Expandable coating compositions and use thereof

1. A coating composition comprising:

(a) a water-based polymer prepared by emulsion polymerization;

(b) a plurality of expandable microspheres having a T 0 (onset of expansion) and T m (maximum expansion); and

(c) optionally, an additive;

wherein the polymer has a modulus of about 0.16 to less than 0.3 MPa and a tan δ greater than 0.35 at the mid-point of the expandable microspheres T 0 and T m , [T 0 +(T m −T 0 )/2].

2. The coating of claim 1 , wherein the polymer has a modulus less than 0.2 MPa and the tan δ is greater than 0.4.

3. The coating of claim 1 , wherein the water-based polymer is selected from the group consisting of vinyl acetate ethylene dispersion, polyvinyl acetate, polyvinyl acetate polyvinyl alcohol, dextrin stabilized polyvinyl acetate, polyvinyl acetate copolymers, vinyl acetate ethylene copolymers, vinyl acrylic, styrene acrylic, acrylic, styrene butyl rubber, polyurethane and mixtures thereof.

4. The coating of claim 1 , wherein the expandable microspheres have a polymeric shell and a hydrocarbon core.

5. The coating of claim 1 , further comprising a defoamer, humectants, surfactant, colorant, crosslinkers, preservatives, filler, pigment, dye, stabilizer, rheology modifier, polyvinyl alcohol, and mixtures thereof.

6. The coating of claim 1 , wherein the coating comprises less than or equal to 30 dry weight percent of the expandable microspheres.

7. The coating of claim 1 , wherein the water-based polymer has an absolute slope, which is log (elastic modulus) verses temperature, of greater than 0.014.

8. The coating of claim 7 , wherein the water-based polymer has an absolute slope, which is log (elastic modulus) verses temperature, of greater than 0.025.

9. The coating of claim 1 , wherein the expandable microspheres have a T 0 of less than 80° C.

10. The coating of claim 9 , wherein the expandable microspheres have a T 0 of less than 90° C.

11. The coating of claim 1 , wherein the expandable microspheres have a T m of greater than 150° C.

12. The coating of claim 11 , wherein the expandable microspheres have a T m of greater than 130° C.

13. The coating of claim 1 , wherein the additive is selected from the group consisting of tackifiers, plasticizers, wax dispersion additive, preservative, and mixtures thereof.

14. The coating of claim 13 , wherein the wax dispersion additive has a melting point less than 100° C.

15. The coating of claim 14 , wherein the wax dispersion additive is selected from the group consisting of paraffin, beeswax, synthetic polyethylene wax, and mixtures thereof.

16. An article comprising a substrate and a composition comprising the adhesive of claim 1 .

17. The article of claim 16 which is a shipping or mailing protective package.

18. A process for forming an article comprising the steps of:

(a) preparing a coating composition comprising (i) a water-based polymer prepared by emulsion polymerization selected from the group consisting of vinyl acetate ethylene dispersion, polyvinyl acetate, polyvinyl acetate polyvinyl alcohol, dextrin stabilized polyvinyl acetate, polyvinyl acetate copolymers, vinyl acetate ethylene copolymers, styrene butyl rubber, polyurethane and mixtures thereof and (ii) a plurality of expandable microspheres having a T 0 and T m ; wherein the polymer has a modulus less than 0.3 MPa and a tan δ greater than 0.35 at [T 0 +(T m −T 0 )/2];

(b)applying the coating onto a substrate, which is a paper, paperboard, wood, foil, plastic or plastic film;

(c) drying the coating to substantially remove the water, wherein the drying temperature is less than T 0 ; and

(d) expanding the composition at a temperature of T 0 or greater.

19. A process for forming an article comprising the steps of:

(a) preparing a coating composition comprising (i) a water-based polymer prepared by emulsion polymerization selected from the group consisting of vinyl acetate ethylene dispersion, polyvinyl acetate, polyvinyl acetate polyvinyl alcohol, dextrin stabilized polyvinyl acetate, polyvinyl acetate copolymers, vinyl acetate ethylene copolymers, styrene butyl rubber, polyurethane and mixtures thereof and (ii) a plurality of expandable microspheres having a T 0 and T m ; wherein the polymer has a modulus less than 0.3 MPa and a tan δ greater than 0.35 at the mid-point of the expandable microspheres T 0 and T m , [T 0 +(T m −T 0 )/2];

(b) applying the coating onto a substrate, which is a paper, paperboard, wood, foil, plastic or plastic film;

(b1) optionally, drying the coating to substantially remove the water, wherein the drying temperature is less than T 0 ;

(c) applying an adhesive composition onto a different portion of the first substrate;

(d) optionally, drying the coating to substantially remove the water, wherein the drying temperature is less than T 0 ;

(e) expanding the composition at a temperature of To or greater.

20. The process of claim 19 , wherein steps (b) and (c) are conducted as a single step.

21. A coating composition comprising:

(a) a water-based polymer prepared by emulsion polymerization selected from the group consisting of vinyl acetate ethylene dispersion, polyvinyl acetate, polyvinyl acetate polyvinyl alcohol, dextrin stabilized polyvinyl acetate, polyvinyl acetate copolymers, vinyl acetate ethylene copolymers, styrene butyl rubber, polyurethane and mixtures thereof;

(b) a plurality of expandable microspheres having a T 0 (onset of expansion) and T m (maximum expansion); and

(c) optionally, an additive;

wherein the polymer has a modulus of less than 0.3 MPa and a tan δ greater than 0.35 at the mid-point of the expandable microspheres T 0 and T m , [T 0 +(T m −T 0 )/2].