Emulsion polymerized styrene acrylic/nanocellulose composite coating to improve the strength and hydrophobicity of kraft paper

Improving the mechanical and water repelling property of kraft paper will extend its use for packaging application. In this work, we developed a cellulose nanofiber (CNF)-based colloidal polymer nanocomposite that was used as coating for improving those properties of kraft paper. In this case, the polymer latex was obtained by the mini-emulsion copolymerization of styrene (St), 2-ethyl hexyl acrylate (EHA) initiated by ammonium persulfate. The CNFs were incorporated into the styrene-acrylic copolymer matrix by the in-situ polymerization and ex-situ mixing process keeping the CNF concentration up to 1.0 wt%. All the latexes showed particle size below 100 nm and excellent colloidal stability (Zeta potential > −32 mV) for several months. The nanocomposite films showed improved mechanical properties (tensile strength upto 7.8 MPa, elongation upto 1096 %) than the pristine copolymer. The in-situ prepared nanocomposite at 1.0 wt% CNF showed the highest storage modulus. The latex-coated kraft paper showed improved tensile index (31.0–45.1 Nm/g) compared to the uncoated paper (20.3 Nm/g) and also high hydrophobicity (water contact angle ∼120°) for the ex-situ prepared nanocomposites. The results are quite promising to develop paper-based packaging materials using nanocellulose in combination with synthetic polymers.