistance could be
obtained with PVOH:ionomer ratios from about 10:90 to about 40:60,
while providing the best water absorption resistance.
[0159] The results of the MVTR tests showed reduced moisture
transmission for the coated substrates compared to the untreated
substrate.
[0160] The results summarized in Table 7 show that aqueous blends
of ionomers and PVOH can be used as coatings to provide excellent
grease resistance and improved water resistance for paper and
paperboard substrates. Addition of relatively small amounts of PVOH
to ionomer dispersions can dramatically improve grease
resistance.
* * * * *