Barrier coating of an elastomer and a dispersed layered filler in a liquid carrier

A barer coated article formed by

• (1) applying to a substrate without melt processing an aqueous solution comprising:
• (a) a butyl-containing polymer;
• (b) a dispersed exfoliated layered filler having an aspect ratio about 1000 or greater, wherein the ratio of said polymer to said filler ranges from 20.1 to 1:1;
• and
• (c) at least one surfactant, herein the solids content of said solution is less than 17%;
• and
• (2) allowing said solution to dry to a barrier coating having the same polymer to filler as in said solution,
• wherein said coating provides an at least 10-fold greater reduction in gas, vapor, and chemical permeability than a coating formed of said polymer alone.

A method of producing a coated article comprising

• (1) applying to a substrate without melt processing an aqueous solution comprising:
• (a) an elastomeric polymer;
• (b) a dispersed exfoliated layered filler having an aspect ratio greater than 25, wherein the ratio of said polymer to said filler ranges from 20:1 to 1:1;
• and
• (c) at least one surfactant, wherein the solids content of said solution is less than 30%;
• and
• (2) allowing said solution to dry to a barrier coating having the same polymer to filler as in said solution,
• wherein said coating provides to said substrate an at least 10-fold greater reduction in gas, vapor, and chemical permeability than a coating formed of said polymer alone.