High Performance Copolymer Dispersions for Flexible … · EAA Dispersion History • EAA...
Transcript of High Performance Copolymer Dispersions for Flexible … · EAA Dispersion History • EAA...
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High Performance Copolymer Dispersions for Flexible Packaging
October 17, 2005
Christopher Guy & Norman Seung
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Agenda
• Ethylene Acrylic Acid Dispersion History• Overview of Ethylene Acrylic Acid
Chemistry Used• Versatility of Markets and Applications• Limitations of Traditional EAA Dispersions• New and Future Developments with EAA
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EAA Dispersion History
• EAA Dispersions have been commercially available since the early 80’s
• Features of Traditional EAA dispersions:– High Acrylic Acid Content (20%)– 100% Waterbased– Surfactant-Free– Runs on Conventional Coating Equipment– FDA and BGVV Approvals
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O
OC+
H
HC
H
H
C
H
H
C-
Ethylene Acrylic Acid
H
H
C-
H
H
C-
H
H
C-
H
H
C-
H
C-
H
H
C-
H
H
C-
H
H
C-
H
H
C-
O OHC
H
HC
H
CH
--
Ethylene Acrylic Acid Chemistry
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Polyethylene lamellaecontaining no branching
Polyethylene lamellaecontaining branching
Branching and comonomers interfere with the folding process.
Branching in PE decreases the crystallinity.
Effect of Branching on Crystallinity
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Typical Properties of Ethylene and Acrylic Acid
Ethylene• Water Resistance• Flexibility• Barrier Properties• Chemical Resistance
Acrylic Acid• Adhesion• Low Heat-Seal
Temperature• Toughness• Optics
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Application Requirements
Parameters affecting adhesion• Wettability• Chemical attraction• Flow characteristics of polymer
– Viscosity of aqueous dispersion– Melt-flow of deposited polymer
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Surface Wetting
30354045505560
0 20 40 60 80 100
Temperature (deg. C)
Dyn
e / c
m
10% AA20% AA MI 300w/ defoamer20% AA MI 1300Low Visc.w/IPA
Increasing Coating Temperature Lowers Surface Tension
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Chemical Attraction
Hydrogen Bonding adds: - melt strength- tensile strength- hot tack
Carboxyl Group
C0
0 HC0
0H
--
+ C0
0 H+
-0C0H
-
+
+
Adhesion to polar substrates
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Flow Characteristics
• Shearing stress of the coating can impact the viscosityof EAA dispersions.
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Application Specifics
• Applied via low viscosity coating equipment (gravure, flexo, air knife, meyer rod)
• Dry the dispersion to remove water and fuse polymer• Cool coating to 140°F (60°C) to prevent blocking• Aging is not required - can be extrusion coated
immediately • Typical priming coating weights
– Non-porous films and foil - 0.5 to 1.0 g/m²– Paper - 0.8 to 1.2 g/m²
• Typical lamination coating weight– Least porous substrate - 1.6 to 2.4 g/m²
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Applicator:gravure
flexomeyer rod
Substrate
Aqueous Dispersion of EAA (10-25% non-volatile)
Drying
(60 – 130°C)
Typical Coating of the Substrate0.5 – 2 g/m2
Application Specifics
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Excellent Good Poor(>3lbs/in) (1-3 lbs/in) (<0.5 lbs/in)
Aluminum PE PPSteel EVA PETGlass Nylon PVCPaper CPE EVOHIonomers Copper PCEMAA
180° T-peel test of composite samples
EAA Adhesion Recommendations
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Typical Primers Used
• Polyurethane (one and two parts)• Polyester and polyester urethane• Acrylics (various different types)• Polyvinylidene chloride• Polyethylene imine• Vinyl (copolymer and blends)
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Agenda
• Ethylene Acrylic Acid Dispersion History• Overview of Ethylene Acrylic Acid
Chemistry Used• Versatility of Markets and Applications• Limitations of Traditional EAA Dispersions• New and Future Developments with EAA
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Aqueous inks Metallized Paper Paper saturation
Textile warp sizing Coatings Coated filler
Lamination Flexible packaging Bottle coatings
Paint Fabric coatings Nonwoven binders
Primer / Tie Coat Glass fiber sizing Heat Seal Coatings
Overprint varnishes Can & coil coatings Medical
Possibilities…
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Medical
• Medical Device Packaging– Excellent adhesion to Tyvek®– Forms a clear, flexible and breathable film– Enables gas-sterilization– FDA and BGVV Compliant
• Medical Garments– Melt flow reaches 1,300 g/10 min (190°C)– Binder for multiple layer porous sheets
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Heat Seal Coatings
• Improving line speeds with– Low heat seal temperature, sealing 20-30°C
lower than polyethylene– Excellent hot tack
• Low viscosity coating allows application on traditional coating equipment
• Pattern Applied if Desired• Thinner films than extrusion coatings• FDA and BGVV compliant
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Metallized Paper
• Pre-treatment coating used to prepare base paper to accept metallization
• Improves vaporized aluminum adhesion to paper
• Post-metallizing coating to protect aluminum surface of paper and reduce oxidation
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Paper and Film Lamination
• Used as a tie layer• Adhesion to
– Foil, Paper, LDPE, Nylon • Water, grease and oil resistant• Effective at low coating weights• Applied via conventional coating
equipment
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Agenda
• Ethylene Acrylic Acid Dispersion History• Overview of Ethylene Acrylic Acid
Chemistry Used• Versatility of Markets and Applications• Limitations of Traditional EAA Dispersions• New and Future Developments with EAA
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New Developments
• High Performance Characteristics– Enabling Adhesion to More Substrates – Increasing Bond Strength– Reducing Heat Seal Temperature– Improving Hot Tack– FDA and BGVV Food Compliance
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Enabling Adhesion to More Substrates
• Coating adhesion to:– PP – PET– PVC
• New Developments with Michem®Prime show improved adhesion to a wide range of substrates and can eliminate need for a primer.
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Bond Strength to LDPE
0
50
100
150
200
250
300
350
400
450
100 110 120 130 140 150 160
Temperature (°C)
Bon
d St
reng
th to
LD
PE (g
MP 48525RMP2960MP498345NMP4983R
Improving Bond Strength
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Future Modifications
• Capabilities include modification to:– Water Sensitivity– Heat Seal Temperature– Hot Tack– Foam Control– Rheology Control
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Conclusions• Developments in EAA Dispersion
Chemistry have enabled:– Faster line speeds in flexible packaging with
lower heat seal temperatures– Increased Versatility of Substrate Use with
Improved Adhesion to Broad Range of Substrates
– Improved Bond Strength– Broadened Application Ease of Use– Maintained FDA and BGVV Compliance
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Contact Information:Christopher Guy9080 Shell RoadCincinnati, Ohio 45236513.793.7766 (p)513.793.2504 (f)[email protected]
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