Coated paperboards and paperboard containers having improved tactile and bulk insulation properties

a technology of paperboard and coating, which is applied in the field of forming paperboard products, can solve the problems of containers suffering a number of drawbacks, the whole side of paperboard has to be coated, and the polyolefin insulated coating cannot be printed onto the surface of paperboard, and achieve excellent insulation properties and high gm taber stiffness

Inactive Publication Date: 2005-05-26
DIXIE CONSUMER PROD
View PDF44 Cites 64 Cited by
  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0043] The bulk enhanced paperboard of the present invention may be pressed into high quality articles of manufacture having a high GM Taber stiffness and GM tensile stiffness. Useful articles made from the bulk enhanced paperboard include cartons, folding paper boxes, cups, plates, compartmented plates, bowls, canisters, French fry sleeves, hamburger clam shells, rectangular take-out containers, food buckets, heat insulating containers coated or laminated with a polyolefin and foamed with the wat

Problems solved by technology

Foamed polyolefin insulated coating cannot be printed onto the surface of the paperboard and, consequently, the whole side of the paperboard has to be coated.
While a sense of bulkiness may be provided to some extent in styrofoam and thick pulp-molded containers, such containers suffer a number of drawbacks.
For example, unlike pressed paperboard containers, styrofoam containers are often brittle and they are environmentally unfriendly because they are not biodegradable.
Also, styrofoam containers are not cut-resistant and it is difficult to apply printing to the surface of styrofoam containers.
Additionally, because of their bulkiness, styrofoam containers take up large amounts of shelf space and are costly to ship.
Pulp-molded containers similarly are not cut-resistant and have poor printability characteristics.
Additionally, pulp-molded containers typically have weak bottoms.
For example, one persistent problem in such papers is poor retention of the expandable microspheres or other bulk enhancing additives on the embryonic paper web made in the course of manufacturing the paperboard.
This poor retention results in relatively low bulk enhancement of the resulting paperboard per unit weight of bulk enhancing additive added, making the enhancement process unnecessarily costly.
A further problem resulting from the poor retention of microspheres and other bulk enhancers experienced in prior art bulk enhancement methods is fouling of the papermaking apparatus with unretained microspheres and other bulk enhancing additives.
A related problem associated with the addition of microspheres and other bulk enhancing additives in the papermaking process is their uneven distribution within the resulting paperboard.
Paperboards prepared using prior art enhancement techniques have exhibited a decided asymmetry, with microspheres and other bulk enhancing additives migrating to one of the outer surfaces of the paper web and causing undesired roughness in the surface of the finished paper and hence interference with the smooth and efficient operation of the papermaking apparatu

Method used

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
View more

Image

Smart Image Click on the blue labels to locate them in the text.
Viewing Examples
Smart Image
  • Coated paperboards and paperboard containers having improved tactile and bulk insulation properties
  • Coated paperboards and paperboard containers having improved tactile and bulk insulation properties
  • Coated paperboards and paperboard containers having improved tactile and bulk insulation properties

Examples

Experimental program
Comparison scheme
Effect test

example 2

Coated Mate Formation

[0248] Below is a description of the process for applying textured coating using a Neenah Technical Center Faustel coater rotogravure deck and subsequent product formation. A commercially available coating sold by Industrial Adhesive Corporation of Chicago, Ill., under designation DB-3-DS was used. This coating comprises an acrylic binder to which have been charged a blend of adhesives and 16-30% microspheres. The coating delivers a textured coating with a height of approximately 0.001″-0.010″. Applied coating can not be removed from the paper substrate without effort. The coating is applied using the design illustrated in FIG. 4C with a coverage area of 55%. Three pounds of the coating were applied to a 3000 square foot ream of paperboard.

[0249] The roll was chemically etched by Gravure, Inc., of Lymon, S.C., using an 85-line screen with a 10-12 pitch wall, 80-85 microns in depth. A 12-inch wide pattern was etched continuously around the roll face. Coating wa...

example 3

Preparation of Texture Coated Hamburger and Sandwich Wrap

[0251] Hamburger and sandwich wrap specimens of 14 mil and 19 mil depths were screen-printed with a textured coating comprising 30% Expancel, 1820 microspheres, 50% Acronal S504 latex binder, and 20% clay pigment. Thickener (Alcogum L-29) was added to facilitate screen-printing. A coating weight of thirteen pounds per 3000 square foot ream was applied generating 8 mils of coating caliper. FIG. 4E design was used for the pattern for the screen-printed hamburger or sandwich wrap textured pattern. The coated wrap had a significantly greater thermal insulation for the hand touching the surface, and the wrap had also much improved friction resistance. The thermal and friction resistance is comparable to that obtained when textured plates or cups are produced.

example 4

Sample of Texture Coated Hamburger Wrap

[0252] Hamburger wrap specimens of 14 mil and 19 mil depths were screen printed as disclosed in Example 3. The solids formulation were as follows:

TABLE 4Expancel Coating for Hamburger Graphic on Quilt WrapCompoundAddition% Dry SolidsSolidsorder29.0Expancel 820 microspheres45%248.0BASF Acronal 504 latex50%119.0Hydrafine Clay70%3As desiredAlcogum L-29 Thickener30%74Glycerin100% 5Drewplus L407 Antifoam28%4As desiredNotox Ink100% 6

[0253] The resulting texture coated hamburger wrap is shown in FIG. 37 which is a photograph of a section of the hamburger wrap.

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
Login to view more

PUM

PropertyMeasurementUnit
Thicknessaaaaaaaaaa
Lengthaaaaaaaaaa
Fractionaaaaaaaaaa
Login to view more

Abstract

A method of making a texture-coated and/or insulation coated container from a flat paperboard blank in which a heat-hardenable liquid polymeric binder texturizing and/or insulating agent coating mixture is applied to one surface of the blank in a pattern of covered and open areas. This coating mixture is subjected to heat to cure the polymeric binder and expand the texturizing and/or insulating agent, optionally treated with moisture, and optionally heated to form the blank into the shape of a container, and the container produced by this method. The containers such as cups, plates, etc., are useful in food service. These containers have a coefficient of static friction which is about 0.2 to 2.0 and over and a kinetic coefficient of friction which is about 0.22 to 1.5.

Description

[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 09 / 018,563, filed Feb. 4, 1998, which is a continuation-in-part of U.S. patent application Ser. No. 08 / 806,947, filed Feb. 26, 1997, both of which are incorporated herein by reference, in their entirety.BACKGROUND OF THE INVENTION [0002] This invention relates generally to processes for forming paperboard products and to the products formed by such processes. More particularly, this invention relates to a method of making disposable paperboard containers with textured coatings and to the texture-coated containers formed by that method. This invention also relates to coatings having superior bulk and insulation properties. [0003] In addition, this invention relates to an improved paperboard, to improved shaped paperboard products, and to methods of making such paperboard and shaped paperboard products, including heat insulating paperboard containers, such as cups, having as their wall surface a foam...

Claims

the structure of the environmentally friendly knitted fabric provided by the present invention; figure 2 Flow chart of the yarn wrapping machine for environmentally friendly knitted fabrics and storage devices; image 3 Is the parameter map of the yarn covering machine
Login to view more

Application Information

Patent Timeline
no application Login to view more
IPC IPC(8): B65D65/42B65D75/18B65D81/38B65D85/36D21H19/82D21H19/84D21H21/54D21H27/10
CPCB65D65/42Y10T428/1307B65D81/3823B65D81/3874B65D2585/363D21H19/822D21H19/84D21H21/54D21H27/10B65D81/3446B65D2581/3479Y10T428/24372Y10T428/24934Y10T428/273Y10T428/1303Y10T428/24802B65D75/18Y10T428/31895Y10T428/31906Y10T428/31993
Inventor SWOBODA, DEAN P.SWIONTEK, ANTHONY J.HARTJES, TIMOTHY P.SHANTON, KENNETH J.SANDSTROM, ERLAND R.
Owner DIXIE CONSUMER PROD
Who we serve
  • R&D Engineer
  • R&D Manager
  • IP Professional
Why Eureka
  • Industry Leading Data Capabilities
  • Powerful AI technology
  • Patent DNA Extraction
Social media
Try Eureka
PatSnap group products

Browse by: Latest US Patents, China's latest patents, Technical Efficacy Thesaurus, Application Domain, Technology Topic.

© 2024 PatSnap. All rights reserved.Legal|Privacy policy|Modern Slavery Act Transparency Statement|Sitemap