Characteristics of pigment-filled polymer coatings on paperboard

Adding plate-like pigments such as talc or kaolin clay to a styrene-butadiene (SB) dispersion before coating paperboard on a pilot scale resulted in a coated material with improved water vapour barrier properties. Addition of paraffin wax further significantly reduced the water vapour permeability. A limited study was also performed using poly(vinyl alcohol) (PVA) as the matrix material and a similar result was obtained. In addition to the barrier properties, the surface characteristics (gloss, roughness, surface energy and chemical composition) and the printability of the coated substrate were evaluated. In general, it was found that the properties of the coated material were improved if the surface of the base substrate was smoothened prior to coating by a suitable surface treatment such as hot calendering or precoating. Such a treatment gave a more homogeneous coating film on the substrate. A comparison of the experimental results with the prediction of models for the effect of impermeable particles on the vapour permeability indicated that the pigments were not optimally dispersed (or oriented) in the coating layer. There is thus room for improvement. In a further series of experiments, nanoclays were incorporated into the coating layers. Exfoliation of the silicate layers was indicated in laboratory coating experiments using SB, but not on the pilot-scale coated materials. Thus no significant effects on the barrier properties were observed for such coated specimens. With PVA as the matrix polymer and low contents of the nanoclay, a marked decrease in the water vapour permeability took place, indicating a more pronounced exfoliation.