WO2010093563A1 - Low density paper and paperboard with two-sided coating - Google Patents
Low density paper and paperboard with two-sided coating Download PDFInfo
- Publication number
- WO2010093563A1 WO2010093563A1 PCT/US2010/023290 US2010023290W WO2010093563A1 WO 2010093563 A1 WO2010093563 A1 WO 2010093563A1 US 2010023290 W US2010023290 W US 2010023290W WO 2010093563 A1 WO2010093563 A1 WO 2010093563A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- paperboard
- paper
- basis weight
- basecoat
- substrate
- Prior art date
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/80—Paper comprising more than one coating
- D21H19/84—Paper comprising more than one coating on both sides of the substrate
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/54—Starch
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
- D21H19/64—Inorganic compounds
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/10—Coatings without pigments
- D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
- D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
Definitions
- the present patent application is directed to low density paper and paperboard and, more particularly, to low density paper and paperboard having a smooth, coated surface on both sides.
- Paperboard is commonly used in various packaging applications. For example, high end personal care or commercial printing applications and the like. The paperboard often receives a variety of graphic treatments to enhance its visual impact on the shelf. Likewise, quality papers to be utilized as a medium for printing require smooth coated surfaces, with few imperfections to facilitate the printing of high quality text and graphics.
- the disclosed low density paper or paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf (PPS 10, soft platen) smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being less than about Y 1 , wherein Yi is a function of the caliper thickness (X) in points and is calculated using Eq. 1 as follows:
- the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 2 , wherein Y 2 is a function of the caliper thickness (X) in points and is calculated using Eq. 2 as follows:
- the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 3 , wherein Y 3 is a function of the caliper thickness (X) in points and is calculated using Eq. 3 as follows:
- the disclosed low density paperboard may include a fiber substrate and a coating applied to each side of the fiber substrate to form a coated structure, the coated structure having a Parker Print Surf smoothness on each side of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being at most about Y 4 , wherein Y 4 is a function of the caliper thickness (X) in points and is calculated using Eq. 4 as follows:
- the disclosed low density paperboard may include a fiber substrate, a topcoat, and a coating positioned between the fiber substrate and the topcoat, the fiber substrate, the basecoat and the topcoat forming a coated structure, wherein the coated structure has a Parker Print Surf smoothness of at most about 2 microns, a caliper thickness and a basis weight, the basis weight being between about Yi and about Y 5 , wherein Yi and Y 5 are functions of the caliper thickness (X) in points and are calculated used Eq. 1 above and Eq. 5 as follows:
- Fig. 1 is a graphical comparison of density versus caliper thickness of certain prior art paper and paperboard materials to paper and paperboard according to the present disclosure
- Fig. 2 is a cross-sectional view of one aspect of the disclosed low density paper or paperboard
- Fig. 3 is a graphical representation of basis weight versus caliper thickness of various exemplary aspects of the disclosed low density paperboard
- FIG. 4 is a schematic illustration of a first aspect of a process for preparing the disclosed low density paperboard
- Fig. 5 is a schematic illustration of a second aspect of a process for preparing the disclosed low density paperboard
- Fig. 6 is a graphical representation of density versus smoothness (Parker Print Surf) of certain prior art 10 point (caliper) products.
- Fig. 7 is a graphical representation of density versus smoothness (Parker Print Surf) values of certain prior art 12 point (caliper) products.
- one aspect of the disclosed low density paperboard may include a fiber substrate 12, a basecoat 14a, 14b and an optional topcoat 16a, 16b.
- the coating formulations may differ from side-to-side in formulation as well as in amount applied. Additionally, one side may have only a base coating, while the other side could be both base and top coated.
- the paperboard 10 may have a caliper thickness T and layers of coating on each side on which graphics may be printed. Additional layers may be used without departing from the scope of the present disclosure.
- the fiber substrate 12 may be a paper or paperboard substrate.
- fiber substrate broadly refers to any paper or paperboard material that is capable of being coated with a basecoat, and may be a single-ply substrate or a multi-ply substrate. Those skilled in the art will appreciate that the fiber substrate may be bleached or unbleached. Generally, the fiber substrates noted herein have uncoated basis weights of about 65 pounds per 3000 ft 2 or more. Examples of appropriate substrates include paper cover stock, linerboard and solid bleached sulfate (SBS).
- the fiber substrate 12 may include a substantially chemically (rather than mechanically) treated fiber, such as an essentially 100 percent chemically treated fiber. Examples of appropriate chemically treated fiber substrates 12 include solid bleached sulfate paperboard or solid unbleached sulfate paperboard.
- the fiber substrate 12 may be substantially free of plastic pigments or other chemical bulking agents for increasing bulk, such as hollow plastic pigments or expandable microspheres, Still furthermore, the fiber substrate 12 may be substantially free of ground wood particles.
- the topcoat 16a, 16b is an optional layer and may be any appropriate topcoat.
- the topcoat 16a, 16b may include calcium carbonate, clay and various other components and may be applied to the basecoat 14a, 14b as a slurry.
- Topcoats are well known by those skilled in the art and any conventional or non-conventional topcoat 16a, 16b may be used without departing from the scope of the present disclosure.
- the basecoat 14a, 14b may be any coating that improves the smoothness of the surface of the paperboard 10 without substantially reducing the caliper thickness T of the paperboard 10, thereby yielding a smooth (e.g., Parker Print Surf smoothness below about 2.0 microns) and low density paper or paperboard.
- a smooth e.g., Parker Print Surf smoothness below about 2.0 microns
- the basecoat 14a, 14b may be a carbonate/clay basecoat.
- the carbonate/clay basecoat may include a ground calcium carbonate component, a platy clay component and various optional components, such as latex binders, thickening agents and the like.
- the carbonate/clay basecoat may be dispersed in water such that it may be applied to the fiber substrate 12 as a slurry using, for example, a blade coater such that the carbonate/clay basecoat substantially fills the pits and crevices in the fiber substrate 12 without substantially coating the entire surface of the fiber substrate 12.
- a low density paperboard 10 may be prepared by the process 20 illustrated in Fig. 4.
- the process 20 may begin at the head box 22 which may discharge a fiber slurry onto a Fourdrinier 24 to form a web 26.
- the web 26 may pass through one or more wet presses 28 and, optionally, through one or more dryers 30.
- a size press 32 may be used and may slightly reduce the caliper thickness of the web 26 and an optional dryer 34 may additionally dry the web 26.
- the web 26 may pass through a calender 36 with the nip loads substantially reduced to minimize or avoid reduction in caliper thickness.
- the calender 36 would be run as a dry calender.
- the calender 36 may be omitted or bypassed. Then, the web 26 may pass through another optional dryer 38 and to the first coater 40a.
- the first coater 40a may be a blade coater or the like and may apply the carbonate/clay basecoat 14a onto the web 26.
- An optional dryer 42a may dry, at least partially, the carbonate/clay basecoat 14a prior to application of the optional topcoat 16a at the second coater 44a.
- Optional dryer 46a may dry the topcoat 16a.
- coating will be applied to the opposite side of the sheet by passing through a coater 40b which may be a blade coater or the like and may apply a basecoat 14b onto the web 26.
- An optional dryer 42b may at least partially dry the basecoat 14b prior to application of the optional topcoat 16b at coater 44b.
- Another optional dryer 46b may finish the drying process before the web 26 proceeds to the optional gloss calender 48 and the web 26 is rolled onto a reel 50.
- the basecoat 14a, 14b may be a film- forming polymer solution applied to the fiber substrate 12 and then brought into contact with a heated surface in a nip, causing the solution to boil and create voids in the film which remain after the film is dried, resulting in a smooth surface.
- the film forming polymer may be a starch and the heated surface may be a heated roll.
- a low density paper or paperboard 10 may be prepared by the process 60 illustrated in Fig. 5.
- the process 60 may begin at the head box 62 which may discharge a fiber slurry onto a Fourdrinier 64 to form a web 66.
- the web 66 may pass through one or more wet presses 68 and, optionally, through one or more dryers 70.
- a size press 72 may be used, and may slightly reduce the caliper thickness of the web 66 and an optional dryer 74 may additionally dry the web 66.
- the web 66 may pass through a calender 76 with the nip loads substantially reduced to minimize or avoid reduction in caliper thickness. If used, the calender 76 may be run as a dry calender.
- the calender 76 may be omitted or bypassed. Then, the web 66 may pass to an application 78 of the film forming polymer followed by contacting in a nip with a heated roll 80 and a press roll to form a smooth surface with voids in the polymer film. After application and heat/pressure treatment of the film forming polymer, the web 66 may pass through another optional dryer 82 and to the first coater 84a.
- the first coater 84a may be a blade coater or the like and may apply a conventional basecoat (e.g., as a second basecoat) onto the starch-coated web 66.
- An optional dryer 86a may dry, at least partially, the basecoat prior to application of an optional topcoat at the second coater 88a. Dryer 90a may dry the topcoat. The opposite side of the sheet may then be coated via coater 84b which may be a blade coater or the like and may apply conventional basecoat onto web 66. An optional dryer 86b may at least partially dry the basecoat prior to application of an optional topcoat at the next coater 88b. Another optional dryer 90b may finish drying before the web 66 proceeds to the optional gloss calender 92 and finished product is rolled onto a reel 94. The gloss calender 92 may be a soft nip calender, a hard nip calender, or may be omitted or bypassed.
- basecoats 14a, 14b, topcoats 16a, 16b and associated application techniques disclosed above may substantially increase the smoothness of the resulting paper or paperboard 10 without substantially increasing the density of the paper or paperboard 10 (i.e., the caliper thickness of the fiber substrate 12 may be substantially maintained throughout the coating process).
- Fig. 6 and 7 demonstrate the typical trend that as a product becomes more dense it can become smoother. It is obvious from the graphs that the products formed in examples 1 and 2 herein described are significantly different in this regard than other products in the ability to maintain low parker print surf values at new low levels of density.
- a low density uncoated solid bleached sulfate (SBS) board having a basis weight of about 125 lbs/3000 ft 2 was prepared using a full-scale production process.
- a high-bulk, carbonate/clay basecoat was prepared having the following composition: (1) 50 parts XP 6170 from Imerys Pigments, Inc. (a high aspect ratio clay), (2) 50 parts Hydracarb 60 from Omya, Inc. (a ground calcium carbonate), (3) 18 parts of a latex binder, and (4) a synthetic thickener in a quantity sufficient to raise the viscosity of the blend to 2000 centipoise, at 20 rpm, on a Brookf ⁇ eld viscometer.
- a topcoat was prepared having the following composition: 70 parts fine carbonate; 30 parts fine clay; 14 latex binder and minor amounts of coating lubricant, dispersant, synthetic viscosity modifier, defoamer and dye.
- the basecoat was applied to the uncoated board using a trailing bent blade applicator. 2-sided coating application was achieved utilizing four coating heads.
- the basecoat was applied such that the minimal amount of basecoat needed to fill the voids in the sheet roughness remained on the sheet, while scraping the excess basecoat from the sheet to leave a minimum amount of basecoat above the plane of the fiber surface.
- the basecoat was applied at a coat weight of about 7 lbs/3000 ft 2 .
- the topcoat was applied over the basecoat to further improve the surface smoothness.
- the topcoat was applied at a coat weight of about 7 lbs/3000 ft 2 . Coat weights were about the same on each side.
- the resulting coated structure had a total basis weight of about 1531bs/3000 ft 2 , a caliper of about 0.012 inches (12 points) and a Parker Print Surf (PPS 10S) smoothness of about 1.10 microns on the wire side and 1.30 microns on the felt side.
- PPS 10S Parker Print Surf
- a low density uncoated board having a basis weight of about 1101b/3000 ft 2 was prepared using a pilot production process.
- a high-bulk, carbonate/clay basecoat was prepared having the following composition: (1) 50 parts XP 6170 from Imerys Pigments, Inc. (a high aspect ratio clay), (2) 50 parts Hydracarb 60 from Omya, Inc. (a ground calcium carbonate), (3) 18 parts of a latex binder, and (4) a synthetic thickener in a quantity sufficient to raise the viscosity of the blend to 2000 centipoise, at 20 rpm, on a Brookf ⁇ eld viscometer.
- a topcoat was prepared having the following composition: 70 parts fine carbonate; 30 parts fine clay; 14 parts latex binder; and minor amounts of coating lubricant, dispersant, synthetic viscosity modifier, defoamer and dye.
- the basecoat was applied to the uncoated board using a trailing bent blade applicator. 2-sided coating application was achieved utilizing four coating heads.
- the basecoat was applied such that the minimal amount of basecoat needed to fill the voids in the sheet roughness remained on the sheet, while scraping the excess basecoat from the sheet to leave a minimum amount of basecoat above the plane of the fiber surface.
- the basecoat was applied at a coat weight of about 7 lbs/3000 ft 2 .
- the topcoat was applied over the basecoat to further improve the surface smoothness.
- the topcoat was applied at a coat weight of about 7 lbs/3000 ft 2 . Coat weights were about the same on each side.
- the resulting coated structure had a total basis weight of about 1341bs/3000 ft 2 , a caliper of about O.OlOinches (10 points) and a Parker Print Surf (PPS 10S) smoothness of about 1.20 microns on the wire side and 1.30 microns on the felt side. :
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- Inorganic Chemistry (AREA)
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Abstract
Description
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Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP10703769.9A EP2376708B1 (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
CA2751653A CA2751653C (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
MX2011007138A MX2011007138A (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating. |
BRPI1004551-1A BRPI1004551B1 (en) | 2009-02-10 | 2010-02-05 | cardboard and low density paper with double sided coating |
CN2010800072550A CN102362030A (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
US13/140,247 US9567709B2 (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
US15/430,589 US10619306B2 (en) | 2009-02-10 | 2017-02-13 | Low density paper and paperboard with two-sided coating |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US15132309P | 2009-02-10 | 2009-02-10 | |
US61/151,323 | 2009-02-10 |
Related Child Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US13/140,247 A-371-Of-International US9567709B2 (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
US15/430,589 Continuation US10619306B2 (en) | 2009-02-10 | 2017-02-13 | Low density paper and paperboard with two-sided coating |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2010093563A1 true WO2010093563A1 (en) | 2010-08-19 |
Family
ID=42111681
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US2010/023290 WO2010093563A1 (en) | 2009-02-10 | 2010-02-05 | Low density paper and paperboard with two-sided coating |
Country Status (7)
Country | Link |
---|---|
US (2) | US9567709B2 (en) |
EP (1) | EP2376708B1 (en) |
CN (1) | CN102362030A (en) |
BR (1) | BRPI1004551B1 (en) |
CA (1) | CA2751653C (en) |
MX (1) | MX2011007138A (en) |
WO (1) | WO2010093563A1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US9463893B2 (en) | 2011-12-29 | 2016-10-11 | Tetra Laval Holdings & Finance S. A. | Packaging laminate for a packaging container, as well as a packaging container produced from the packaging laminate |
Families Citing this family (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US10961663B2 (en) * | 2017-01-25 | 2021-03-30 | Westrock Mwv, Llc | Paperboard with low coat weight and high smoothness |
KR20220006609A (en) | 2019-05-10 | 2022-01-17 | 웨스트락 엠더블유브이, 엘엘씨 | Smooth low-density cardboard structure and method for manufacturing the same |
USD980069S1 (en) | 2020-07-14 | 2023-03-07 | Ball Corporation | Metallic dispensing lid |
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- 2010-02-05 CA CA2751653A patent/CA2751653C/en active Active
- 2010-02-05 CN CN2010800072550A patent/CN102362030A/en active Pending
- 2010-02-05 EP EP10703769.9A patent/EP2376708B1/en not_active Revoked
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US9463893B2 (en) | 2011-12-29 | 2016-10-11 | Tetra Laval Holdings & Finance S. A. | Packaging laminate for a packaging container, as well as a packaging container produced from the packaging laminate |
Also Published As
Publication number | Publication date |
---|---|
EP2376708A1 (en) | 2011-10-19 |
EP2376708B1 (en) | 2016-07-13 |
US9567709B2 (en) | 2017-02-14 |
US20110244205A1 (en) | 2011-10-06 |
BRPI1004551B1 (en) | 2021-01-05 |
CA2751653A1 (en) | 2010-08-19 |
US10619306B2 (en) | 2020-04-14 |
BRPI1004551A2 (en) | 2017-05-30 |
CA2751653C (en) | 2017-08-29 |
MX2011007138A (en) | 2011-08-15 |
CN102362030A (en) | 2012-02-22 |
US20170159241A1 (en) | 2017-06-08 |
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