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Sustainable Barrier SBS Paperboard Coatings Using Co-Polymerized Shape Engineered Pigments" (2006)

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Sustainable Barrier SBS Paperboard Coatings Using Co-Polymerized Shape Engineered Pigments Western Michigan University ScholarWorks at WMU Dissertations Graduate College 12-2006 Sustainable Barrier SBS Paperboard Coatings Using Co- Polymerized Shape Engineered Pigments Lokendra Pal Western Michigan University Follow this and additional works at: https://scholarworks.wmich.edu/dissertations Part of the Engineering Commons Recommended Citation Pal, Lokendra, "Sustainable Barrier SBS Paperboard Coatings Using Co-Polymerized Shape Engineered Pigments" (2006). Dissertations. 975. https://scholarworks.wmich.edu/dissertations/975 This Dissertation-Open Access is brought to you for free and open access by the Graduate College at ScholarWorks at WMU. It has been accepted for inclusion in Dissertations by an authorized administrator of ScholarWorks at WMU. For more information, please contact [email protected]. SUSTAINABLE BARRIER SBS PAPERBOARD COATINGS USING CO-POLYMERIZED SHAPE ENGINEERED PIGMENTS by Lokendra Pal A Dissertation Submitted to the Faculty of The Graduate College in partial fulfillment of the requirements for the Degree of Doctor of Philosophy Department of Paper Engineering, Chemical Engineering and Imaging Dr. Margaret K. Joyce, Advisor Western Michigan University Kalamazoo, Michigan December 2006 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. UMI Number: 3243163 INFORMATION TO USERS The quality of this reproduction is dependent upon the quality of the copy submitted. Broken or indistinct print, colored or poor quality illustrations and photographs, print bleed-through, substandard margins, and improper alignment can adversely affect reproduction. In the unlikely event that the author did not send a complete manuscript and there are missing pages, these will be noted. Also, if unauthorized copyright material had to be removed, a note will indicate the deletion. ® UMI UMI Microform 3243163 Copyright 2007 by ProQuest Information and Learning Company. All rights reserved. This microform edition is protected against unauthorized copying under Title 17, United States Code. ProQuest Information and Learning Company 300 North Zeeb Road P.O. Box 1346 Ann Arbor, Ml 48106-1346 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Copyright by Lokendra Pal 2006 Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. ACKNOWLEDGMENTS I would like to express my gratitude to my graduate advisor, Dr. Margaret K. Joyce, for her worthy assistance, advice, and guidance throughout the dissertation and beyond that. I would also like to thank my committee members Dr. Paul D. Fleming, and Dr David E. Knox, for their advice. The collaboration between the Department of Paper Engineering, Chemical Engineering and Imaging and MeadWestvaco Corporation made this work possible. The financial support from MeadWestvaco during the course of this study is gratefully acknowledged. In addition to this, the company was generous enough to provide access to facilities at Charleston SC and Chillicothe OH. Special thanks to Mr. Charles Ruffner, for his assistance and advice during the course of this study. Special thanks also to Mr. Matthew Stoops, for his support during the coating trials. Many thanks to my friends, colleagues and others who contributed in many different ways. Finally, my deepest gratitude and appreciation to my parents, for their love, support, sacrifice and encouragement needed to bring this dissertation to completion. An expression much greater than “special recognition” goes to my wife, Sapana, and my son, Siddhant, for their endurance and constant encouragement. Lokendra Pal ii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. TABLE OF CONTENTS ACKNOWLEDGMENTS........................................................................................... ii LIST OF TABLES........................................................................................................ viii LIST OF FIGURES...................................................................................................... x CHAPTER I. INTRODUCTION.......................................................................... 1 References ................................................................................................ 7 H. LITERATURE REVIEW.................................................................... 13 Liquid Transport Mechani sms ................................................................ 17 Permeability ..................................................................................... 18 Diffusion ........................................................................................... 19 Capillary Transport .......................................................................... 21 Surface Energy ......................................................................................... 23 Nano-Composite/Structured Coatings ................................................... 26 Conventional and Barrier Coatings ........................................................ 29 The Packing of Particles .......................................................................... 33 The Structure of Paper Coatings ............................................................. 35 MacroPac Simulation Software .............................................................. 37 References ................................................................................................ 38 m. STATEMENT OF THE PROBLEM AND OBJECTIVES............................. 47 IV. EXPERIMENTAL DESIGN................................................................. 49 Materials................................................................................................... 51 iii Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Table of Contents—continued Coating Preparations and Application Methods ................................... 53 Phase I: Conventional Pigment Polymer (CPP) Coatings 53 Phase II: Co-Polymerized (COP) Coatings ................................... 57 Calendering and Conditioning of Samples ................................... 60 Testing and Instruments .................................................................. 60 Appendix .................................................................................................. 64 Particle Size Analysis of Co-Polymerized (COP) Coatings ....... 64 V. SHAPE ENGINEERED PIGMENTS BASED BARRIER COATINGS FOR SBS PAPERBOARD....................................................... 65 Abstract .................................................................................................... 65 Introduction .............................................................................................. 66 The Structure of Clay Minerals....................................................... 68 Effect of Relative Humidity and Temperature on Paperboard Properties .......................................................................................... 70 Experimental Design ............................................................................... 71 Materials........................................................................................... 71 Coating Formulations and Application Methods .......................... 73 Calendering and Conditioning of Samples ................................... 74 Testing ............................................................................................... 74 Results and Discussion ............................................................................ 76 Coatings ............................................................................................ 76 Pigments ............................................................................................ 76 Application Methods ........................................................................ 77 iv Reproduced with permission of the copyright owner. Further reproduction prohibited without permission. Table of Contents—continued Conclusions .............................................................................................. 82 References ................................................................................................ 83 Appendix .................................................................................................. 87 Microphotograph Using Scanning Electron Microscopy (SEM )............................................................................................... 87 VI. HIGH BARRIER SUSTAINABLE CO-POLYMERIZED COATINGS..................................................................................................... 89 Abstract .................................................................................................... 89 Introduction .............................................................................................. 90 Experimental Design ............................................................................... 95 Materials........................................................................................... 95 Coating Formulations and Application Methods .......................... 97 Calendering and Conditioning of Samples ................................... 98 Testing ..............................................................................................
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