Coating composition, a coated article, and method of forming such articles

• US 8,859,661 B2
• Filed: 11/14/2008
• Issued: 10/14/2014
• Est. Priority Date: 11/15/2007
• Status: Active Grant

• Current Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Original Assignee: Dow Global Technologies LLC (Dow, Inc.)
• Inventors: Attal, Jamel F.
• Primary Examiner(s): PAK, HANNAH J
• Application Number:
  US12/740,150
• Publication Number:
  US 20100230062A1
• Time in Patent Office: 2,160 Days
• Field of Search: 428/365, 428/481, 524/501, 524/522, 524/444, 524/422, 106/413, 162/168.1
• US Class Current: 524/422
• CPC Class Codes: C08K 3/26 Carbonates; Bicarbonates
• CPC Class Codes: C08K 3/28 Nitrogen-containing compounds
• CPC Class Codes: C08L 13/00 Compositions of rubbers containing carboxyl groups
• CPC Class Codes: C08L 23/04 Homopolymers or copolymers of ethene
• CPC Class Codes: C08L 23/10 Homopolymers or copolymers of propene
• CPC Class Codes: C08L 2666/02 Organic macromolecular compounds, natural resins, waxes or and bituminous materials
• CPC Class Codes: C08L 2666/06 Homopolymers or copolymers of unsaturated hydrocarbons; Derivatives thereof
• CPC Class Codes: C08L 33/00 Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and only one being terminated by only one carboxyl radical, or of salts, anhydrides, esters, amides, imides or nitriles thereof; Compositions of derivatives of such polymers
• CPC Class Codes: C08L 9/00 Compositions of homopolymers or copolymers of conjugated diene hydrocarbons
• CPC Class Codes: C09D 123/02 not modified by chemical after-treatment
• CPC Class Codes: Y02P 20/582 Recycling of unreacted starting or intermediate materials
• CPC Class Codes: Y10T 428/2915 including textile, cloth or fabric
• CPC Class Codes: Y10T 428/3179 Next to cellulosic

Abstract

The instant invention is a coating composition, a coated article, and method forming such coated articles. The coating composition comprises (a) a dispersion; and (b) a solution acrylic polymer, an emulsion polymer latex, or combinations thereof. The dispersion comprises at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof; at least one or more stabilizing agents; and a fluid medium. A coated article comprises a substrate comprising cellulosic materials; and at least one or more coating layers present on at least one or more surfaces of the substrate. The one or more coating layers may be derived from a coating composition comprising (a) a dispersion; and (b) a solution acrylic polymer, an emulsion polymer latex, or combinations thereof. The dispersion comprises at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof; at least one or more stabilizing agents; and a fluid medium. The method of forming a coated article comprises the steps of (1) selecting a substrate comprising cellulosic materials; (2) selecting a coating composition comprising (a) a dispersion comprising at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof; at least one or more stabilizing agents; and a fluid medium; and (b) a solution acrylic polymer, an emulsion polymer latex, or combinations thereof; (3) applying said coating composition to at least one or more surfaces of said substrate; (4) removing a at least a portion of the water; and (5) thereby forming said coated article.

Claims

1. A coating composition comprising:

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

wherein a pulpable substrate coated with the coating composition is repulpable.

2. The coating composition according to claim 1, wherein said ethylene-based thermoplastic polymer is an alpha-olefin interpolymer of ethylene and at least one or more comonomers selected from the group consisting of propylene, a C₄ to C₂₀ linear, branched or cyclic diene, vinyl acetate, and a compound represented by the formula H₂C═

CHR, wherein R is a C₁ to C₂₀ linear, branched or cyclic alkyl group or a C₆ to C₂₀ aryl group, or wherein said propylene-based thermoplastic polymer is an alpha-olefin interpolymer propylene and at least one or more comonomers selected from the group consisting of ethylene, a C₄ to C₂₀ linear, branched or cyclic diene, and a compound represented by the formula H₂C═

CHR, wherein R is a C₁ to C₂₀ linear, branched or cyclic alkyl group or a C₆ to C₂₀ aryl group.

3. The coating composition according to claim 1, wherein said dispersion comprises from 25 to 74 percent by the combined volume of the at least one or more base polymers and the at least one or more stabilizing agents based on the total volume of said dispersion.

4. The coating composition according to claim 1, wherein said coating composition further comprises a crosslinker.

5. The coating composition according to claim 4, wherein said crosslinker is zinc ammonium carbonate, and wherein said coating composition comprises 2 to 7 percent by weight of said zinc ammonium carbonate.

6. The coating composition according to claim 1, wherein said stabilizing agent comprises a partially or fully neutralized ethylene-acid copolymer.

7. The coating composition according to claim 1, wherein at least a portion of the water is removed at a temperature in the range of less than the melting point temperature of said base polymer selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof, or wherein at least a portion of the water is removed at a temperature in the range of greater than or equal to the melting point temperature of said base polymer selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof.

8. A coated product comprising:

a substrate comprising cellulosic materials; and

at least one or more coating layers present on at least one or more surfaces of said substrate, wherein said coating layer is derived from a coating composition comprising;

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

wherein the coated product is repulpable.

11. The coated product according to claim 8, wherein said coated product comprises 1 g to 10 g by weight of the coating composition per meter square of the substrate.

12. The coated product according to claim 8, wherein said substrate comprises at least one or more fibers selected from the group consisting of natural cellulosic fibers, synthetic cellulosic fibers, and mixtures thereof.

9. A coated product comprising a coating application product of:

a substrate comprising cellulosic materials; and

a coating composition present on at least one or more surfaces of said cellulosic substrate, wherein said coating composition comprises;

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

wherein the coated product is repulpable.

10. The coated product according to claim 9, wherein said coating composition being applied onto at least one or more surfaces of said substrate via coating, spraying, extruding, impregnating, or padding.

13. A method of forming a coated product comprising the steps of:

selecting a substrate comprising cellulosic materials;

selecting a coating composition comprising;

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

applying said coating composition to at least one or more surfaces of said substrate;

removing at least a portion of the water;

thereby forming said coating product, wherein said coating product is repulpable.

14. A method of forming a coated product comprising the steps of:

selecting one or more cellulosic fibers;

selecting a coating composition comprising;

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

incorporating said coating composition onto said one or more cellulosic fibers;

forming said one or more cellulosic fibers incorporating said coating composition into a web;

removing at least a portion of the water;

thereby forming said coated cellulosic product, wherein said coated cellulosic product is repulpable.

15. A method of forming a coated product comprising the steps of:

selecting one or more cellulosic fibers;

selecting a coating composition comprising;

a dispersion comprising;

at least one or more base polymers selected from the group consisting of an ethylene-based thermoplastic polymer, a propylene-based thermoplastic polymer, and mixtures thereof;

at least one or more stabilizing agents; and

a fluid medium comprising water; and

a solution acrylic polymer consisting essentially of 31 to 33 weight % acrylic polymer, 65-67 weight % water, and 1-2 weight % dipropylene glycol monoethyl ether,

wherein said coating composition comprises 6.1 to 10 percent by weight of said solution acrylic polymer based on the weight of said coating composition and wherein the solution acrylic polymer is neutralized with ammonia to increase its solubility; and

incorporating said coating composition onto said one or more cellulosic fibers;

forming said one or more cellulosic fibers incorporating said coating composition into a web;

removing at least a portion of the water;

thereby forming said coated cellulosic product;

wherein said coated cellulosic product is repulpable.