Patent ID: 8889228

Claim:
A method for extrusion coating a substrate, the method comprising applying an extrusion coating composition to a surface of the substrate by extrusion coating, whereby the extrusion coating composition contacts a chill roll surface, the extrusion coating composition consisting essentially of: (a) one or more ethylene-based polymers selected from the group consisting of polyethylene homopolymers and polyethylene copolymers prepared from only two different monomers, the ethylene-based polymers having a density no greater than 0.940 g/cc; and (b) an inorganic particulate material having an average particle size of no greater than 1.5 μm and a particle loading of at least 25 weight percent, based on the total weight of the polyolefin and inorganic particulate material in the coating composition, wherein the extrusion coating composition is characterized in that it reduces the extrusion coating noise level at the chill roll release point by at least 3 dB relative to an identical extrusion coating process conducted with the same extrusion coating composition absent the inorganic particulate material, wherein the noise level at the chill release point is measured using a chrome-plated gloss chill roll with a surface roughness of 0.5 μm at an extrudate temperature of 320° C. and an air gap of 250 mm for an extrusion coating of 25 g/m 2 applied at a line speed of 300 mpm or an extrusion coating of 12 g/m 2 applied at a line speed of 500 mpm.