BASF’s patent US20110046284 deals with novel treated mineral pigments for aqueous based barrier coatings.
Corrugated fiberboard containers are used in many high humidity bulk packaging applications such as for fresh fruit and produce items. To overcome the known impairment in the strength of corrugated fiberboard in high humidity service, it is customary to treat such containers, or the corrugated fiberboard sheets or blanks from which the containers are formed, by impregnating them with a material resistant to moisture.
Applications can also include films for food items such as cookie and cracker packaging. In these particular cases, the object of the package is not only to hold the contents, but also to provide resistance to moisture vapor transmission (from the environment to inside the package) which would otherwise diminish the shelf life of the contained cookies, crackers, or the like, where the shelf life is determined by the time it takes the products to pick up sufficient moisture to render them stale. In cookie and cracker packaging applications, for example, the general object of the barrier layer is to substantially keep moisture out or to slow its ingress.
In the past, external coating layers of higher density polyethylenes (HDPE) were needed to achieve a target water vapor transmission resistance (WVTR). Practice often included the addition of a second coating layer to provide other desired properties. These were often relatively poor in HDPE to achieve physical properties such as tear resistance, and/or mechanical properties such as heat seal. Such combinations typically result in added costs and may affect other important properties necessary to the packaging industry. Therefore, a need exists for a moisture barrier film or container fabricated such that the article will have relatively low WVTR combined with improved physical properties.
The BASF patent solves the following problem:
This invention is directed to high performance pigment containing coating systems for use in aqueous-based barrier coatings. Specifically, the invention consists of novel pigments and pigment systems and blending technologies applied to aqueous based coating systems that will provide desired properties in paper and paper board based packaging.This invention is directed to novel pigments, pigment systems (including components not classified as pigments) and formulations for use in an aqueous coating system applied onto cellulosic (paper and/or paperboard) and non-cellulosic substrates (polyethylene (PE), polylactic acid (PLA), polyvinyl acetate (PVAc), etc.) to impart barrier properties. This invention is also directed to a paper or paperboard coated with a pigment system in an aqueous coating system.An embodiment of this invention is directed to a method for preparing an aqueous based coating system for coating onto paper and/or paperboard for providing barrier to liquid, moisture vapor, oil and grease, which comprises mixing a polymer emulsion system or natural-based binding system with a pigment system.Another embodiment of this invention is directed to an aqueous based coating system for coating onto paper and/or paperboard for providing barrier to liquid, moisture vapor, oil and grease, which comprises a polymer emulsion system or natural-based binding system and a pigment system.Yet another embodiment of this invention is directed to a coating system for coating onto a paper and/or paperboard comprising a pigment system, a crosslinker, a polymer emulsion or natural-based binding system that has been hydrophobized by the addition of materials selected from the group consisting of silanes, siloxanes, siloxane/silicone resin blends, and their carbon-based analogs and optionally, a defoaming agent.Another embodiment of this invention is directed to a coating system for coating onto a paper and/or paperboard comprisinga hydrophobized pigment system; a water based binder system, a defoaming agent, a thickening agent and optionally, a crosslinker.Yet another embodiment of this invention is directed to a coating composition for improving the sealability of paper and/or paperboard comprising a pigment system whereby a pigment in the pigment system has been thermally treated prior to surface treatment with a poly-dimethylsiloxane/high molecular weight silicone resin blend.As used herein, the term pigment refers to minerals as known to one skilled in the arts as, for example, kaolin, bentonite, mica, talc, attapulgite and zeolite, in their natural or synthetic form and any combination thereof. Pigment systems refer to pigments that have been surface treated to enable or improve barrier properties. The surface treatment comprises of various materials known to one skilled in the art, for example, surfactants, hydrophobically-modified polymers, styrene-acrylic resin emulsion, styrene-butadiene latex emulsions, blends of styrene acrylic and styrene butadiene latex emulsions, and silanes, siloxanes, siloxane/silicone resin blends, and their carbon-based analogs. The term pigment and pigment system may at times be used interchangeably, as the person skilled in the art will appreciate the terms as used in their respective contexts.As used herein, the term polymer emulsion or latex includes materials such as styrene-acrylic resin emulsion, styrene-butadiene latex emulsions, and blends of styrene acrylic and styrene butadiene latex emulsions. Monomers suitable for use in the production of emulsion systems for paper coating or binding formulation can generally be ethylenically unsaturated monomers including styrene, butadiene, vinyl acetate, carboxylic acids, (meth)acrylic acid esters, (meth)acrylamide, and (meth)acrylonitrile. As used herein, the term natural-based binding system is known to one skilled in the art as, for example, starches, proteins and caseins. Polymer emulsion system refers to polymer emulsions and various additives, such as a cross linker or a defoamer, that when combined with the pigment system make the coating system.As used herein, the term emulsion system refers to various emulsions for combining with the pigment system to develop the coating system. Emulsion systems (also commonly referred to as latexes) comprise styrene-acrylic resin emulsion, styrene-butadiene latex emulsions, blends of styrene acrylic and styrene butadiene latex emulsions etc. Monomers suitable for use in the production of emulsion systems for paper coating or binding formulation can generally be ethylenically unsaturated monomers including styrene, butadiene, vinyl acetate, carboxylic acids, (meth)acrylic acid esters, (meth)acrylamide, and (meth)acrylonitrile.As used herein, the term inorganic materials includes materials such as carbides, oxides and nitrides.
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