Process for preparing waterborne heat seal coating compositions

1. A process for preparing a waterborne heat seal coating composition comprising the steps of:

a) melt blending ethylene vinyl acetate copolymer, at least one tackifier, and optionally a surfactant in a mixing and conveying zone to form a melt blend;

b) contacting the melt blend with an initial aqueous stream comprising a neutralizing agent, water, and optionally a surfactant in an emulsification zone to form a dispersion; and

c) diluting the dispersion with water in a dilution zone to form the waterborne heat seal coating composition

wherein the process is a continuous process.

2. The process of claim 1 , wherein the process is performed in an extruder.

3. The process of claim 1 , wherein a wax is also added to the ethylene vinyl acetate copolymer, tackifier, and optional surfactant to form the melt blend of step a).

4. The process of claim 1 , wherein the mixing and conveying zone is operated at a temperature in the range of from 140 to 160° C. and the emulsification zone is operated at a temperature in the range of from 80 to 120° C.

5. The process of claim 1 , wherein the neutralizing agent is potassium hydroxide.

6. The process of claim 1 , wherein the waterborne heat seal coating composition has a degree of neutralization of acid groups in the range of from 25 mole percent to 70 mole percent, based on the total acid content of the waterborne heat seal coating composition.

7. The process of claim 1 , wherein the waterborne heat seal coating composition comprises from 40 weight percent to 80 weight percent water.

8. The process of claim 1 , wherein the ethylene vinyl acetate is present in an amount in the range of from 50 to 85 weight percent, and the tackifier is present in an amount in the range of from 6 to 20 weight percent based on the total weight of the solids in the waterborne heat seal coating composition.

9. A waterborne heat seal coating composition produced by the process of claim 1 .