Barrier recycled paperboard and method for manufacturing thereof

Patent metadata

Field	Value
Publication number	US-2023175206-A1
Application number	US-202117912806-A
Country	US
Kind code	A1
Filing date	Mar 8, 2021
Priority date	Mar 20, 2020
Publication date	Jun 8, 2023
Grant date	—

Abstract

A coated paperboard includes a recycled paperboard substrate having a first side and a second side, a first aqueous barrier coating applied over the first side, and a second aqueous barrier coating applied over the first aqueous barrier coating. The first aqueous barrier coating is formed from a mixture of binder and pigment. The second aqueous barrier coating is formed from a mixture of binder and pigment.

First claim

1 . A coated paperboard comprising:
a recycled paperboard substrate having a first side and a second side; a first aqueous barrier coating applied over the first side, wherein the first aqueous barrier coating is formed from a mixture of binder and pigment; and a second aqueous barrier coating applied over the first aqueous barrier coating, wherein the second aqueous barrier coating is formed from a mixture of binder and pigment.

2 . The coated paperboard of claim 1 , wherein the recycled paperboard substrate is produced from at least 1%, by weight, recovered fibers.

3 - 16 . (canceled)

17 . The coated paperboard of claim 1 , wherein the recycled paperboard substrate has a caliper thickness of at least 4 points (0.004 inch).

18 - 21 . (canceled)

22 . The coated paperboard of claim 1 , wherein the recycled paperboard substrate has a caliper thickness of ranging from 4 points to 36 points (0.004 inch to 0.036 inch).

23 - 25 . (canceled)

26 . The coated paperboard of claim 1 , further comprising a basecoat between the first side of the recycled paperboard substrate and the first aqueous barrier coating.

27 . The coated paperboard of claim 26 , wherein the basecoat is formed from a mixture of binder and pigment.

28 . The coated paperboard of claim 26 , wherein the basecoat is formed from a mixture of binder and pigment, wherein the binder of the basecoat is present in the mixture in an amount of 5-35 parts per 100 parts of pigment by weight.

29 - 30 . (canceled)

31 . The coated paperboard of claim 26 , wherein the basecoat is formed from a mixture of binder and pigment, wherein the binder of the basecoat comprises at least one of latex binder and natural binder.

32 . (canceled)

33 . The coated paperboard of claim 26 , wherein the basecoat is formed from a mixture of binder and pigment, wherein the pigment of the basecoat comprises one or more of clay, calcium carbonate, and titanium oxide.

34 - 38 . (canceled)

39 . The coated paperboard of claim 26 , wherein the basecoat has a coat weight from 2 to 14 pounds per 3000 ft2.

40 - 41 . (canceled)

42 . The coated paperboard of claim 1 , wherein the binder of the first aqueous barrier coating is present in the mixture in an amount of 30 to 50 parts per 100 parts of pigment by weight.

43 - 47 . (canceled)

48 . The coated paperboard of claim 1 , wherein binder of the first aqueous barrier coating is latex binder.

49 . (canceled)

50 . The coated paperboard of claim 1 , wherein the first aqueous barrier coating further includes a natural co-binder.

51 - 55 . (canceled)

56 . The coated paperboard of claim 1 , wherein the first aqueous barrier coating includes an additive, wherein the additive is present in the mixture in an amount of up to 4 parts per 100 parts of pigment by weight.

57 - 88 . (canceled)

89 . The coated paperboard of claim 1 , wherein binder of the second aqueous barrier coating is latex binder.

90 . (canceled)

91 . The coated paperboard of claim 1 , wherein the second aqueous barrier coating further includes a natural co-binder.

92 - 96 . (canceled)

97 . The coated paperboard of claim 1 , wherein the second aqueous barrier coating includes an additive, wherein the additive is present in the mixture in an amount of up to 4 parts per 100 parts of pigment by weight.

98 - 123 . (canceled)

124 . The coated paperboard of claim 1 , wherein a 3M kit test value is at least 5.

125 - 130 . (canceled)

131 . The coated paperboard of claim 1 , wherein the coated paperboard has a 30-minute oil Cobb test of at most 5 grams per square meter.

132 - 134 . (canceled)

135 . The coated paperboard of claim 1 , wherein the coated paperboard has a water vapor transmission rate of less than 800 grams per square meter per day.

136 - 139 . (canceled)

140 . The coated paperboard of claim 1 , wherein the coated paperboard is repulpable to the extent that after repulping the percentage accepts is at least 85%.

141 - 144 . (canceled)

145 . A container, the container comprising the coated paperboard of claim 1 .

146 . A method for manufacturing coated paperboard, the method comprising:
applying a first aqueous barrier coating over a first side of a recycled paperboard substrate, wherein the first aqueous barrier coating is formed from a mixture of binder and pigment; and applying a second aqueous barrier coating over the first aqueous barrier coating, wherein the second aqueous barrier coating is formed from a mixture of binder and pigment.

147 - 149 . (canceled)

150 . A coated paperboard comprising:
a recycled paperboard substrate having a first side and a second side; and a first aqueous barrier coating applied over the first side, wherein the first aqueous barrier coating is formed from a mixture of binder and pigment.

151 - 236 . (canceled)

237 . A method for manufacturing coated paperboard, the method comprising:
applying a first aqueous barrier coating over a first side of a recycled paperboard substrate, wherein the first aqueous barrier coating is formed from a mixture of binder and pigment.

238 - 239 . (canceled)

Assignees

• Westrock Mwv Llc

Inventors

• Clark Terry L
• Reigle Scott J
• Pang Jiebin
• Deats William G

Classifications

• B65D65/42

  Applications of coated or impregnated materials · CPC title

• D21H23/34

  Knife or blade type coaters · CPC title

• D21H27/10

  Packing paper (packaging materials of special type or form B65D65/38) · CPC title

• D21H11/14 Primary

  Secondary fibres (working-up waste paper D21C5/02) · CPC title

• D21H19/60

  Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters · CPC title