Coated substrate

Abstract

A substrate coated with a first coating composition comprising an alcohol-based binder and an inorganic particulate material and a second coating composition comprising a latex binder and a phyllosilicate, and methods for making said coated substrate.

1 . A substrate coated with:
 a first coating comprising at least one alcohol-based binder and an inorganic particulate material,   wherein the at least one alcohol-based binder is a polymer comprising a carboniferous backbone having hydroxyl functional groups appended therefrom, and wherein the inorganic particulate material is selected from the group consisting of an alkaline earth metal carbonate, alkaline earth metal sulphate, an aluminosilicate, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, and a combination thereof; and   a second coating comprising at least one latex binder and a talc,   wherein the at least one latex binder is selected from the group consisting of natural rubber latex, a copolymer comprising of alkene monomers and styrene monomers, polyurethane, polyester, polyethyleneacrylate dispersions, and a combination thereof;   wherein the first and second coatings are layered such that the first coating is closer to the substrate than the second coating, and the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating;   wherein the talc and latex binder are present in the second coating in a weight ratio of from about 4:1 to about 1:3, and   wherein the substrate has an oil vapor transmission rate (OVTR) equal to or less than about 5 gsm (g/m 2 ) per day.   
     
     
         2 . The substrate according to  claim 1 , wherein the substrate is paper. 
     
     
         3 . The substrate according to  claim 1 , wherein the alcohol-based binder is polyvinyl alcohol. 
     
     
         4 . The substrate according to  claim 1 , wherein the inorganic particular material comprises an alkaline earth metal carbonate or sulphate, an aluminosilicate, talc, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate or a combination thereof. 
     
     
         5 . The substrate according to  claim 1 , wherein the latex binder is a styrene butadiene binder. 
     
     
         6 . (canceled) 
     
     
         7 . The substrate according to  claim 1 , wherein the inorganic particulate material in the first coating has a shape factor equal to or greater than about 10. 
     
     
         8 . The substrate according to  claim 1 , wherein the inorganic particulate material and alcohol-based binder are present in the first coating in a weight ratio of from about 5:1 to about 1:10. 
     
     
         9 . The substrate according to  claim 1 , wherein the first coating has a coat weight equal to or less than about gsm (g/m 2 ). 
     
     
         10 . The substrate according to  claim 1 , wherein the total coat weight of the first and second coatings is equal to or less than about 50 gsm (g/m 2 ). 
     
     
         11 . The substrate according to  claim 1 , wherein the substrate has a moisture vapour transmission rate (MVTR) equal to or less than about 200 gsm (g/m 2 ) per day. 
     
     
         12 . (canceled) 
     
     
         13 . A method of coating a substrate comprising coating the substrate with a first coating composition and a second coating composition,
 wherein the first coating composition comprises an alcohol-based binder and an inorganic particulate material   wherein the at least one alcohol-based binder is a polymer comprising a carboniferous backbone having hydroxyl functional groups appended therefrom, and wherein the inorganic particulate material is selected from the group consisting of an alkaline earth metal carbonate, alkaline earth metal sulphate, an aluminosilicate, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, and a combination thereof;   wherein the second coating composition comprising at least one latex binder and a talc,   wherein the latex binder is selected from the group consisting of natural rubber latex, a copolymer comprising of alkene monomers and styrene monomers, polyurethane, polyester, polyethyleneacrylate dispersions, and a combination thereof; and   wherein the first and second coating compositions are layered such that the first coating composition is closer to the substrate than the second coating composition, and the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating; and   wherein the talc and latex binder are present in the second coating in a weight ratio of from about 4:1 to about 1:3.   
     
     
         14 . The method of  claim 13 , wherein the first and second coating compositions are applied sequentially to the substrate. 
     
     
         15 . (canceled) 
     
     
         16 . The substrate according to  claim 1 , wherein the talc and latex binder are present in the second coating in a weight ratio of from about 5:1 to about 1:10. 
     
     
         17 . The substrate according to  claim 1 , wherein the talc in the second coating has a shape factor equal to or greater than about 10. 
     
     
         18 . The substrate according to  claim 1 , wherein the second coating has a coat weight equal to or less than about 30 gsm (g/m 2 ). 
     
     
         19 . The substrate according to  claim 4 , wherein the inorganic particulate material comprises calcium carbonate, magnesium carbonate, dolomite, or gypsum. 
     
     
         20 . The substrate according to  claim 1 , wherein the aluminosilicate comprises hydrous kandite clay, kaolin, halloysite clay, ball clay, or anhydrous (calcined) kandite clay comprising metakaolin, fully calcined kaolin, or mica. 
     
     
         21 . A method of coating a substrate comprising coating the substrate with a first coating composition and a second coating composition, wherein:
 the first coating composition comprising at least one alcohol-based binder and an inorganic particulate material,   wherein the at least one alcohol-based binder is a polymer comprising a carboniferous backbone having hydroxyl functional groups appended therefrom, and wherein the inorganic particulate material is selected from the group consisting of an alkaline earth metal carbonate, alkaline earth metal sulphate, an aluminosilicate, perlite, diatomaceous earth, magnesium hydroxide, aluminum trihydrate, and a combination thereof;   wherein the second coating composition comprising at least one latex binder and a talc,   wherein the at least one latex binder is selected from the group consisting of natural rubber latex, a copolymer comprising of alkene monomers and styrene monomers, polyurethane, polyester, polyethyleneacrylate dispersions, and a combination thereof;   the first and second coating compositions are layered such that the first coating composition is closer to the substrate than the second coating composition, and the first coating is directly in contact with the substrate and the second coating is directly in contact with the first coating; and   the first and second coating compositions are applied sequentially to the substrate; and   wherein the talc and latex binder are present in the second coating in a weight ratio of from about 4:1 to about 1:3.   
     
     
         22 . The method according to  claim 13 , wherein the aluminosilicate comprises hydrous kandite clay, kaolin, halloysite clay, ball clay, anhydrous kandite clay, metakaolin, fully calcined kaolin, or mica. 
     
     
         23 . The method of  claim 21 , wherein the aluminosilicate comprises hydrous kandite clay, kaolin, halloysite clay, ball clay, anhydrous kandite clay, metakaolin, fully calcined kaolin, or mica.