LINING MATERIAL, METHOD FOR COATING A MATERIAL FOR PRODUCING A LINING, AND APPARATUS

Abstract: In a method for coating a material and, thus, for producing a lining, there is first (1, 2) applied a dispersion, containing a thermoplastic polymer and an additive, on the surface of a material, i.e. a web (R). The latter is then exposed to a powerful thermal effect in operation (3). This is followed by operations (4, 5) for drying a lining (P) being formed. The invention relates also to the structure of lining (P) as well as to an apparatus for producing said lining (P) by applying the above method.

Description: Lining material, method for coating a material for producing a lining, and apparatus The present invention relates to a lining material. Particularly, but not exclusively, the invention relates to a lining used for coating a plastic or fiber material in a manner that at least one of the surfaces of a sheet-like, film-like or web-like material carries said lining, which has thermoplastic properties and is capable of providing desired tight¬ ness properties. Until now, linings suitable for the above purpose have been primarily produced by the application of two methods. It can be said that the first method is effected by delivering melted polymer through a slit orifice onto the surface of a web-like material. The polymers used in this method are polyoleofines, which have been melted from a granular starting material for delivering it through a slit orifice. The melt polymer stock is delivered in a single layer or in plural layers directly onto a web-like material advancing on a carrier track with temperature in the contact area typically within the range of 120-240°C. It is obvious that this produces a corresponding thermal stress for a material to be coated. A natural consequence of this is that a major thermal stress limits the use of heat-sensitive materials in the applications of this method, although, at least in some applications, it is possible to cool the carrier track i.e. the backing surface. In addition, a method based on the delivery of polymer effected through a slit orifice is typically hampered by problems associated with the adhesion of a coating. For example, when coating cardboard by using PET (polyethylene terephtalate) , suitable raw materials are both scarcely available and their use requires that an apparatus for effecting the method be provided with expensive accessories. One example of the above can be said to be the commercially available Melinar 102 S, which is used by Iggesund and is more expensive than a basic polyester by about 20 %. In addition, an apparatus for applying the method by using the above Melinar 102 S polymer requires a specially designed extruder provided with a screw mechanism required by polyethylene terephtalate, as well as a pressure- equalizing pump. There is further required a separate cardboard pretreatment mechanism, which is fitted with heating and ozonation units, the latter explicitly for oxidation. Another drawback in the method is that, if the desired end product includes hot-sealing linings, the adhesion can only be achieved by applying ap¬ propriate primers on top of the polyethylene tere¬ phtalate layer or oriented polyethylene terephtalate layer (PET or OPET) serving as a basic coating, which primers must be applied prior to the application of a top-layer coating in a separate preceding process stage. The hot-sealing properties for a lining can be produced e.g. by means of LDPE (low density polyethy¬ lene) . Furthermore, when using a method based on slit orifice technology, there will be drawbacks especially when applying a coating on porous materials. The fact is, namely, that the melt polymer stock to be applied on the surface of a porous material easily develops pinholes and, thus, this method cannot be used to control the tightness properties of a lining. In order to overcome this drawback and especially in view of producing a smooth lining, e.g. for preventing the penetration of fat, a method based on slit orifice technology generally requires an increase in the thickness of a coating (essentially a polymer layer) to be applied. This is naturally something that increases the consumption of polymer and thus the price of an end product. Thick linings create a problem in terms of recycling and generally also require, in the processing of recycled stock, especially in the 5 de-inking process, pulper mechanisms designed especial¬ ly for this purpose. t% On the other hand, the use of pigments and fillers in a method based on slit orifice technology is limited 10 by the fact that the above materials will be subjected to thermal and compression stress in a compounding step effected in the slit orifice, whereby the gases released especially from fillers are extremely likely to ruin the properties of an end product as far as 15 tightness is concerned. Another prior art method associated with the production of a lining according to the invention for coating materials in view of creating a lining is a so-called 20 varnishing method, wherein the application of varnish is effected by using various printing processes. Typical varnish coatings have included a PVdC water dispersion (polyvinylidene chloride) and NC (nitrogen cellulose) . The application of varnish coating agents 25 has been effected either in a gravure printing unit or by using a separate varnishing machine. The linings can be provided with a better gas tightness by using a PVCD-based varnish coating but the equipment using the varnishing technique is expensive and, hence, its 30 application has been limited to the use of just a few manufacturers. Especially when the material to be coated is cardboard, the varnishing technique has been capable of producing primarily aesthetic changes, particularly gloss and mar resistance in regard to 35 printing inks as well as protection against yellowing. In practice, pigments and fillers are not used in the varnishing technique. However, the varnishing tech¬ nique may involve the use of additives required by itself as well as additives possibly intended for conditioning optical qualities. An object of the present invention is to introduce a lining material, which is capable of eliminating as thoroughly as possible the drawbacks found in the prior art linings and which facilitates a diversified selection of the properties for the lining according to the intended application of a relevant material, upon which the lining will be applied. In order to achieve this object, a lining material of the invention is primarily characterized by consisting of at least one thermoplastic polymer, which is not cross-bridged when dispersed with water, and of an additive, which has at least one particulate material selected on the basis of covering properties and which can be brought into the form of a water dispersion. Furthermore, one preferred embodiment of a lining material is characterized in that, in regard to a dry matter and in percent by weight, it consists essential¬ ly by 65-85 % of a thermoplastic polymer and by 15- 35 % of an additive, and that at least ten percent by weight of a dry matter in said additive comprises particles with covering properties, having an equiva¬ lent diameter of less than ten μm and more than two μm and that the particles are selected in such a manner that at least 95 percent thereof are capable of fulfilling the condition: ratio X/Y is more than 5, preferably more than 8, said ratio X/Y relating to the ratio between the largest and the smallest dimension of a particle included in a particular group. In this invention, the term additive is used in reference to the following combination of partial components, which at least in most practical app¬ lications has the following composition: a) at least one covering (developing so-called barrier properties) partial component, such as talc or a mixture of talc and silica, b) at least one possible inert partial component, such as a filler and/or titanium oxide (whiteness, opacity) , and c) at least one possible partial adjunct component, particularly for bearing an effect on the processing properties of a coating used in the production of a lining material. Other preferred characterizing features of a lining material of the invention are set forth in appended non-independent claims. Another object of the present invention is to introduce a novel type of method for coating a material in view of producing a lining, said method being capable of eliminating as thoroughly as possible the drawbacks found in the prior art and, thus, of raising the current state of art as well as of producing a lining material of the invention on the surface of a material. In order to achieve this object, a method of the invention is primarily characterized by comprising the following operations: producing a dispersion, whose components include A) water, B) at least one thermoplastic polymer material and C) a particulate additive, consisting of at least one material having covering proper- ties, - applying the dispersion on the material surface as a layer, - subjecting the dispersion layer to a sudden thermal effect in view of bringing about the bonding, preferably cross-bridging at least partially, of at least one thermoplastic polymer material con- tained in the layer still at least partially in the form of a dispersion, whereby said additive consisting at least partially of a particulate material is at least partially linked with the bonding, preferably cross-bridging polymer layer, and - drying said layer at least partially in the form of a dispersion for removing the aqueous component essentially at a temperature that is preferably lower than the bonding temperature of said thermo¬ plastic polymer material. The above-described method, by using a dispersion comprising at least one thermoplastic polymer material and at least a partially particulate additive con¬ sisting of at least one material and by selecting the materials used in the dispersion, can be capable of producing desired lining properties, especially by controlling the process operations, as described in more detail hereinafter. A particularly significant advantage gained by the method is that, having been applied on a material surface as a layer, the disper¬ sion is subjected to a sudden thermal effect in a manner that the quick thermal energy applied to the layer does not exert thermal stress on the actual material to be coated, which is protected by the dispersion, whereby a temperature resulting in the bonding, preferably cross-bridging, of at least one thermoplastic polymer material can be reached in the polymer material, concentrating on the surface of the dispersion and including a particulate, covering additive. Between the above-mentioned developing layer and the material there is a dispersion layer protecting the material against the harmful effects caused by the excessive rise of temperature. This layer can be removed from the coating at a lower temperature prevailing in a separate drying unit, e.g. by the application of normal evaporation. According to another preferred embodiment for a method of the invention, the dispersion is formulated so as to contain in percent by weight: A) water 30-65 % B) at least one thermoplastic polymer 25-60 %, and C) an additive 10-65 % This solution offers the advantage that, by selecting the dispersion components (as percent by weight in dispersion) within the above percentage range, it is possible to obtain in substantially all practical situations the desired and controlled lining properties by controlling the process operations as required by a particular lining. It should be obvious to a person skilled in the art that the applied process quantities must be found out by practical test arrangements. It is obvious that each one of the components can already be in the form of a water dispersion in the dispersion formulating step. Another embodiment for a method of the invention is characterized in that the additive has a composition with at least ten percent by weight thereof comprising particles, having an equivalent diameter of less than ten μm and more than two μm, said particles being selected in a manner that at least 95 % thereof are capable of fulfilling the condition: ratio X/Y is more than 5, preferably more than 8, said ratio X/Y relating to the ratio between the largest and the smallest dimension of a particle included in this particular group. The above-described additive can be used to produce a lining, having very good covering properties and providing desired barrier qualities, said lining being produced at the time said bonding, preferably cross-bridging thermoplastic polymer experiences its bonding, preferably cross-bridging effect. In this context, the equivalent diameter refers to the diameter of such a sphere which has corresponding sedimentation properties (sedigraph test) . In general, the additive can be defined more accurately as follows: a) at least 10 % by weight of the additive comprises a covering partial component (e.g. talc, whose particles have an equivalent diameter of 2 < φ < 10 μm and by 95 percent fulfil the condition X/Y > (5) 8) , the range of variation being 10-98 %, preferably 40-80 %, b) an inert partial component comprises 0-85 %, prefe¬ rably 20-40 % by weight of the additive, and c) a partial adjunct component comprises 0-5 %, prefe¬ rably 2-5 % of the additive. According to one preferred embodiment for a method of the invention, thethermoplastic cross-bridgingpolymer material comprises polymer or a copolymer compound (PVdC) , polyurethane (PU) , polyester (PET) and/or polystyrene (PS) of acryl (PMMA) and/or vinyl (PVC) . The above-listed exemplary polymer materials, either alone or as a combination of two or more polymers, are preferred in view of carrying out the invention, especially on the basis of their cross-bridging properties. In general, it can be concluded that the relevant thermoplastic polymers are selected on the basis of the hardness, tightness and jointing proper¬ ties of a lining for optimizing said combination of qualities so as to suit the intended application. Still, according to another preferred embodiment for a method of the invention, the application of a dispersion is effected in two operations in a manner that - the first operation comprises a so-called roll application step or a like, wherein the dispersion is placed in a container for delivering it there¬ from directly or indirectly by way of at least one roll unit or a like to at least one surface of a material, and the second operation comprises the final smoothing step of a dispersion layer effected by means of jet-like blowing of a fluidized medium, especially a gaseous medium. The above-described process-technical operation can be used to make sure that the dispersion is uniformly spread or applied on a material surface, so that there is a sufficient layer of the dispersion for the following operations included in the method. Further¬ more, by adjusting the equipment for carrying out the first and/or the second operation it is possible to manipulate the thickness of a dispersion layer for controlling the process. In this context, the fluidized medium refers especially to a gaseous medium, such as air, set in a kinetic state. Furthermore, according to a preferred embodiment for a method associated with the application of a disper¬ sion, the rotating direction of a roll unit or a like spreading the dispersion on at least one surface of a material in the first operation is selected to be opposite with respect to the material advancing direction at said roll unit or the like. The above-described process-technical operation can be used in the first operation to effect a so-called roll application step or a like in a manner that the roll unit or a like for transferring the dispersion onto a material surface delivers the dispersion over a relatively long contact area between the outer surface of a roll unit or a like and the material surface, wherein the dispersion essentially produces between said outer surface of a roll unit and said material surface a film layer which is advanced to the second operation for final smoothing and, in many cases, also for thinning the dispersion film layer. In a particularly preferred case, especially when applying the method for lining or coating a continuous web-like material, such as a plastic- or fiber-based material, the first spreading stap of a dispersion is effected by having the dispersion on the bottom surface of a moving web. Thus, according to one preferred embodiment, the first step or operation is located lower in vertical direction than the second operation. This is especially beneficial whenever the dispersion has high viscosity properties. According to another preferred embodiment of the method, the sudden increase of temperature is effected in a manner that, after the spreading step, preferably after one second, the dispersion layer has a surface temperature of at least 100°C. The above-described operation can be used to achieve the bonding, preferably cross-bridging of a thermo- plastic polymer material. The appended claims also disclose a few other preferred embodiments for a method of the invention. The invention relates also to an apparatus for coating a material in view of producing a lining. The ap¬ paratus is primarily characterized by comprising: 5 - first and second elements for the application of a (* dispersion onto the surface of a material in two operations, 10 - means for raising the dispersion temperature abruptly, and elements for drying the dispersion in view of produ¬ cing a lining. 15 The above solution is capable of providing a preferred apparatus for carrying out the method and, thus, for producing a lining material on the surface of a material. 20 The appended non-independent claims directed to an apparatus disclose a few preferred embodiments for the apparatus. 25 A method, an apparatus and a lining material of the invention will now be described in more detail with reference made to the accompanying drawings, in which fig. 1 is a schematic side view showing one 30 embodiment for an apparatus to carry out a method of the invention, fig. 2 is a schematic side view showing par¬ ticularly the application step of a coating 35 having a high viscosity, and fig. 3 is a schematic view in association with reference numerals I-V in fig. 1, showing sequentially the progressive development of a lining by applying the method. The apparatus shown in fig. 1 for carrying out the method is adapted to effect continuous lining or coating of an advancing, web-like, plastic- or fiber- based material R (hereinafter a web) and includes as a first element (not shown in fig. 1) an unrolling station, from which a web R stored in the form of a roll is carried to an application unit 1 included in the first operation. The unrolling station is provided with edge guiding and web tension control devices according to normal technology. The first-stage application unit 1 includes a container la, which contains a dispersion associated with a method of the invention and which is continuously replenished while the method progresses as a continuous process. In addition, the application unit 1 includes a roll or cylinder unit lb, having a width at least substantially equal to that of the web and adapted to rotate around an axis transverse to the web advancing direction in a manner that its rotating direction within a contact zone S between web R and cylinder unit lb is opposite relative to the advancing direction (arrow S) of web R. The cylinder unit lb effecting the first-stage roll application is in a continuous contact with the dispersion carrying the latter upon its outer surface towards web R to be coated, whereupon the dispersion is spread or applied as the web R comes into contact with the first-stage cylinder unit lb over a contact zone shaped as a sector in register with the top surface, said contact zone being indicated in fig. 1 by an arrow S. Thus, a dispersion layer DK developing between web R and cylinder unit lb within contact zone S proceeds along with web R to an app¬ lication unit 2, included in the second stage or operation of dispersion spreading and comprising a cylinder 2b or a like, adapted to be transversely rotatable relative to the web advancing direction (arrows KS) and around which said web R is directed in a manner that the dispersion applied to its surface lies on the outer web surface while the inner surface of web R lies against said cylinder 2b or a like. In register with and outside cylinder 2b or a like there is arranged at least one supply means 2a for a fluidi¬ zed medium, positioned in transverse direction over the entire width of web R the same way as cylinder 2b or a like. The fluidized medium supply means or, in case the fluidized gaseous medium comprises air, a so-called air brush effects the smoothing and/or thinning of the dispersion layer. As shown especially in fig. 1, the first-stage appli- cation unit 1 is located in vertical direction at a substantially lower level than the second-stage application unit 2 whereby, in a first stage or operation, said web R along with a dispersion layer DK carried thereby has a upwardly inclined passage from first to second operation. Following the second-stage application unit 2, said web R together with its applied dispersion layer DK travels to a following process operation along a substantially horizontal passage, said web R arriving immediately in the vicinity of at least one heating unit 3 next in the traveling direction KS, whereby the dispersion layer DK is facing towards said heating unit 3. The heating unit 3 is mounted transversely in the traveling direction KS of web R to extend across the entire width of the web. In a particularly prefer¬ red case, the heating unit 3 comprises a heating unit using infrared radiation as an energy source. This heating unit 3 can be used for subjecting the disper¬ sion layer DK to extremely rapid heating which, according to the method, results in the bonding, preferably cross-bridging of at least one thermoplastic polymer while the temperature of dispersion layer DK, especially its surface temperature, is rising very rapidly, preferably as quickly as in one second (naturally depending on the web traveling speed and the output and location of unit 3) , to a temperature range required by the bonding of a thermoplastic material. Hence, an additive included in the dispersion shall also be at least partially bound or set within the bonding, preferably cross-bridging thermoplastic polymer. Since the rapid heating effect is focused and only has time to focus essentially on that surface of dispersion layer DK facing towards heating unit 3 just for as long as it takes to achieve the bonding, preferably cross-bridging of at least one polymer material, the bottom side of the dispersion layer, i.e. the side closer to web R, shall remain as a so- called protective layer for preventing a substantial temperature increase. This provides the significant advantage that the method can also be applied to materials which, as such, are not capable of tolerating temperatures required for the bonding, preferably cross-bridging of a thermoplastic material. The heating output applied to the dispersion layer is 0.7 /g ± 15 % (watts/gram of dispersion) . Following the rapid heating operation effected by means of heating unit 3 is a drying operation 4 which possibly employs drying air, which is blown by at least one fan 5 and is dried so as to bind water vapour, as well as an array of heating units 4a, preferably adapted to operate on infrared radiation energy, but most preferably in a manner that the output thereof is substantially lower than the heating output of heating unit 3. Furthermore, the final step downstream of heating and drying operation 3, 4 in the process is a dry cooling operation 6, wherein the surface and thermoplastic properties of a dispersion layer, which has already substantially transformed into a lining, are finished by dry blowing only using at least one fan 7. Thereafter, the product can still be cooled by per se known cooling methods to a suitable temperature, followed by winding or sheeting by using conventional equipment known to a skilled person. The operations 3, 4 and indeed 6 are carried out by using enclosed assemblies 8 and 9, having an open bottom facing towards dispersion layer DK and the lining, at least partially developed by now. Fig. 2 illustrates schematically the spreading opera¬ tion of dispersion layer DK at second application unit 2 whenever the dispersion layer consists of a high-viscosity material. As shown in the figure, web R is substantially vertical upon arriving in second- stage application unit 2. The dispersion layer DK is substantially thicker (up to 3-6 times thicker) between first-stage application unit 1 and second-stage application unit 2 than downstream of the second- stage application unit. Since the dispersion consists of a high-viscosity material (within the range of 11- 24 s, preferably about 15 as measured by measuring device DIN CUP 4) , between application units 1 and 2 develops a thick layer contributing to the spreading of dispersion DK and to its penetration into web R with no weeping occurring therefrom. Fig. 3 illustrates schematically the various operations included in the method. Fig. 1 includes Roman numerals I-V for illustrating the development of a coating or dispersion layer DK into a lining P throughout the various process operations, the dry matter content of dispersion layer DK and/or lining P in operations I-V being as follows: Operation I/II 40 - 65 %, preferably 45 - 55 % III 55 - 85 %, preferably 60 - 80 % IV 70 - 95 %, preferably 85 - 90 % V 85 - 100 %, preferably 90 - 98 % The invention and its operability are explained in the following working examples: THE OPERATING APPARATUS Experiments were conducted for the operability of the invention by designing a test apparatus for carrying out operations I-V (fig. 3) . The web advancing speed in tests was 40 m/min. The formation capacity of a lining was 15 g/m 2 . The web length required for this was 15 i. In practice, the apparatus was set up by using a multi-layer tunnel design. The apparatus had a total length of appr. 9 - 10 m, excluding the space required by unwinding and winding rollers. Λ Cylinder 1 b (fig. 1) was a rubber-coated soft cylinder φ 200-300 mm. Cylinder 2 b (fig. 1) was a hard rubber-coated cylinder (cardboard) and a ceramic cylinder (films) φ 100- 250 mm. The consumption of energy for working a coating into a lining in the test apparatus resulted as follows: Heating (operation III) 0.01 K /m 2 /15 g/m 2 of lining Drying (operation IV) 0.002 K /m 2 Fresh air cooling (operation IV) 0.005 KW/m 2 Dry cooling (operation V) 0.001 KW/m 2 EXAMPLE 1 The object in this example was to make a coated folding cardboard backing, whose properties were to include fat tightness in view of using the coated folding cardboard backing particularly in bakery and processed food industry. Thus, the total amount of lining was 15 g/m 2 and the quadratic weight of folding cardboard was 275 g/m 2 . The employed polymer component was a polymer and copolymer combination of acryl and vinyl as follows: Table 1: (polymers) Latex A: PVC (polyvinyl chloride) PVdC (polyvinyldene chloride) PMMA (polymethyl metacrylate) Latex B: PVC (polyvinyl chloride) PVdC (polyvinyldene chloride) PMMA (polymethyl metacrylate) Furthermore, the employed additive component included two recipes according to table 2. Table 1 also dis¬ closes latexes A and B. Table 2: Recipes used in the example Penetration properties are produced by the combined effect of the selection of talc and the polymer combination. The particles of talc (the talc used in the example was modified from a talc variety sold by Norwegian Talc under the trade name Microtalc ATI) have such a size distribution that at least eighty percent of all particles have an equivalent diameter less than 10 μm and in eighty percent it is more than 2 μm. In addi¬ tion, at least 95 % of the talc particles are capable of fulfilling the condition L/h is more than 10. The ratio L/h refers to the ratio between the largest and smallest dimension of a particle. Tightness is obtained by setting the flat particles by means of a binder in an overlapping pattern and in superimposed layers. In view of setting the particles in a correct pattern, it is possible to employ pigment additives, having a low L/h ratio, e.g. silica (the type of silica used in table 2, example 2) . The coating of a folding cardboard web was effected according to the example with additives disclosed both in example 1 and in example 2 by using the polymer and copolymer combinations of acryl and vinyl in the same way as shown in table 1. The resulting products had the following qualities as compared to basic cardboard. Table 3: Comparison of qualities Specification: COPP = moisture resistance test (absorption test) used by board and paper making industry. MVTR = water vapour penetration test according to standard ASTM E96. It should be noted that the amount of dispersion was at the commencement of coating (wet) 25 g/m 2 . The lined folding cardboard described in example 1 had a dry matter content of 61 % and that of example 2 had a dry matter content of 59 %. If an increase in the penetration of water vapour is desired, the talc component can be replaced by silica or some other filler having the X/Y ratio on 90 % of the particles lower than 10 (5-8) . In particular, the optimization of tightness can be effected by using a double lining, whereby one and the same web is run e.g. twice successively through the process operations of the invention. The thickness of dispersion at the initial stage of coating (wet) can be typically within the range of 2 μm - 25 μm. Furthermore, the following discloses an experimental result (with the recipe shown in example of table 2) as to how an increase of the dispersion surface temperature influences the water vapour penetration of a lining (MTVR value) . The table refers to mea¬ suring the surface temperature at the outermost boundary surface of a coating one second after the application of a dispersion layer. Thus, a heater (heating unit 3, fig. 1) has already by this time applied the heating effect to a dispersion layer. Table 4: The effect of surface temperature on the water vapour penetration of a coating The table clearly shows the effect of temperature on tightness. It is based on the adjustment of a closed film thickness effected at the dispersion surface. EXAMPLE 3 Particularly in commercial applications, the recipes of table 2 can yet be replenished by the addition of fillers and dyestuffs even in amounts exceeding the dry matter amounts of a covering partial component (talc or talc/silica) included in the recipes of table 2. The following discloses a few optional trade names, which were tested in test apparatus runs with the recipes of example 1. Table 5: Inert partial components included in additive Filler (Inert material) BlancFixe Micro - manufactured by Sachtleben Micro Mica WT - manufactured by Norwegian Talc Titanium oxide (whiteness, opacity) Tioxide RCR 2 - manufactured by Tioxide Group Hombitan 710 - manufactured by Sachtleben These fillers and dyestuffs did not have an essential significance in terms of achieving covering as well as other desired basic qualities of the invention. On the other hand, they were capable of achieving savings in the manufacturing costs of a lining as well as proper¬ ties having a favourable effect on the appearance of a lining. The partial component of an inert additive can also be composed of dyestuffs other than white, if the lining is to be used for producing a coloured coating. The partial component can also be composed of reflective pigments, such as those reflective within the UV, IR and visible light range e.g. for microwave applications, wherein a magnetron-generated microwave field is intensified and/or directed from the boundary surface of a coating. EXAMPLE 4 The additive may contain adjunct components set forth in the following list for producing and adjusting various properties (the total amount of dry matter in weight percent max. 5 %, varying within the range of 0-5 %, preferably 2-5 %) . These were also tested in the test apparatus e.g. in amounts shown in the recipes of example 1. Table 6: Adjunct components included in additive pH regulator Ammonia, sodium hydroxide (used in the recipes of table 1) Viscosity Aerosil 200, 300 - manufactured by Degussa TEXIPOL 63-002 - manufactured by Scott Bader Versacryl AT 55 - manufactured by Allied Colloids Antiblock (anti-adhesive) Slipaid SL 417 - manufactured by Daniel Products KPS Wax - manufactured by Hoechst Moistening (surface activity) Aerosol MA 80 - manufactured by Cyanamid (used in the recipe of table 2) Dapro W77 - manufactured by Daniel Products Anti-foaming Bevaloid 642 - manufactured by Bevaloid Foamaster H 2 - manufactured by Diamond Shamrock Dispersabilitv properties BYK 155 - manufactured by BYK Chemie (used in the recipes of table 2) Nopcosant K - manufactured by Diamond Shamrock Skilled persons can use the above list on the basis of their knowledge of the art to select partial adjunct components bearing an effect on the desired properties, especially the processing properties in any given application. EXAMPLE 5 The method was tested with various polymer combinations for producing linings that are preferred in terms of of binding a covering additive component as well as in terms of other properties, such as hot-sealing. Table 7: Alternatives for thermoplastic polymer EXAMPLE 6 100 % PMMA - tested NeoCryl BT 48, manufacture of ICI EXAMPLE 7 100 % PVdC - tested Diofan 960, manufacture of BASF EXAMPLE 8 75 % PMMA/PS (aery1-styrene copolymer) - BT 44, manufacture of ICI and 25 % PU (polyurethane) - R 560, manufacture of ICI EXAMPLE 9 50 % PVC/PVcD/PMMA (acryl-vinyl copolymer) - Haloflex DP 402, manufacture of ICI and 50 % PVdC - Diofan 601 EXAMPLE 10 100 % PU (polyurethane) Neotac A 570, manufacture of ICI. All the above polymers and polymer combinations have been used in the test apparatus for coating tests with varying amounts of additive and the results essentially matched those obtained in examples 1 and 2. Thus, the thermoplastic polymers of the invention are characterized by not cross-bridging in a water disper¬ sion but appearing there in ionic form. The bonding of a thermoplastic polymer cannot be achieved until after removing the aqueous phase and reaching a temperature facilitating the cross-bridging. According to the invention, this occurs in a controlled fashion resulting in the form of a film or a membrane. The selected .properties of a lining material can be affected by the selection of both materials and process conditions. One further application for the lining material can be said to be a laminate structure, comprising a first layer of a web material and a lining layer on the inner surface thereof, and a second layer on top of the lining layer, preferably made of a web material and possibly provided with a lining layer of the invention. The lining layer/layers, laid between said first and second layers, can be provided with an adhesive or the bonding of a laminate structure can be effected e.g. by hot-nip pressing, whereby the water has not been completely removed from at least one lining layer serving as an adhesive material. For certain applications the first and/or second layer can be provided with a moisture barrier coating. A particularly preferred embodiment for the above laminate solution is such that the first and the second layer are made of a cellulose-based material, such as paper, cardboard or the like, for producing a redusable, especially pulpable product, which is provided with a moisture barrier and suitable e.g. for food wrappings. When conventional paper has an MVTR value of appr. 1600 g, a laminate solution as described above is capable of providing MVTR values of 3-10 while retaining the paper feel and also its recycling possibility. The production of laminate can be combined e.g. with the apparatus of fig. 1 down- stream thereof or the lamination can be carried out as a separate operation.

Claims: Claims : 1. A lining material, characterized in that, as for the dry matter and in percent by weight, 65-85% thereof comprises a thermoplastic polymer which, when dispersed in water, does not cross-bridge, 15-35% comprises an additive which has at least one particulate material selected on the basis of covering properties and which can be brought into the form of an aqueous dispersion, and that said additive contains at least one inert partial component, especially for obtaining filler and/or bleaching properties, the amount of said inert partial component of the entire amount of additive in weight percent being 1-85%, preferably 20- 40%. 2. A lining material as set forth in claim 1, characterized, in that it comprises a thermoplastic polymer and an additive, that at least ten percent by weight of the dry matter in said additive comprises particles, having covering properties and an equivalent diameter smaller than ten μm and larger than two μm, and that the particles are selected in a manner that at least 95% thereof are capable of fulfilling the condition: ratio X/Y is higher than 5, preferably higher than 8, the ratio X/Y referring to the ratio between the largest and smallest dimension of a particle included in a particle group. 3. A lining material as set forth in claim 1, characterized in that the thermoplastic cross-bridging polymer material comprises a polymer or a copolymer combination (PVdC) of acryl (PMMA) and/or vinyl (PVC) , polyurethane (PU) , polyester (PET) and/or polystyrene (PS). 4. A lining material as set forth in claim 1 or 2, characterized in that the additive particles having covering properties and contributing to tightness consist of talc or a mixture of talc and silica. 5. A lining material as set forth in claim 1 or 2, characterized in that, in weight percent, the amount of a covering partial component used in the additive is 10-98% of the total amount of additive, preferably 40-80%. 6. A lining material as set forth in claim 1 or 2, characterized in that the additive contains at least one adjunct component for bearing effect on the processing properties of a coating in view of building up the lining, the amount of said adjunct component in weight percent of the total amount of additive being 0-5%, preferably 2-5%. 7. A lining material as set forth in any of claims 1-6, characterized in that said lining material is laid between two layers, one of which is a material, such as a web or a like, for building the lining material thereon, said layers preferably consisting of a cellulose-based material. 8. A method for coating a material in view of producing a lining, characterized by the following operations: - producing a dispersion with the following compodnents a) water b) at least one thermoplastic polymer material, and c) a particulate additive, consisting of at least one material having covering properties, applying (1, 2) the dispersion on the material surface as a layer, - subjecting the dispersion layer (DK) to an abrupt thermal effect (3) in order to achieve at least partial bonding, preferably cross-bridging of at least one thermoplastic polymer contained in the layer which is still at least partially in the form of a dispersion, whereby said additive consist¬ ing at least partially of a particulate material is linked with said at least partially bonding, preferably cross-bridging polymer layer, and - drying said layer still at least partially in the form of a dispersion for removing the aqueous component essentially at a temperature which is preferably lower than the bonding temperature of said thermoplastic material. 9. A method as set forth in claim 8, characterized in that the dispersion is formulated to contain in weight percent a) water 30-65% b) at least one thermoplastic cross-bridging polymer 25-60% c) an additive 10-65%. 10. A method as set forth in claim 8, characterized. in that the additive is formulated in a manner that at least ten percent by weight thereof comprises par- tides having an equivalent diameter smaller than ten μm and larger than two μm, and that the particles are selected in a manner that at least 95 percent thereof are capable of fulfilling the condition: ratio X/Y is higher than 5, preferably higher than 8, the ratio X/Y referring to the ratio between the largest and smallest dimension of a particle included in a par¬ ticular group. 11. A method as set forth in claim 8, characterized in that the particles with covering properties consist of talc or a mixture of talc and silica, and/or that the thermoplastic cross-bridging polymer material comprises a polymer or copolymer combination (PVdC) of acryl (PMMA) and/or vinyl (PVC) , polyurethane (PU) , polyester (PET) and/or polystyrene (PS) . 12. A method as set forth in claim 8, characterized in that - the application of a dispersion is effected espe¬ cially in order to adjust an accurate layer thick¬ ness and to seal the porosity possibly occurring in the material for providing a desired barrier effect in two operations as follows - a first operation (1) involves a so-called cylinder application or the like, the dispersion being held in a container for delivering it therefrom directly or indirectly by way of a cylinder unit or a like onto at least one surface of a material, and a second operation (2) involves essentially a final smoothing step of the dispersion layer effected by using the jet-like or similar blowing of a fluidized medium, especially a gaseous medium. 13. A method as set forth in claim 12, characterized in that, in the first operation, the rotating direction of a cylinder unit (lb) or a like is selected to be opposite relative to the advancing direction of a material at said cylinder unit (lb) or the like. 14. A method as set forth in claim 12, characterized in that said first operation (1) is located in vertical direction lower than the second operation (2) . 15. A method as set forth in claim 12 or 14, charac¬ terized, in that the application of second operation (2) is preferably effected at a cylinder unit (2b) reversing the direction of a material, such as a web (R) , to be lined, followed by advancing the dispersion layer preferably in horizontal direction to a heating unit (3) . 16. A method as set forth in claim 8, characterized by effecting an abrupt temperature rise in a manner that, one second after the applying or spreading operation (1, 2) , the surface temperature of dispersion layer (DK) is at least 100°C. 17. A method as set forth in claim 8, characterized in that - in a first drying operation (4) the lining (P) being formed is subjected to both heat and dry air blowing, and - a second drying operation (6) comprises dry air blowing. 18. A method as set forth in any of claims 8-16, characterized in that on top of said lining (P) is laid another material for producing a laminate structure, wherein said lining (P) is positioned between two preferably cellulose-based material layers. 19. An apparatus for coating a material and, hence, for producing a lining, characterized in that the apparatus comprises: - first and second elements (1, 2) for applying a dispersion on the surface of a material in two operations, elements (3) for raising the dispersion temperature abruptly, and - elements (4, 6) for drying the dispersion in order to form a lining (P) . 20. An apparatus as set forth in claim 19, charac¬ terized in that, in order to carry out the application of a dispersion in two operations, the apparatus comprises - a first-stage applicator unit (1) , a so-called cylinder application unit or a like, the disper¬ sion being held in a container for delivering it therefrom directly or indirectly by way of a cylinder unit or a like onto at least one surface of a material, and - a second-stage applicator unit (2) for directing the jet-shaped or a like blow of a fluidized medium, especially a gaseous medium, to the dispersion Λ layer essentially for achieving its final smooth¬ ing operation. 21. An apparatus as set forth in claim 19 or 20, characterized in that said first-stage applicator unit (1) is positioned in vertical direction at a lower level than said second-stage applicator unit (2) , said web (R) being adapted to travel between operations (1, 2) in substantially vertical direction. 22. An apparatus as set forth in claim 19, charac¬ terized in that said elements (3) for abruptly raising the dispersion temperature include at least one device emitting energy in the form of radiation, especially infrared energy, the power level of said device, with the dispersion within the range of action of elements (3) , being selected in a manner that the temperature at the exposed surface of dispersion layer (DK) (surface temperature) rises within one second to at least 100°C, whereby water evaporates from the disper¬ sion within said range of action of elements (3) , as calculated in percent by weight, 15-25% of the total amount of dispersion layer (DK) . 23. An apparatus as set forth in claim 19, charac¬ terized in that the dispersion drying operation includes at least two steps and, thus, the apparatus comprises - first elements (4) for applying both heat and dry air blowing to said lining (P) being formed, and - second elements (6) for applying dry air blowing to the lining being formed, whereby - the dry matter content of lining (P) downstream of said second elements (6) is 85-100%, preferably 90-98%.

Inventors: REPO HARRI, REPO, HARRI
Applicants: FLEXPAP OY
Application year: 1992
Main classification: B05C3
IPC codes: D21H19, D21H23, D21H25