Barrier coating a non-elastomeric polymer and a dispersed layered filler in a liquid carrier and coated articles

Abstract

Barrier coating mixtures contain in a carrier liquid, (a) a non-elastomeric polymer; (b) an exfoliated layered platelet-like silicate filler which may or may not have been acid or base treated that has not been functionalized with organic cations having an aspect ratio greater than 25; and (c) at least one additive, wherein the total solids content is less than 30% and the amount of filler is between 5% to about 60% of the total solids content. Coated articles and containers, freestanding films and packaging films are produced using the barrier coating mixtures. Methods of manufacturing such coated products are also encompassed.

1 . A method for making a nanocomposite coating composition in the form of an aqueous emulsion, suspension, colloidal dispersion and/or latex, comprising:
 a) providing an aqueous dispersion of non-elastomeric polymer;   b) providing an aqueous dispersion of a substantially exfoliated silicate filler material not functionalized with organic cations, the silicate filler having an aspect ratio greater than 25;   c) treating the aqueous dispersion of the substantially exfoliated filler material with an acid or a base; and   d) combining the treated aqueous dispersion of the substantially exfoliated filler material with the aqueous dispersion of the non-elastomeric polymer to form the nanocomposite.   
   
   
       2 . The method according to  claim 1 , further comprising drying the nanocomposite to form a barrier film. 
   
   
       3 . The method according to  claim 2 , wherein the non-elastomeric polymer is polyvinylidene chloride. 
   
   
       4 . The method according to  claim 2 , wherein the non-elastomeric polymer is a polyester polymer. 
   
   
       5 . The method according to  claim 2 , wherein the non-elastomeric polymer is a polyacrylic polymer. 
   
   
       6 . The method according to  claim 2  wherein the non-elastomeric polymer is a polyurethane polymer. 
   
   
       7 . The method according to  claim 1 , wherein the silicate filler is vermiculite. 
   
   
       8 . The method according to  claim 1 , wherein the silicate filler is montmorillonite.