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

a technology of paperboard and insulation properties, which is applied in the field of coated paperboards and paperboard containers having improved tactile and bulk insulation properties, can solve the problems of environmental unfriendly, styrofoam containers are often brittle, and containers suffer a number of drawbacks, and achieve excellent insulation properties and high gm taber stiffness

Inactive Publication Date: 2006-03-16
DIXIE CONSUMER PROD
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

[0037] 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

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.
It should be noted that prior art extrusion foamed coatings cannot be pattern applied, and therefore have to cover the whole side of the board.
Prior art bulk-enhanced paper products, such as those disclosed in U.S. Pat. Nos. 3,941,634 and 3,293,114, resulting from the addition of expandable microspheres and other bulk enhancing additives and methods for making such paper, suffer from a number of drawbacks.
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 i

Method used

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  • 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 Plate Formation

[0253] 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-333-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.

[0254] 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...

example 3

Preparation of Texture Coated Hamburger and Sandwich Wrap

[0256] Hamburger and sandwich wrap specimens of 14 mil and 19 mil depths were screen-printed with a textured coating comprising 30% Expancel 820 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

[0257] 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 Wrap% DryCompoundAdditionSolidsSolidsorder29.0Expancel 820 microspheres45%248.0BASF Acronal 504 latex50%119.0Hydrafine Clay70%3As desiredAlcogum L-29 Thickener30%74 Glycerin100%5Drewplus L407 Antifoam28%4As desiredNotox Ink100%6

[0258] The resulting texture coated hamburger wrap is shown in FIG. 37 which is a photograph of a section of the hamburger wrap.

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Abstract

An improved paperboard has been bulk enhanced by retaining a substantial portion microspheres in a suitable distribution within the paperboard. As in one embodiment, the high retention of the bulk enhancing additives is believed to result from the incorporation of suitable retention aids. The paperboard is able to be formed into suitable paperboard containers without loss of integrity. The resulting containers have increased hold times when they contain hot or cold food or drink.

Description

[0001] This is a continuation of application Ser. No. 10 / 801,825, filed Mar. 17, 2004, now co-pending, which is a continuation of application Ser. No. 09 / 018,563, filed Feb. 4, 1998, now U.S. Pat. No. 6,740,373 B1, which is a continuation-in-part of application Ser. No. 08 / 806,947, filed Feb. 26, 1997, now abandoned, all of which are incorporated herein by reference in their entireties.BACKGROUND OF THE INVENTION [0002] Disposable paper containers, such as plates, trays, bowls, airline meal containers and cafeteria containers, are commonly produced by pressing flat paperboard blanks into the desired shape between appropriately shaped and heated forming dies. Various protective coatings are typically applied to the blanks before forming to make the resulting paperboard containers moisture-resistant, grease-resistant, more readily printable, etc. Often, printing is also applied to the top surface for decoration. A large number of paper products are produced by this method every year. ...

Claims

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Application Information

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IPC IPC(8): B32B29/00B32B5/16B65D65/42B65D75/18B65D81/38B65D85/36D21H19/82D21H19/84D21H21/54D21H27/10
CPCB32B29/06B65D65/42B65D75/18B65D81/3823B65D81/3874B65D2585/363Y10T428/25D21H19/84D21H21/54D21H27/10D21H27/30Y10T428/1303D21H19/822Y10T428/31895Y10T428/31982Y10T428/31906
Inventor SWOBODA, DEAN P.SWIONTEK, ANTHONY J.HARTJES, TIMOTHY P.SHANTON, KENNETH J.SANDSTROM, ERLAND R.
Owner DIXIE CONSUMER PROD
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