Lining material, method for coating a material for producing a lining, and apparatus

A lining material for forming a tight barrier coating on a base material, said lining comprising:

• a thermoplastic polymer that does not cross-link in an aqueous dispersion, said thermoplastic polymer being 65%-85% of said lining by dry matter weight and including at least one member being selected from the group consisting of acrylates, polyvinylchlorides, polyurethanes, polyesters, and polystyrenes;
• an additive including at least one particulate material having barrier-forming properties and at least one adjunct component affecting processing properties of said coating, said adjunct component is 0% to 5% of the additive by weight, said additive being in an aqueous dispersion and being 15%-35% of said lining by dry matter weight;
• and
• at least 95% of the particles of said at least one particulate material fulfill the condition that the ratio between the largest and the smallest dimensions of a particle of said particulate material is greater than 5:1, and at least ten percent by dry matter weight of said particles of said additive have barrier-forming properties and an equivalent diameter between ten .mu.m and two .mu.m.

A method for forming a non-porous barrier coating on a base material, said method comprising the steps of:

• A) producing a dispersion including:
• 1) water being 30% to 65% of said dispersion by weight;
• 2) at least one thermoplastic cross-linking polymer being 25% to 60% of said dispersion by weight;
• and
• 3) a particulate additive being 10% to 35% of said dispersion by weight, said additive including at least one particulate material having barrier-forming properties, at least 95% of the particles of said at least one particulate material fulfill the condition that the ratio between the largest and the smallest dimension of a particle of said particulate material is greater that 5:1;
• B) applying said dispersion as a layer on a surface of the base material;
• C) abruptly subjecting said dispersion layer to heat to produce a temperature of at least 100.degree. C. on a surface of said dispersion;
• and
• D) exposing said dispersion layer to a temperature less than 100.degree. C. to remove said water.

An apparatus for forming a non-porous barrier coating on a base material, said apparatus comprising:

• first and second application elements for applying a layer of a dispersion on a surface of the base material;
• elements for abruptly raising a surface temperature of said dispersion layer to at least 100.degree. C.;
• and
• elements for drying said dispersion layer at a temperature below 100.degree. C. to form a lining.