Calcium Carbonate Coating Composition for Binder Reduction
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Solution Overview
Problem
Existing barrier and paper coating compositions require high amounts of binders to achieve desired barrier properties, which is costly and environmentally undesirable, and there is a need for improved compositions that can reduce the binder usage while maintaining or enhancing barrier properties.
Innovation Solution
A composition comprising a blend of calcium carbonate particulate materials with specific particle size distributions (1.7 µm to 2.3 µm, 0.8 µm to 1.2 µm, and 0.1 µm to 0.5 µm) that allows for reduced binder usage by enhancing packing efficiency and barrier properties when used in barrier and paper coating applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high amounts of binder are used in barrier coating compositions, then desired barrier properties are achieved, but cost and environmental impact increase
Solution Approach 1:
The invention changes the particle size distribution parameters of the inorganic particulate material, specifically creating a bimodal distribution with d10 of 0.8-1.2 μm and d90 of 1.7-2.3 μm. This parameter optimization enables reduced binder content while maintaining barrier properties, as the specific particle size range creates more efficient packing and tortuous paths for permeation
Solution Approach 2:
The invention uses composite inorganic particulate materials comprising calcium carbonate with specific surface area of 25-35 m²/g, combined with controlled particle size distribution. This composite approach allows the material to achieve both good dispersion (reducing binder needs) and effective barrier properties simultaneously
2Quantity of substance
If inorganic particulate material is added to reduce binder, then binder amount decreases, but achieving desired barrier properties becomes more difficult
Solution Approach 1:
The invention optimizes multiple parameters of the inorganic particulate material simultaneously: particle size distribution (d10: 0.8-1.2 μm, d90: 1.7-2.3 μm), specific surface area (25-35 m²/g), and particle shape (sphericity 0.6-0.8). These parameter changes enable the material to provide effective barrier properties with reduced binder content by creating optimal packing density and tortuous paths
3Productivity
If inorganic particulate material with specific particle size distribution is used, then packing efficiency improves, but composition complexity increases
Solution Approach 1:
The invention segments the particle size distribution into specific ranges (d10: 0.8-1.2 μm, d90: 1.7-2.3 μm) rather than using a broad or monodisperse distribution. This segmentation creates optimal packing efficiency by preventing both agglomeration (from too fine) and poor filling (from too coarse), while the segmentation itself is achieved through standard industrial milling and classification processes
Solution Approach 2:
The invention changes the particle size distribution parameters to a bimodal pattern with specific d10 and d90 values. This parameter change improves packing efficiency by creating interlocking structures between smaller and larger particles, reducing void spaces. The complexity is managed by specifying narrow ranges rather than complex multi-component systems
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composition achieves improved barrier properties with reduced binder content, enabling more efficient and cost-effective coating solutions while maintaining or improving the performance of barrier and paper coatings.
Implementation Method 1
the inorganic particulate material in said composition has a CPVC point of less than about 29 pph binder and a steepness factor less than or equal to about 28
Data Source
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AI summary
A composition comprising at least one inorganic particulate material such as calcium carbonate, use of a said composition in a barrier coating composition or in a paper coating composition, a method for making said composition, a method for making a paper coating composition and a method for making a coated product.