Abstract
Adding pigments into waterborne barrier coatings improves barrier properties and cost-effectiveness but increases the risk of crack formation during folding. Crack formation is affected by pigment shape, aspect ratio, and concentration; however, the exact mechanism for these effects is still not well understood. In this work, a systematic model was used to understand the influence of the paper and coating thickness, the latex and pigment modulus, the pigment shape and aspect ratio, and pigment concentration on the failure of waterborne barrier coatings during folding. A finite element method-based model was solved with a commercial package to simulate the folding process. These simulations were compared to experimental results to verify the key parameters that affect coating failure. High paper and coating thickness, pigment loadings, pigment aspect ratios, and modulus differences between latex and pigment increased the likelihood of failure. Experiments and models using lower modulus spherical plastic pigments were more difficult to fail than coatings made with higher modulus kaolin. The maximum strain for coatings bent to a set curvature was the smallest when the modulus of latex and pigment were similar. The model agreed closely with experimental results for two pigment types at various pigment loadings.
Similar content being viewed by others
References
Siracusa, V, Rocculi, P, Romani, S, Dalla Rosa, M, “Biodegradable Polymers for Food Packaging: A Review.” Trends Food Sci. Technol., 19 (12) 634–643 (2008)
Ryan, NM, McNally, G, Welsh, J, “The Use of Aqueous Based Barrier Polymer Emulsion Systems in Coated Carton Board Laminates.” Antec-Conf. Proc., 3 3230 (2003)
Brown, RA, Budd, PM, Price, C, Satgurunathan, R, “The Permeability of Poly(butyl acrylate)/Poly(vinylidene chloride-stat-acrylonitrile) Core/Shell Emulsion Polymers for Use as Gas Barrier Coatings.” Eur. Polym. J., 29 (2–3) 337–342 (1993)
Arai, K, “Recent Trends in Latex Technology for Paper Coating.” Japanese Journal of Paper Technology, 43 (7) 23–30 (2000)
Rissa, K, Vähä-Nissi, M, Lepistö, T, Savolainen, A, “Talc-Filled Water-Based Barrier Coatings.” Paper Timber, 84 (7) 467–472 (2002)
Vähä-Nissi, M, Savolainen, A, “Filled Barrier Dispersion Coatings.” In: Tappi Coating Conference, pp. 287–304 (1999)
Adams, JM, “Particle Size and Shape Effects in Materials Science: Examples from Polymer and Paper Systems.” Clay Miner., 28 (4) 509–530 (1993)
Zhu, Y, Bousfield, D, Gramlich, WM, “The Influence of Pigment Type and Loading on Water Vapor Barrier Properties of Paper Coatings Before and After Folding.” Prog. Org. Coat., 132 201–210 (2019)
Alam, P, Toivakka, M, Carlsson, R, Salminen, P, Sandås, S, “Balancing Between Fold-Crack Resistance and Stiffness.” J. Compos. Mater., 43 (11) 1265–1283 (2009)
Prall, K, The Viscoelastic Behavior of Pigmented Latex Coating Films, Doctoral Dissertation, UMaine (2000)
Zhu, Z, Salminen, P, Chen, G, Toivakka, M, “Mechanical Properties of Pigment Coating Composites Containing Starch.” In: 13th TAPPI Advanced Coating Fundamentals Symposium, October 2014
Rättö, P, Hornatowska, J, Changhong, X, Terasaki, O, “Mechanical Pulping: Cracking Mechanisms of Clay-Based and GCC-Based Coatings.” Nordic Pulp Pap. Res. J., 26 (4) 485–492 (2011)
Najafi, SMH, Tajvidi, M, Bousfield, DW, “Production and Mechanical Characterization of Free-Standing Pigmented Paper Coating Layers with Latex and Starch as Binder.” Prog. Org. Coat., 123 138–145 (2018)
Vidal, D, Bertrand, F, “Recent Progress and Challenges in the Numerical Modeling of Coating Structure Development.” In: Proceedings of the 2006 TAPPI Advanced Coating Fundamentals Symposium, p. 241. TAPPI Press Atlanta, GA, USA, February 2006
Eksi, G, Bousfield, DW, “Modeling of Coating Structure Development.” Tappi J., 80 (2) 125–135 (1997)
Vidal, D, Zou, X, Uesaka, T, “Modeling Coating Structure Development Using a Monte Carlo Deposition Method. Part 1: Modeling Methodology.” Tappi J., 2 (4) 3–8 (2003)
Vidal, D, Zou, X, Uesaka, T, “Modeling Coating Structure Development Using a Monte Carlo Deposition Method. Part 2: Validation of the Model and Case Study.” Tappi J., 2 (5) 16–20 (2003)
Hiorns, T, Nesbitt, T, “Particle Packing of Blocky and Platey Pigments—A Comparison of Computer Simulations and Experimental Results.” In: Proceedings of TAPPI Advanced Coating Fundamentals Symposium, May 2003
Vidal, D, Zou, X, Uesaka, T, “Modelling Coating Structure Development: Monte-Carlo Deposition of Particles with Irregular Shapes.” Nordic Pulp & Pap. Res. J., 19 (4) 420–427 (2004)
Husband, JC, Preston, JS, Gate, LF, Storer, A, Creaton, P, “The Influence of Pigment Particle Shape on the In-plane Tensile Strength Properties of Kaolin-Based Coating Layers.” Tappi J., 5 (12) 3–8 (2006)
Larsson, M, Engström, G, Vidal, D, Zou, X, “Compression of Coating Structures During Calendering.” In: 2006 TAPPI Advanced Coating Fundamentals Symposium, Turku, Finland, February 2006
Lepoutre, P, Rigdahl, M, “Analysis of the Effect of Porosity and Pigment Shape on the Stiffness of Coating Layers.” J. Mater. Sci., 24 (8) 2971–2974 (1989)
Alam, P, Xu, Q, Toivakka, M, Hämäläinen, H, Syrjälä, S, “The Elastic Modulus of Paper Coating in Tension and Compression.” In: CD-ROM Proceedings of the 2007 TAPPI Coating Conference. TAPPI Press Atlanta, GA, USA, 2007
Toivakka, M, Bousfield, DW, “Modeling of Coating Layer Mechanical Properties.” In: TAPPI Advanced Coating Fundamentals Symposium, 2001
Prall, KM, Shaler, SM, LePoutre, PF, “Pigmented Latex Coatings: Microstructure and Viscoelastic Mechanical Properties.” Nordic Pulp Pap. Res. J., 15 (5) 564–571 (2000)
Azadi, P, Farnood, R, Yan, N, “Discrete Element Modeling of the Mechanical Response of Pigment Containing Coating Layers Under Compression.” Comput. Mater. Sci., 42 (1) 50–56 (2008)
Azadi, P, Farnood, R, Yan, N, “Modeling the Effect of Pigment Morphology on the Dynamic Compression of Coating Layers Using DEM.” Comput. Chem. Eng., 32 (12) 3084–3089 (2008)
Kan, CS, Kim, LH, Lee, DI, Van Gilder, RL, “Viscoelastic Properties of Paper Coatings Structure/Property Relationship to End Use Performance.” In: Coating Conference TAPPI (1996)
Rättö, P, “Mechanical Properties of Coating Layers.” J. Pulp Pap. Sci., 30 (1) 335–340 (2004)
Lapčík, L, Maňas, D, Lapčíková, B, Vašina, M, Staněk, M, Čépe, K, Rowson, NA, “Effect of Filler Particle Shape on Plastic-Elastic Mechanical Behavior of High Density Poly(Ethylene)/Mica and Poly(Ethylene)/Wollastonite Composites.” Compos. B Eng., 141 92–99 (2018)
Chan, JX, Wong, JF, Hassan, A, Mohamad, Z, Othman, N, “Mechanical Properties of Wollastonite Reinforced Thermoplastic Composites: A Review.” Polym. Compos., 41 (2) 395–429 (2020)
Seretis, GV, Manolakos, DE, Provatidis, CG, “On the Stainless-Steel Flakes Reinforcement of Polymer Matrix Particulate Composites.” Compos. B Eng., 162 80–88 (2019)
Gupta, N, Nagorny, R, “Tensile Properties of Glass Microballoon-Epoxy Resin Syntactic Foams.” J. Appl. Polym. Sci., 102 (2) 1254–1261 (2006)
Hönle, S, Schmauder, S, “Micromechanical Simulation of Crack Growth in WC/Co Using Embedded Unit Cells.” Comput. Mater. Sci., 13 (1–3) 56–60 (1998)
Ayyar, A, Chawla, N, “Microstructure-Based Modeling of Crack Growth in Particle Reinforced Composites.” Compos. Sci. Technol., 66 (13) 1980–1994 (2006)
Zhang, X, Chen, T, Ma, S, Qin, H, Ma, J, “Overcoming the Strength-Ductility Trade-Off of an Aluminum Matrix Composite by Novel Core-Shell Structured Reinforcing Particulates.” Compos. B Eng., 206 108541 (2021)
Aghdam, MM, Smith, DJ, Pavier, MJ, “Micromechanical Modelling of Layered Systems Containing Titanium Alloy and Titanium MMC Subjected to Bending.” Mater. Sci. Technol., 16 (7–8) 848–852 (2000)
Aghdam, MM, Kamalikhah, A, “Micromechanical Analysis of Layered Systems of MMCs Subjected to Bending-Effects of Thermal Residual Stresses.” Compos. Struct., 66 (1–4) 563–569 (2004)
Nichols, ME, Darr, CA, Smith, CA, Thouless, MD, Fischer, ER, “Fracture Energy of Automotive Clearcoats—I. Experimental Methods and Mechanics.” Polym. Degrad. Stabil., 60 (2–3) 291–299 (1998)
Hutchinson, JW, Suo, Z, “Mixed Mode Cracking in Layered Materials.” In: Advances in Applied Mechanics, vol. 29, pp. 63–191 (1991)
Beuth, JL, Jr, “Cracking of Thin Bonded Films in Residual Tension.” Int. J. Solids Struct., 29 (13) 1657–1675 (1992)
Bathija, AP, Elastic Properties of Clays, Doctoral Dissertation, Colorado School of Mines (2009)
Engineering ToolBox. Poisson’s Ratio. https://www.engineeringtoolbox.com/poissons-ratio-d_1224.html (2008)
Fein, K, Bousfield, DW, Gramlich, WM, “The Influence of Versatile Thiol-Norbornene Modifications to Cellulose Nanofibers on Rheology and Film Properties.” Carbohy. Polym., 230 115672 (2020)
ASTM. Standard Test Methods for Mandrel Bend Test of Attached Organic Coatings. West Conshohocken, PA: ASTM (2013)
Toivakka, M, Eklund, D, Bousfield, DW, “Prediction of Suspension Viscoelasticity Through Particle Motion Modeling.” J. Non Newton. Fluid Mech., 56 (1) 49–64 (1995)
Acknowledgements
We would like to thank the industrial sponsors of the University of Maine Paper Surface Science Program for input and support of this work.
Author information
Authors and Affiliations
Corresponding author
Additional information
Publisher's Note
Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.
Rights and permissions
About this article
Cite this article
Zhu, Y., Bousfield, D. & Gramlich, W. Failure prediction of waterborne barrier coatings during folding. J Coat Technol Res 18, 1117–1129 (2021). https://doi.org/10.1007/s11998-021-00465-1
Received:
Revised:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s11998-021-00465-1