Barrier coating of an elastomer and a dispersed layered filler in a liquid carrier and coated articles
First Claim
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1. A coated article comprising an elastomeric substrate that contains air or a gas under pressure, and having on an interior or exterior surface of said substrate a barrier coating formed by:
- (a) applying to said surface without melt processing or high shear mixing an aqueous solution comprising;
(i) an elastomeric polymer;
(ii) a dispersed exfoliated layered filler having an aspect ratio greater than 25; and
(iii) at least one surfactant, wherein the solids content of said solution is less than 30% and the weight ratio of said polymer to said filler ranges from 20;
1 to 1;
1; and
(b) drying said solution to form said barrier coating, wherein said dried barrier coating has a polymer to filler weight ratio, which ranges from 20;
1 to 1;
1 and wherein said coating provides at least 10-fold greater reduction in gas, vapor, and chemical permeability than a coating formed of said polymer alone.
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Abstract
Applications of barrier coating mixtures containing in a carrier liquid, (a) an elastomeric (preferably butyl-containing) polymer; (b) a dispersed exfoliated layered filler having an aspect ratio greater than 25; and (c) at least one surfactant, wherein the solids content of the mixture is less than 30% and the ratio of polymer (a) to filler (b) is between 20:1 and 1:1 include coated articles, which are elastomeric, e.g., sports balls and inflatable articles. Methods of manufacturing such coated products are also encompassed.
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Citations
36 Claims
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1. A coated article comprising an elastomeric substrate that contains air or a gas under pressure, and having on an interior or exterior surface of said substrate a barrier coating formed by:
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(a) applying to said surface without melt processing or high shear mixing an aqueous solution comprising;
(i) an elastomeric polymer;
(ii) a dispersed exfoliated layered filler having an aspect ratio greater than 25; and
(iii) at least one surfactant, wherein the solids content of said solution is less than 30% and the weight ratio of said polymer to said filler ranges from 20;
1 to 1;
1; and
(b) drying said solution to form said barrier coating, wherein said dried barrier coating has a polymer to filler weight ratio, which ranges from 20;
1 to 1;
1 and wherein said coating provides at least 10-fold greater reduction in gas, vapor, and chemical permeability than a coating formed of said polymer alone.- View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A method of manufacturing an article comprising an elastomeric substrate that contains air or another gas under pressure, comprising:
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(a) applying directly on an interior or exterior surface of said substrate a barrier coating mixture, wherein said coating is formed by applying to said surface without melt processing an aqueous solution comprising;
(i) an elastomeric polymer;
(ii) a dispersed exfoliated layered filler having an aspect ratio greater than 25; and
(iii) at least one surfactant, wherein the solids content of said solution is less than about 30% and the weight ratio of said polymer to said filler ranges from 20;
1 to 1;
1; and
(b) drying said solution to a barrier coating, wherein said dried barrier coating has a weight ratio of polymer to filler, which ranges from about 20;
1 to about 1;
1 and wherein said coating provides at least 10-fold greater reduction in gas, vapor, and chemical permeability than a coating formed of said polymer alone.- View Dependent Claims (34, 35)
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36. A sports ball comprising an elastomeric substrate that contains air or a gas under pressure, and having on an interior or exterior surface of said ball or at the interface of said surfaces a barrier coating formed by applying to said surface without melt processing an aqueous solution comprising:
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(a) an elastomeric polymer;
(b) a dispersed exfoliated layered filler having an aspect ratio greater than 25; and
(c) at least one surfactant, wherein the solids content of said solution is less than about 30% and the weight ratio of said polymer to said filler ranges from 20;
1 to 1;
1.
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Specification