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WO2024206171A1 - Revêtement barrière à base d'eau contenant de la bentonite de sodium et son procédé de fabrication - Google Patents

Revêtement barrière à base d'eau contenant de la bentonite de sodium et son procédé de fabrication Download PDF

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Publication number
WO2024206171A1
WO2024206171A1 PCT/US2024/021198 US2024021198W WO2024206171A1 WO 2024206171 A1 WO2024206171 A1 WO 2024206171A1 US 2024021198 W US2024021198 W US 2024021198W WO 2024206171 A1 WO2024206171 A1 WO 2024206171A1
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WIPO (PCT)
Prior art keywords
sodium bentonite
coating
binder
styrene
copolymers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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PCT/US2024/021198
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English (en)
Inventor
Pradnya Dilip RAO
Sherman David COX
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Specialty Minerals Michigan Inc
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Specialty Minerals Michigan Inc
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Publication date
Application filed by Specialty Minerals Michigan Inc filed Critical Specialty Minerals Michigan Inc
Priority to CN202480020455.1A priority Critical patent/CN120936550A/zh
Publication of WO2024206171A1 publication Critical patent/WO2024206171A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/38—Coatings with pigments characterised by the pigments
    • D21H19/40—Coatings with pigments characterised by the pigments siliceous, e.g. clays
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38—Packaging materials of special type or form
    • B65D65/42—Applications of coated or impregnated materials
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/71—Mixtures of material ; Pulp or paper comprising several different materials not incorporated by special processes
    • D21H17/74—Mixtures of material ; Pulp or paper comprising several different materials not incorporated by special processes of organic and inorganic material
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/58—Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16—Sizing or water-repelling agents
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
    • D21H21/52—Additives of definite length or shape
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/10—Packing paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D2565/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D2565/38—Packaging materials of special type or form
    • B65D2565/381—Details of packaging materials of special type or form
    • B65D2565/382—Details of packaging materials of special type or form made of special paper
    • B65D2565/383—Details of packaging materials of special type or form made of special paper made of recycled paper

Definitions

  • the disclosure relates to water-based barrier coatings and method for making waterbased barrier coatings that contain sodium bentonite.
  • Paper-based packaging materials are utilized around the world.
  • the barrier coatings of paper and packaging applications primarily depend on petroleum-based materials and synthetic polymers such as waxes, polyvinyl alcohol, polyolefins (Gironi & Piemonte, 201 1). These materials are cost-effective, easily available, and provide a significant barrier against water vapor, oil/grease, and oxygen for packaging applications.
  • these materials have major disadvantages such as poor recyclability of coated paper and non-biodegradability which can adversely impact the environment.
  • Ideal packaging material in the context of food packaging must have a good barrier to oxygen, water vapor, and oil/grease while being derived from biobased, recyclable, compostable, and/or otherwise ecofriendly sources. Barrier property needs can vary depending on the coating application and ultimate use of the paper product.
  • Nanoclays have been used in a variety of applications and are generally found advantageous for their ability to swell in water.
  • Sun et al reported a nanoclay/latex composite for improving barrier properties in coatings. See Sun et al., Comps Science Tech 67 (2007) 1823-1829. Consistent with conventional expectations and uses of nanoclays, Sun et al. teaches that the nanoclay must be fully exfoliated in the coating and that cationic surface modifications of the clay and/or use of dispersants was required.
  • a process for preparing an aqueous barrier coating for a paper substrate can include admixing a dry powder of chemically unmodified sodium bentonite with a binder; and subjecting the admixture to high shear mixing under conditions such that the sodium bentonite disperses in the binder and at least a portion of the sodium bentonite maintains a tactoid form to thereby form the barrier coating.
  • the binder can be water-based or water soluble.
  • a process for preparing an aqueous barrier coating for a paper substrate can include admixing a dry powder of chemically unmodified sodium bentonite with a polymer latex binder; and subjecting the admixture to high shear mixing under conditions such that the sodium bentonite disperses in the polymer latex and at least a portion of the sodium bentonite maintains a tactoid form to thereby form the barrier coating.
  • the process in accordance with the disclosure can further include coating a paper substrate with the barrier coating.
  • an aqueous barrier coating can include unmodified sodium bentonite dispersed in a binder, wherein the sodium bentonite is dispersed under high shear conditions such that the sodium bentonite is present in the form of tactoids.
  • the coating can be free of dispersant.
  • Figure 1 is a graph showing liquid water resistance of barrier coated papers by Water Cobb.
  • Figure 2 is a graph showing water vapor transmission rates of barrier coatings at tropical conditions 90% RH and 38 °C.
  • Figure 3 is a photograph of oil barrier property testing on a coating in accordance with the disclosure.
  • Figures 4A to 4D are particle size distribution graphs of sodium bentonite for use in coatings in accordance with the disclosure.
  • Figure 5 is a scanning electron microscopy image of a coating in accordance with the disclosure, showing tactoids of sodium bentonite being present in the coating.
  • Figure 6 is a graph showing water vapor transmission rate performance for coatings in accordance with the disclosure and conventional coatings formed as single layer coatings and tested under tropical conditions.
  • Figure 7 is a graph showing water vapor transmission rate performance for coatings in accordance with the disclosure and conventional coatings formed as double layer coatings and tested under tropical conditions.
  • Water-based coatings in accordance with the disclosure include chemically unmodified sodium bentonite dispersed in a binder to advantageously provide a barrier coating that is aqueous based. It has been advantageously found that barrier coating properties can be achieved through the incorporation of dry sodium bentonite, with the sodium bentonite used as the raw material in the coating being its natural hydrophilic state and without exfoliation. Exfoliation of the sodium bentonite can occur under the high shear mixing conditions used in dispersing the sodium bentonite in the binder when preparing the coatings of the disclosure. Advantageously, no pre-processing of the sodium bentonite is needed before dispersing within the binder.
  • Coatings of the disclosure include a chemically unmodified sodium bentonite dispersed in a binder using high shear mixing conditions such that at least a portion of the sodium bentonite is present in the coating in the form of tactoids.
  • Figure 5 is an SEM image of a coating in accordance with the disclosure, showing the presence of tactoids in the coating.
  • the coatings of the disclosure can be aqueous-based barrier coatings.
  • Methods of making aqueous based barrier coatings in accordance with the disclosure can include admixing a dry powder of chemically unmodified sodium bentonite with a binder and subjecting the admixture to high-shear mixing under conditions such that the sodium bentonite disperses in the binder and at least a portion of the sodium bentonite maintains a tactoid form.
  • sodium bentonite refers to bentonite having at least 50% sodium cation.
  • the sodium bentonite used in the methods and coatings of the disclosure is chemically unmodified sodium bentonite and optionally can be mechanically unmodified.
  • mechanically unmodified sodium bentonite refers to sodium bentonite that may or may not have sodium ion exchange, but that has not been subject to mechanical shearing prior to incorporation into a coating, and that retains its natural hydrophilic state.
  • “chemically unmodified sodium bentonite” refers to a sodium bentonite that may or may not have sodium ion exchange, but not been subject to chemical modification, such as with organic modifiers.
  • the sodium bentonite admixed with the binder is chemically and mechanically unmodified and optionally exfoliated during dispersion of the sodium bentonite in the binder thereby modifying the sodium bentonite present in the final coating by mechanical shearing.
  • the sodium bentonite admixed with the binder is chemically unmodified.
  • the sodium bentonite is chemically unmodified.
  • Figures 4A to 4D show particle size distributions for unmodified sodium bentonites which can be used in the coatings and methods of the disclosure.
  • the sodium bentonite used in the coatings and methods of the disclosure can have less than about 12% moisture.
  • the sodium bentonite is incorporated into the binder of the coatings in a dry particulate or powder state, without pre-swelling or exfoliation, and dispersed in the binder using high-shear mixing.
  • High shear mixing conditions can be selected and tailored to provide for exfoliation of the sodium bentonite while dispersing the sodium bentonite in the binder. It has been found that use of sodium bentonite that has been exfoliated during dispersion results in high shape factor sodium bentonite being present in the final coating.
  • High shaper factor refers to a shape factor above 4 as measure by the ratio of the Horiba dso measured with static light scattering to the Zave particles size measured with dynamic light scattering. It has advantageously been found that exfoliation during dispersion within the binder increases the shape factor of the sodium bentonite, while allowing a portion of the sodium bentonite to be maintained in tactoid form.
  • the sodium bentonite can have at least about 60%, at least about 65%, at least about 70%, at least about 75%, at least about 80% montmorillonite.
  • the coatings of the disclosure have been observed to achieve improved barrier properties, as compared to conventional talc and kaolin containing coatings.
  • the coatings of the disclosure can achieve comparable, if not improved, barrier coating properties, as compared to talc or kaolin containing coatings with significantly reduced loading levels of the sodium bentonite. Additionally, the coatings of the disclosure can be formed without the need for added dispersant.
  • the sodium bentonite is dispersed in the binder using high shear mixing conditions that achieve a coating in which at least a portion of the sodium bentonite is present in tactoid form.
  • high shear mixing can be achieved, for example, by mixing with a tip speed of about 655 ft/min to about 3300 ft/min (200 m/min to 1010 m/min).
  • High shear mixing can be performed using any known methods or combinations of methods, including, but not limited to, using a Cowles mixer, sonication, and rotor-stator mixing.
  • High shear mixing can include, for example, sonication for at least 1 min.
  • Sonication times can be about 1 min to about 40 min, about 10 min to about 30 min, or about 5 min to about 25 min. Other suitable times include about 1 , 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, 33, 34, 35, 36, 37, 38, 39, and 40 mins and values therebetween and ranges defined by those values.
  • High shear can be performed for example under conditions to reduce or protect against overheating.
  • sonication can be performed using a jacketed vessel with water circulation and a pulsing method to prevent overheating.
  • the high shear mixing process can result in exfoliation of the sodium bentonite during dispersion within the binder, while also allowing tactoid form of the sodium bentonite to remain present in the coating.
  • the sodium bentonite within the coating can, as a result, have increased shape factor as compared to the starting material before dispersion.
  • the sodium bentonite after dispersion can have a shape factor, for example, of at above 4.
  • Shape factor as referenced herein is a ratio of the Horiba dso measurement using static light scattering to the Zave size as measured by dynamic light scattering. It has been observed that sodium bentonite having a shape factor above 4 can be obtained by high shear mixing with the binder, such as by sonication for 5 min or more or using a roto-stator type shearing device.
  • the coating can include any suitable aqueous binder .
  • the binder can be an aqueous polymer latex.
  • non-latex binders can also be used.
  • binders can be one or more of an anionic polymer latex, such as Styrene butadiene, polyolefin, styrene acrylates, ethylene acrylic acid copolymers, ethylene vinyl alcohol copolymers, polyurethanes, epoxy resins, polyesters, polyolefins, carboxylated styrene-butadiene latexes, carboxylated styrene acrylate latexes; polyvinylidene chlorides; polyvinyl chlorides; starches; styrene-acrylic copolymers; styrene-maleic anhydrides; polyvinyl alcohols; polyvinyl acetates; carboxymethyl celluloses; silicones; waxes; neopre
  • the sodium bentonite can be added to the binder in amounts of about 1wt% to about 20wt%, about 1 wt% to about 5 wt%, about 3 wt% to about 15 wt%, or about 10 wt% to about 20 wt%, based on a total weight of the coating on a dry weight basis.
  • Other suitable amounts include, based on a total weight of the coating on a dry weight basis, of about 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 11 , 12, 13, 14, 15, 16, 17, 18, 19, and 20 wt%, and any values therebetween, and any ranges defined by such values.
  • a percent (%) of sodium bentonite in the coatings of the disclosure refers to a weight percent based on a total weight of the coating on a dry weight basis.
  • Loading levels of sodium bentonite can be significantly lower than required with talc or kaolin in conventional coatings, while maintaining or even exhibiting improved barrier properties.
  • the sodium bentonite loading in the coatings of the disclosure can be 2 to 60 times lower than required for other platy minerals- based barrier coatings, such as talc or kaolin coatings.
  • the coatings of the disclosure are for use in coating porous substrate, such as paper and paperboard.
  • the coatings of the disclosure can have a solids content of about 5% to about 55%, about 15% to about 55%, about 20% to about 40%, about 30% to about 50%, or about 10% to about 25%.
  • Other suitable solids content includes about 5, 10, 15, 20, 25, 30, 35, 40, 45, 50, 55% and any values therebetween and ranges defined by such values.
  • Coatings prepared by the dry addition of the sodium bentonite can advantageously have solids contents that are equal to or greater than the solids content of the binder.
  • coatings prepare with wet addition of the sodium bentonite have lower solids content than the binder as a result of the liquid present in the slurry of the sodium bentonite.
  • the coatings of the disclosure can be coated by conventional paper coating methods, such as drawdown coating, blade coating, curtain coating, rotogravure coating (gravure coating), machine roll-to-roll coating, size press, reverse roll coating, hot melt coating flexbar coating/Flexo coating, film transfer coating, die-slot coating, wet film applicator coating, coating film casting using filtration and evaporation, dip coater, extrusion coating.
  • the substrate can be coated, for example, with any desired coating weight and/or number of coating layers.
  • the coatings can be coated with a coating weight of about 1 g/m 2 to about 35 g/m 2 , about 1 g/m 2 to about 25 g/m 2 , about 5 g/m 2 toa bout 15 g/m 2 .
  • the coating weight can be about 1 , 2, 3, 4, 5, 6, 7, 8, 9, 10, 1 1 , 12, 13, 14, 15, 16, 17, 18, 19, 20, 21 , 22, 23, 24, 25, 26, 27, 28, 29, 30, 31 , 32, 33, 34, or 35 g/m 2 and any values therebetween or ranges defined by such values.
  • the coatings of the disclosure can be a single layer coating and have a coat weight of less than 10 g/m 2 , for example, about 2 g/m 2 to less than 10 g/m 2 , or about 4 g/m 2 to about 8 g/m 2 .
  • Other suitable single-layer coat weights can include about 1 , 2, 3, 4, 5, 6, 7, 8, and 9 g/m 2 and any values therebetween and ranges defined by such values. It has been advantageously observed that the beneficial effects of the coatings of the disclosure, including sodium bentonite as opposed to kaolin or talc, can allow for single layer coatings to be used while achieving desired barrier properties.
  • the coatings of the disclosure demonstrated a 31 % improvement in barrier properties with a 3% dry addition of sodium bentonite in the coating as compared to pure latex.
  • Coatings of the disclosure having 3% dry addition of the sodium bentonite also demonstrated a 39% improvement over a comparative coating formulation containing 40% loading of competitive product BarrisurfTM LX kaolin clay. Dry addition of the sodium bentonite in the coating demonstrated a more than 30% improvement in barrier properties as compared to wet addition.
  • the porous substrates for use with coatings of the disclosure can generally include any paper or paperboard products for which a barrier coating is desired.
  • Paper substrates onto which the coatings of the disclosure can be coated can include, but are not limited to, solid bleached sulfate (SBS) paper, folding box board (FBB), white top liner (WTL), low basis weight papers such as fast-food wrappers, copy paper, coated and uncoated paper and paperboard, coated unbleached kraft (CUK) paper, and coated recycled paperboard.
  • SBS solid bleached sulfate
  • FBB folding box board
  • WTL white top liner
  • low basis weight papers such as fast-food wrappers, copy paper, coated and uncoated paper and paperboard, coated unbleached kraft (CUK) paper, and coated recycled paperboard.
  • Coatings of the disclosure can be tailored to provide water vapor transmission rates or other barrier properties based on intended application of the paper substrate.
  • the barrier coating can provide a ⁇ 40 g/m 2 /d water vapor transmission rate (WVTR) at tropical conditions (38°C and 90% RH), and/or water COBB 60 mins ⁇ 1 g/m 2 . It is generally understood in the art that WVTR at tropical conditions for ultra-high barrier applications is ⁇ 10 g/m 2 /d, high barrier applications is ⁇ 100 g/m 2 /d, medium barrier applications is 100-400 g/m 2 /d, and low barrier >400 g/m 2 /d. Barrier coatings in accordance with the disclosure can be tailored for any of the foregoing applications.
  • the aqueous barrier coating in accordance with the disclosure was prepared as follows: In a 1000 ml steel container, 370 g of Tykote® 1004 Styrene-butadiene latex at 52% solids was weighed. To that, 10.7 g of sodium bentonite at 10% moisture and 27.7 g of water were added. The resulting slurry was mixed thoroughly using a Premier model 2500HV Cowles- type mixer with a 2.5-inch (6.35 cm) diameter blade at a tip speed of 2945 ft/min for 30 mins. Using the oven drying method, the final solid content of the formulation was determined to be 45%.
  • a slurry of sodium bentonite was created in water by adding 11.1 g of dry sodium bentonite at 10% moisture to 200 g of water. Then using a Premier model 2500HV Cowles-type mixer with a 2.5-inch (6.35 cm) diameter blade, the suspension was stirred at a tip speed of 2945 ft/min for 15 minutes. Using the oven drying method the solid content of this water-based sodium bentonite slurry was determined to be 5%.
  • the barrier coating formulation was generated in a 1000 ml steel container by mixing 370 g of Tykote® 1004 Styrene-butadiene latex at 52% solids content and 178.1 g of the prepared sodium bentonite slurry at 5% solid content. Then the mixture was stirred at a tip speed of 2945 ft/min for 15 mins using the same Cowles-type mixer. Using the oven drying method, the final solid content of the formulation was determined to be 45%.
  • a slurry of sodium bentonite was created in 300 gm of water by adding 0.0608 g of ACUMER 9300 at 45% solids followed by 38 g of powder at 10% moisture. Stirred the mixture for 15 mins using a Premier model 2500HV Cowles-type mixer with a 2.5-inch (6.35 cm) diameter blade at a tip speed of 2945 ft/min. Using the oven drying method, the final solid content of the slurry was determined to be 11%. To make barrier formulation, 70.4 g of slurry at 1 1% solids was added to 304 g of Tykote® 1004 Styrene-butadiene latex at 52% solids. Stirred the resulting barrier formulation for 15 mins at a tip speed of 2945 ft/min using the same Cowles-type mixer.
  • a drawdown coating method was used to make barrier coatings on 350 g/m 2 SBS (solid bleached sulfate) board. Each paper board has double-layer coatings of the same formulation and Rod numbers from 4-13 were used to make different coat weights. Two coat weights were produced with average coat weights of 13-15 g/m 2 and 23-25 g/m 2 . Paper coated with barrier formulation was then tested for liquid water resistance (water Cobb) by TAPPI 441 , water vapor transmission rate (WVTR) by TAPPI T 464, and Oil and grease barrier (OGR) by Oil cobb. The oil cobb method is modified TAPPI 441 method to test OGR.
  • Raw, chemically unmodified sodium bentonite having a moisture content of 8% and a dry particle size of a minimum 99.00% finer than 200 mesh (74 microns) and wet particle size of a minimum of 99.75% finer than 200 mesh (74 microns).
  • the particle size of dispersed sodium bentonite was determined using the Horiba LA950 static light scattering instrument.
  • a 1 .0% bentonite suspension was created by adding 0.5 g of bentonite powder to 50 ml of a D.L water solution with a 0.005% DAXAD® 30 dispersant concentration. The resulting suspension was sonicated using 0.5-inch horn at setting 1 .5, for 8 minutes to disperse it.
  • the dispersed suspension was added dropwise to the Horiba LA950 cell to achieve a red laser % transmittance of 89-91%, and the particle size was determined using standard settings and refractive indices for calcium carbonate. This method measures a particle size related to the larger, basal plane dimension of the bentonite.
  • the particle size of sodium bentonite was also determined by the dynamic light scattering (DLS) technique using a Malven Zetasizer 1000 instrument. Either a dispersed or undispersed suspension can be used. The suspension was diluted to 0.1% solids using DI water. The diluted suspension was transferred to an instrument cuvette (1 cm x 1 cm plastic with all faces transparent), and the cuvette placed in the instrument measurement chamber. Standard software settings were used to measure size using water as a solvent and refractive index of sodium bentonite (1 .503). The resulting Zave value (the hydrodynamic diameter) is reported. This instrument is designed to measure nanoparticles and hence we used this technique to provide a value related to, though much larger than the smaller thickness dimension of the sodium bentonite plates. Measured Zave values of sodium bentonite varied from 500 to 1500 nm.
  • shape factor (SF) of bentonite could be calculated as a ratio of two particle size methods - using the ratio of diameters from static light scattering (Horiba LA- 950) to diameters from dynamic light scattering (DLS). With bentonite it was observed that sedimentation could not be used due to it extremely long settling time.
  • the shape factor (SF) was calculated by taking the ratio of median particle size (d50) determined by Horiba light scattering to the Zave particle size determined using Malvern Zetasizer 1000 DLS in microns.
  • the resulting SF values for sodium bentonite may vary from 3.5 to 7, with higher values indicating a higher degree of delamination and higher particle aspect ratio.
  • Low SF A 5% solids sodium bentonite slurry in DI water was made as in the above "No Acumer” example, except the volume was 500 mL and high-speed mixing with the Cowles was only at 2000 rpm for 5 minutes.
  • High SF Another 500 mL of 5% solids starting slurry was sonicated for a total of 20 minutes in a water-cooled beaker with constant mixing with a propeller stirrer. To avoid heating, sonication was turned on and off in 10 seconds on/20 seconds off cycles for a total of 20 minutes on time.
  • Coatings in accordance with the disclosure were prepared having high and low shaped factor sodium bentonite, as well as with dry and wet addition of the sodium bentonite.
  • the chemically unmodified sodium bentonite as described in Example 2 was used as the starting material in the coatings of the disclosure.
  • the coatings in accordance with the disclosure each included 3% sodium bentonite on a dry weight basis. Barrier performance of these coatings were compared to each other, as well as to a coating of Tykote® 1004 (pure latex) and a BarrisurfTM LX (kaolin) containing coating.
  • a coating in accordance with the disclosure having dry addition of 3% sodium bentonite with a low shape factor was prepared by combining 150 g of Tykote® 1004 with 2.6 g of dry sodium bentonite powder. To create the low shape factor formulation, this mixture was stirred at 2000 RPM for 5 minutes using a 2.5-inch diameter Cowles blade. The formulation was diluted to 47% by adding DI water. This formulation was kept overnight then viscosity, pH, and solids were measured.
  • a coating in accordance with the disclosure having dry addition of 3% sodium bentonite with a high shape factor was prepared by combining 150 g of Tykote® 1004 with 2.6 g of dry sodium bentonite powder.
  • this mixture was stirred at 2000 RPM for 5 minutes, followed by sonication for 20 minutes with a pulsing function, alternating between 30 seconds on and 30 seconds off. The pulsing function was used to prevent overheating.
  • the formulation was diluted to 47% by adding DI water. This formulation was kept overnight then viscosity, pH, and solids were measured.
  • a coating in accordance with the disclosure having wet addition of 3% sodium bentonite with a low shape factor was prepared by first forming a sodium bentonite slurry.
  • the slurry was prepared as described in Example 3 for preparing a low shape factor sodium bentonite slurry.
  • 25 g of sodium bentonite dry powder was mixed with 475 g of water, sheared at 2000 RPM for 5 minutes using 2.5-inch Cowles blade to achieve a final bentonite slurry solids concentration of 5%.
  • 150 g of Tykote® 1004 were combined with 48.2 g of the wet 5% sodium bentonite slurry.
  • the Tykote® 1004 latex and sodium bentonite slurry were then mixed at 800 RPM for 15 minutes using a propeller-type overhead mixer. This formulation was kept overnight then viscosity, pH, and solids were measured.
  • a coating in accordance with the disclosure having wet addition of 3% sodium bentonite with a high shape factor was prepared by first forming a sodium bentonite slurry.
  • the slurry was prepared as described in Example 3 for preparing a high shape factor sodium bentonite slurry.
  • 25 g of sodium bentonite dry powder was mixed with 475 g of water, sheared at 2000 RPM for 5 minutes using 2.5-inch Cowles blade.
  • the same formulation was sonicated for 20 minutes with a pulsing function, alternating between 10 seconds on and 20 seconds off. The pulsing function was used to prevent overheating.
  • the final solids of sodium bentonite slurry was 5%.
  • Tykote® 1004 150 g of Tykote® 1004 were combined with 48.2 g of the wet 5% sodium bentonite slurry. The Tykote® 1004 latex and sodium bentonite slurry were then mixed at 800 RPM for 15 minutes using a propeller-type overhead mixer. This formulation was kept overnight then viscosity, pH, and solids were measured
  • the BarrisurfTM LX (kaolin) comparative example coating was prepared as a 40% BarrisurfTM LX - Tykote® 1004 formulation. 150 g of Tykote® 1004 were combined with 84.4 g of BarrisurfTM LX slurry. BarrisurfTM LX slurry had a solid content of 61 .6%. This mixture was then blended at 800 RPM for 15 minutes using a propeller-type overhead mixer. This formulation was kept overnight then viscosity, pH, and solids were measured. [0054] For each of the coating formulations, the coatings were applied to 175 g/m 2 white top liner using an automated draw-down coater at a speed of 40 m/min.
  • the coatings underwent drying in the oven at 103°C for 10 minutes, followed by conditioning in the CTH room for 24 hours. Both single and double layers of coating were applied.
  • the targeted coat weight was 5.8 ⁇ 0.4 g/m 2
  • the targeted coat weight was 10.8 ⁇ 0.3 g/m 2 .
  • circles with a diameter of 7.62 cm were cut and utilized for WVTR testing under tropical conditions (38 °C ,90% RH).
  • Table 3 provides the viscosity, pH, and solids content of the coating formulations prepared.
  • *3% sodium bentonite refers to 3 wt% sodium bentonite based on the total weight of the coating on a dry weight basis.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Dispersion Chemistry (AREA)
  • Paper (AREA)
  • Paints Or Removers (AREA)

Abstract

Un revêtement barrière aqueux pour produits en papier peut comprendre une bentonite de sodium chimiquement non modifiée dispersée dans un liant, la bentonite de sodium étant dispersée dans des conditions de cisaillement élevé de telle sorte que la bentonite de sodium est présente sous la forme de tactoïdes.
PCT/US2024/021198 2023-03-24 2024-03-22 Revêtement barrière à base d'eau contenant de la bentonite de sodium et son procédé de fabrication Pending WO2024206171A1 (fr)

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Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110132975A1 (en) * 2008-03-14 2011-06-09 Tetra Laval Holdings & Finance S.A. Packaging laminate, method for manufacturing of the packaging laminate and packaging container produced therefrom
US20110293957A1 (en) * 2008-12-30 2011-12-01 Caisa Johansson barrier material and method for making the same
WO2019189229A1 (fr) * 2018-03-28 2019-10-03 日本製紙株式会社 Matériau barrière en papier
EP4067078A1 (fr) * 2019-11-26 2022-10-05 Oji Holdings Corporation Stratifié barrière

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20110132975A1 (en) * 2008-03-14 2011-06-09 Tetra Laval Holdings & Finance S.A. Packaging laminate, method for manufacturing of the packaging laminate and packaging container produced therefrom
US20110293957A1 (en) * 2008-12-30 2011-12-01 Caisa Johansson barrier material and method for making the same
WO2019189229A1 (fr) * 2018-03-28 2019-10-03 日本製紙株式会社 Matériau barrière en papier
EP4067078A1 (fr) * 2019-11-26 2022-10-05 Oji Holdings Corporation Stratifié barrière

Non-Patent Citations (2)

* Cited by examiner, † Cited by third party
Title
"HANDBOOK OF PAPER AND BOARD", 20 January 2006, WILEY-VCH-VERL., Weinheim, DE, ISBN: 978-3-527-30997-9, article WERNER J. AUHORN: "Chapter 3: Chemical Additives", pages: 62 - 149, XP055382763, DOI: 10.1002/3527608257.ch3 *
SUN ET AL., COMPS SCIENCE TECH, vol. 67, 2007, pages 1823 - 1829

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