Paperboard structure with at least one barrier coating layer

Patent metadata

Field	Value
Publication number	US-2022195671-A1
Application number	US-202217689041-A
Country	US
Kind code	A1
Filing date	Mar 8, 2022
Priority date	Feb 19, 2018
Publication date	Jun 23, 2022
Grant date	—

Abstract

A paperboard structure that includes a paperboard substrate which includes a first major side and a second major side along with at least one barrier coating layer on the first major side. The barrier coating layer(s) may include a binder and a pigment, wherein the binder has a glass transition temperature of at least 20° C., wherein a ratio of the binder to the pigment is at least about 1:2 by weight.

First claim

1 . A paperboard structure comprising:
a paperboard substrate comprising a first major side and a second major side opposed from said first major side; and at least one barrier coating layer on said first major side, wherein said barrier coating layer comprises a binder and a pigment, and wherein said binder has a glass transition temperature of at least 20° C., wherein a ratio of said binder to said pigment is at least about 1:2 by weight.

2 . (canceled)

3 . The paperboard structure of claim 1 wherein said glass transition temperature is at least 25° C.

4 . (canceled)

5 . The paperboard structure of claim 1 wherein said glass transition temperature is at least 30° C.

6 - 8 . (canceled)

9 . The paperboard structure of claim 1 wherein a ratio of said binder to said pigment is about 1:2 to about 9:1 by weight.

10 . The paperboard structure of claim 1 wherein a ratio of said binder to said pigment is about 1:1 to about 4:1 by weight.

11 . The paperboard structure of claim 1 wherein said binder comprises at least one of styrene-acrylate, styrene-butadiene rubber, ethylene acrylic acid, polyvinyl acetate, and polyester dispersion.

12 - 14 . (canceled)

15 . The paperboard structure of claim 1 wherein said pigment comprises clay.

16 . The paperboard structure of claim 1 wherein said pigment comprises CaCO 3 .

17 . The paperboard structure of claim 1 wherein said pigment comprises clay and CaCO 3 .

18 . The paperboard structure of claim 1 wherein at least 60 percent by weight of the pigment is comprised of particles having a particle size less than 2 microns.

19 . (canceled)

20 . The paperboard structure of claim 1 wherein at least 80 percent by weight of said pigment is comprised of particles having a particle size less than 2 microns.

21 . (canceled)

22 . The paperboard structure of claim 1 wherein said pigment comprises at least one of:
a coarse ground CaCO 3 with a particle size of about 60% less than 2 microns;
a fine ground CaCO 3 with a particle size of about 90% less than 2 microns; and
a fine ground CaCO 3 with a mean particle diameter size of about 0.4 microns.

23 - 25 . (canceled)

26 . The paperboard structure of claim 1 providing a 30-minute water Cobb test of less than about 20 g/m 2 .

27 . (canceled)

28 . The paperboard structure of claim 1 providing a blocking rate of less than 3 at 40° C. and at 60 psi in a 24-hour period.

29 . The paperboard structure of claim 1 further comprising a base coat layer between said paperboard substrate and said barrier coating layer.

30 . The paperboard structure of claim 29 wherein said base coat layer comprises a binder and a pigment.

31 . The paperboard structure of claim 1 further comprising a second barrier coating layer on said second major side.

32 . The paperboard structure of claim 1 wherein said paperboard substrate has a caliper ranging from about 4 points to about 30 points.

33 . (canceled)

34 . The paperboard structure of claim 32 wherein said caliper ranges from about 13 points to about 18 points.

35 . (canceled)

36 . The paperboard structure of claim 1 wherein said paperboard substrate has a basis weight of about 85 to about 250 pounds per 3,000 square feet.

37 . The paperboard structure of claim 1 having a repulpability of at least 80 percent.

38 - 39 . (canceled)

40 . The paperboard structure of claim 1 being heat-sealable.

41 . The paperboard structure of claim 1 further comprising a second barrier coating layer on said first major side.

42 . (canceled)

43 . The paperboard structure of claim 41 providing a 30-minute water Cobb test of less than 6 g/m 2 .

44 . (canceled)

45 . The paperboard structure of claim 41 providing a 30-minute hot water Cobb test of less than 15 g/m 2 .

46 - 47 . (canceled)

48 . The paperboard structure of claim 41 providing a 30-minute hot coffee Cobb test of less than 15 g/m 2 .

49 - 50 . (canceled)

51 . The paperboard structure of claim 41 providing a blocking rate of less than 3 at 50° C. and at 60 psi in a 24-hour period.

52 - 55 . (canceled)

56 . A method for manufacturing a paperboard structure comprising:
preparing a barrier coating composition comprising a binder and a pigment, wherein said binder, when dried, has a glass transition temperature of at least 20° C.; and applying said barrier coating composition to a paperboard substrate to form a first barrier coating layer.

57 . The method of claim 56 further comprising applying a second barrier coating composition over said first barrier coating layer to form a second barrier coating layer.

58 . The method of claim 56 further comprising drying said barrier coating composition.

Assignees

• Westrock Mwv Llc

Inventors

• Pang Jiebin
• Melton Natasha G
• Parker Steven
• Krug Teresa

Classifications

• D21H19/60

  Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters · CPC title

• D21H19/385

  Oxides, hydroxides or carbonates · CPC title

• D21H19/822

  two superposed coatings, both being pigmented · CPC title

• D21H19/38

  characterised by the pigments · CPC title

• D21H21/16 Primary

  Sizing or water-repelling agents · CPC title