WO2024044448A1

WO2024044448A1 - Coated cellulosic substrates and coated cellulosic containers

Info

Publication number: WO2024044448A1
Application number: PCT/US2023/070997
Authority: WO
Inventors: Zack SIMONCELLI; Rahul Bhardwaj; Chitai C. YANG; Justin L. BENNETT; Courtney R. JOHNSON; Ronald J. Binshtok; Carly J. DEHENAU; Jiebin Pang
Original assignee: Westrock Mww, Llc
Priority date: 2022-08-26
Filing date: 2023-07-26
Publication date: 2024-02-29

Abstract

A coated cellulosic substrate includes a cellulosic substrate having a first major side and a second major side, a printable coating on the first major side of the cellulosic substrate, an aqueous overprint water barrier coating on the printable coating, and a moisture vapor barrier coating on the second major side of the cellulosic substrate.

Description

COATED CELLULOSIC SUBSTRATES AND COATED CELLULOSIC CONTAINERS

PRIO RIT Y

[0001] This application claims priority from U.S. Ser. No. 63/401,217 filed on August 26, 2022, the entire contents of which are incorporated herein by reference.

FIELD

[0002] The present application relates to the field of coated cellulosic substrates and coated cellulosic containers, in particular coated cellulosic substrates and coated cellulosic containers for containing cold food products.

B A C KG R O UND

[0003] Yogurt cups are traditionally made with all plastic material such as polypropylene (PP) or high impact polystyrene (HIPS) but recently paper-based yogurt cups are constructed from a paperboard structure that includes low density polyethylene extruded on both sides of a paperboard substrate, which renders paper-based yogurt cups difficult to recycle.

[0004] Accordingly, those skilled in the art continue with research and development in the field of coated cellulosic substrates and coated cellulosic containers, in particular coated cellulosic substrates and coated cellulosic containers for containing cold food products such as yogurt.

S U MMARY

[0005] Disclosed are coated cellulosic substrates.

[0006] In one example, the disclosed coated cellulosic substrate includes a cellulosic substrate having a first major side and a second major side, a printable coating on the first major side of the cellulosic substrate, an aqueous overprint water barrier coating on the printable coating, and a moisture vapor barrier coating on the second major side of the cellulosic substrate.

[0007] Also disclosed are coated cellulosic containers. [0008] Tn one example, the disclosed coated cellulosic container includes a sidewall component having a first end and a second end, and a bottom component enclosing the first end of the sidewall component, wherein at least one of the sidewall component and bottom component includes the coated cellulosic substrate.

[0009] Other examples of the disclosed coated cellulosic substrates and coated cellulosic containers will become apparent from the following detailed description, the accompanying drawings and the appended claims.

B RIE F D E S C RIPT IO N O F THE D RAWIN GS

[0010] Fig. 1 is a cross-section of a coated cellulosic substrate according to an example of the present description.

[0011] Fig. 2 is a perspective view of an unprinted sidewall blank made from the coated cellulosic substrate of Fig. 1.

[0012] Fig. 3 is a perspective view of a printed sidewall blank made from the unprinted sidewall blank of Fig. 2.

[0013] Fig. 4 is a side view of an exemplary container including the coated cellulosic substrate of Fig. 1.

[0014] Fig. 5 is a perspective view of the container of Fig. 4.

[0015] Fig. 6 is a perspective view of a lid for the container of Fig. 4.

[0016] Fig. 7 is a cross sectional view of overlapped seam of a sidewall of the container of Fig. 4.

[0017] Fig. 8 is a graph showing plastic weight reduction for high density polyethylene coatings compared with conventional polypropylene cups and paperboard cups coated with low density polyethylene.

[0018] Fig. 9 is a graph relating to a trial showing water resistance of aqueous overprint water barrier coatings. D E T A ILE D D E S C R IP T IO N

[0019] Fig. 1 is a cross-section of a coated cellulosic substrate 10 according to an example of the present description. The coated cellulosic substrate 10 has a first major side 11 and a second major side 12. The coated cellulosic substrate 10 includes a cellulosic substrate 20 having a first major side 21 and a second major side 22, a printable coating 30 on the first major side 21 of the cellulosic substrate 20, an aqueous overprint water barrier coating 40 on the printable coating 30, and a moisture vapor barrier coating 50 on the second major side 22 of the cellulosic substrate 20.

[0020] The coated cellulosic substrate 10 is particularly useful for manufacturing coated cellulosic containers for containing cold food products, particularly yogurt cups. The coated cellulosic substrate 10 provides moisture vapor barrier properties on the second major side 22 of the cellulosic substrate 10 by way of the moisture vapor barrier coating 50. The coated cellulosic substrate 10 further provides for printability and water barrier properties on the first major side 21 of the cellulosic substrate 10 by way of the printable coating 30 and the aqueous overprint water barrier coating 40. It has been determined that an aqueous overprint water barrier coating 40 can provide sufficient water barrier properties to resist penetration of external condensation. By way of utilizing the aqueous overprint water barrier coating 40, a recyclability of the coated cellulosic substrate 10 can be improved.

[0021] Although the coated cellulosic substrate of the present description is described with reference to the example of Fig. 1 , modifications may occur to those skilled in the art upon reading the specification. In an example, in Fig. 1, any of the layers 10, 20, 30, 40, and 50 may be substituted with multiple of the same layers. In another example, additional different layers may be added to the coated cellulosic substrate. The present description includes such modifications and is limited only by the scope of the claims.

[0022] The cellulosic substrate 20 may include any web of fibrous material that is capable of applying the coatings of the present description thereon. The cellulosic substrate 20 may be a paperboard substrate. The cellulosic substrate 20 may be bleached or unbleached. For example, the cellulosic substrate 20 may include a coated natural kraft board, a solid bleached sulfate board, a solid unbleached sulfate board, a coated recycled board, a coated white lined chipboard, or a folding boxboard.

[0023] The thickness of the cellulosic substrate 20 may depend on various factors, such as the density of the cellulosic substrate. For example, the cellulosic substrate 20 may have a caliper thickness in a range of 6 points to 36 points (1 point equals 0.001 inch). As one specific example, the cellulosic substrate 20 may have a caliper thickness of 7 points to 30 points. As another specific example, the cellulosic substrate 20 may have a caliper thickness in a range of 9 points to 25 points. As another specific example, the cellulosic substrate 20 may have a caliper thickness in a range of 12 points to 20 points. As yet another specific example, the cellulosic substrate 20 may have a caliper thickness in a range of 15 points to 18 points. As used herein, 1 point equals 0.001 inches, which equals 25.4 micrometers (pm).

[0024] The weight of the cellulosic substrate 20 may depend on various factors. For example, the cellulosic substrate may have a basis weight ranging from 60 to 350 pounds per 3,000 square feet. As one specific example, the cellulosic substrate 20 may have a basis weight of 100 to 300 pounds per 3000 ft². As another specific example, the cellulosic substrate 20 may have a basis weight of 140 to 220 pounds per 3000 ft².

[0025] The printable coating 30 may be applied to the paperboard substrate to improve a printing quality of the cellulosic substrate 20.

[0026] The printable coating 30 may include a mixture of pigment and binder. The pigment may include, for example, an inorganic pigment. The inorganic pigment may include, for example, clay. The clay may include, for example, kaolin clay. The binder may include, for example, an emulsion polymer binder.

[0027] In a specific example, the amount of binder in the printable coating may range from 5 to 25 parts by weight per 100 parts by weight of pigment. In another specific example, the amount of binder in the printable coating may range from 10 to 20 parts by weight per 100 parts by weight of pigment.

[0028] The printable coating 30 may be applied in any manner that is capable of applying the printable coating 30 onto the cellulosic substrate 20. Examples of coaters which may be employed include air knife coaters, blade coaters, rod coaters, bar coaters, multi-bead coaters, roll coaters, roll/bladc coaters, cast coaters, laboratory coaters, gravure coaters, kiss coaters, liquid application systems, reverse roll coaters, curtain coaters, spray coaters and extrusion coaters.

[0029] The coated cellulosic substrate 10 may further includes a printed ink (not shown) on the printable coating to display information relating to the contents of a container formed therefrom. The coated cellulosic substrate 10 may be printed with indicia, such as high-quality advertising text and graphics, by a printing operation. The printing operation may include any apparatus or system capable of marking the coated cellulosic substrate with indicia. For example, the printing operation may include a printing press capable of printing high quality text and/or graphics (e.g., advertising text and graphics) onto the coated cellulosic substrate. Specific examples of printing techniques include offset printing, gravure printing, flexographic printing and digital printing.

[0030] The aqueous overprint water barrier coating 40. The aqueous overprint water barrier coating 40 includes any aqueous water barrier coating composition suitable for applying on the cellulosic substrate 20 over a printed ink on the printable coating 30 therein. The aqueous overprint water barrier coating 40 is applied in an amount sufficient to provide water barrier properties to resist penetration of external condensation. The coat weight applied may depend on the composition of the aqueous overprint water barrier coating.

[0031] The aqueous overprint water barrier coating is applied such that, on the first major side, the cellulosic substrate has low 30 minute Water Cobb test value, preferably a 30 minute Water Cobb test value of 80 grams per square meter or less, preferably 70 grams per square meter or less, more preferably 60 grams per square meter or less, more preferably 50 grams per square meter or less, more preferably 40 grams per square meter or less, more preferably 30 grams per square meter or less, more preferably 20 grams per square meter or less, more preferably 10 grams per square meter or less.

[0032] In an example, the aqueous overprint water barrier coating may include a combination of acrylic resin, styrene-acrylic copolymer, and diammonium zinc biscarbonate. In particular, a specific coating useful as an aqueous overprint water barrier coating of the present description is ACTGREEN® BARRIER CTG AQ2149000-2. [0033] Tn another example, the aqueous overprint water barrier coating may include an amine salt of modified acrylic copolymer. In particular, an exemplary specific coating useful as an aqueous overprint water barrier coating of the present description is coating 1918M from Coatings & Adhesives Corporation.

[0034] In an example, the coat weight of the aqueous overprint water barrier coating applied ranges from 5 to 50 BCM (billion cubic microns per square inch). In another example, the coat weight of aqueous overprint water barrier coating applied ranges from 5 to 10 BCM (billion cubic microns per square inch). In another example, the coat weight of aqueous overprint water barrier coating applied ranges from 10 to 20 BCM (billion cubic microns per square inch). In another example, the coat weight of aqueous overprint water barrier coating applied ranges from 20 to 50 BCM (billion cubic microns per square inch).

[0035] The moisture vapor barrier coating 50 on the second major side 22 of the cellulosic substrate 20 includes any moisture vapor barrier coating suitable for applying on the cellulosic substrate 20. The moisture vapor barrier coating 50 is applied in an amount sufficient to provide moisture vapor barrier properties to resist water vapor passing through the moisture vapor barrier coating 50 to the underlying cellulosic substrate 20.

[0036] The thickness of the moisture vapor barrier coating may depend on the composition of the moisture vapor barrier coating. The moisture vapor barrier coating 50 may include, for example, an aqueous coating or high density polyethylene. In a specific example, the moisture vapor barrier coating 50 includes one or more polyethylene (e.g., high density polyethylene) layers having a density in a range of between 0.90 and 0.97 g/cm³. In another specific example, the moisture vapor barrier coating 50 includes high density polyethylene having a density in a range of between 0.93 and 0.97 g/cm³. In another specific example, the moisture vapor barrier coating 50 includes high density polyethylene having a density in a range of between 0.94 and 0.97 g/cm³. The high density polyethylene may be applied using any available technique.

Examples of suitable techniques for applying the one or more high-density polyethylene layers include extrusion coating, extrusion laminate, and adhesive lamination. In an example, multiple high-density polyethylene layers may be coextruded onto the paperboard substrate. In another example, a first high-density polyethylene layer may be laminated onto the paperboard, and then a second high-density polyethylene layer may be extruded onto the paperboard. Tn yet another example, a first high-density polyethylene layer may be extruded onto the paperboard, and then a second high-density polyethylene layer may be laminated onto the paperboard.

[0037] When high density polyethylene is used as the moisture vapor barrier coating, the high density polyethylene may enable reducing the polymer layer thickness and hence plastic reduction for the resulting coated cellulosic container. FIG. 8 shows plastic weight reduction calculations for high density polyethylene coated paperboard cup compared with a polypropylene cup or a paperboard cup coated with low density polyethylene.

[0038] High density polyethylene works better than low density polyethylene due to its higher density which originates from its higher crystallinity. Higher crystallinity provides better moisture vapor resistance by reducing its permeability through the high density polyethylene coating. High density polyethylene has a lower moisture vapor transmission rate compared with low density polyethylene, polylactic acid and polyethylene terephthalate.

[0039] The moisture vapor barrier coating 50 has a thickness sufficient to achieve the desired moisture vapor barrier properties. In an example, the moisture vapor barrier coating 50 has a thickness ranging from 0.2 to 8 mils, wherein 1 mil equals 0.001 inch. In another example, the moisture vapor barrier coating has a thickness ranging from 0.5 to 4 mils. Tn another example, the moisture vapor barrier coating has a thickness ranging from 1 to 2 mils.

[0040] The moisture vapor barrier coating 50 is applied such that, on the second major side, the cellulosic substrate has low 30 minute Water Cobb test value, preferably a 30 minute Water Cobb test value of 3 grams per square meter or less on the second major side of the cellulosic substrate, more preferably 2 grams per square meter or less, more preferably 1.5 grams per square meter or less, more preferably 1.4 grams per square meter or less, more preferably 1.3 grams per square meter or less, more preferably 1.2 grams per square meter or less.

[0041] The moisture vapor barrier coating 50 is applied such that, on the second major side, the cellulosic substrate has low moisture vapor transmission rate, preferably a moisture vapor transmission rate of 100 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate, more preferably 50 grams per square meter per day or less, more preferably 25 grams per square meter per day or less, more preferably 10 grams per square meter per day or less, more preferably 9 grams per square meter per day or less, more preferably 8 grams per square meter per day or less, more preferably 7 grams per square meter per day or less, more preferably 6 grams per square meter per day or less, more preferably 5 grams per square meter per day or less.

[0042] As shown in Figs. 2 and 3, the present description includes a sidewall blank 100 made from the coated cellulosic substrate 10. The sidewall blank 100 may be unprinted or printed having a printed ink 112 formed on the first major side 11 of the printable coating 30 and covered by the aqueous overprint water barrier coating 40.

[0043] As shown in Figs. 4 to 6, the present description includes a coated cellulosic container 140 includes a sidewall component 142 having a first end 150 and a second end 152, and a bottom component 144 enclosing the first end 150 of the sidewall component 142. The sidewall component 142 may be formed by, for example, die-cutting a sidewall blank from a sheet of the disclosed coated cellulosic substrate into the desired configuration (e.g., trapezoidal), such the sidewall blanks 100, 110 of Figs. 2 and 3. The sidewall blank may include a first longitudinal end and a second longitudinal end. The sidewall component 142 may be formed by overlapping both longitudinal ends to surround an interior cavity of the container, forming an overlapped seam in which the first longitudinal end is positioned inside the second longitudinal end.

[0044] At least one of the sidewall component 142 and the bottom component 144 includes the coated cellulosic substrate 10. The coated cellulosic container 140 may further include a first lid component 146 enclosing the second end 152 of the sidewall component 142. Referring to Figs.

4 and 6, the coated cellulosic container 140 may include a first lid component 146 enclosing the second end 152 of the sidewall component 142 and a second lid component 126. The coated cellulosic container 140 may further include a food product contained in an internal volume of the coated cellulosic container, in particularly a cold food product such as yogurt.

[0045] The bottom 124 may formed from the disclosed paperboard. Various techniques may be used to seal the bottom 124 to the sidewall 122. As one example, a lower end of the sidewall 122 may be shaped to form a circumferential recess 130. The bottom 124 may be placed into the recess 130 and sealed to the sidewall 122. Suitable techniques for sealing the bottom 124 to the sidewall 122 include hot air heat seal and ultrasound scaling.

[0046] The lid 126 may be an unsealed plastic lid 126. The lid 126 may attach to the sidewall 122 by way of, for example, an interference fit. An upper end of the sidewall 122 may be rolled over to form a bead 132. The lid 126 may be made to form an interference fit with the bead 132 at the upper end of the sidewall 122, such that the lid 126 may be repeatedly removed and attached to cover the paperboard container 120.

[0047] Another example of a paperboard container 140 is illustrated in Figs. 15 and 16. A paperboard container 140 formed from the disclosed paperboard may include a sidewall 142, a bottom 144 and a lid 146. The sidewall 142 may be formed by, for example, die-cutting a sidewall blank from a sheet of the disclosed paperboard into the desired configuration (e.g., trapezoidal), such the sidewall blanks 100, 110 of Figs. 10 and 11. The sidewall blank may include a first longitudinal end and a second longitudinal end. The sidewall 142 may be formed by overlapping both longitudinal ends to surround an interior cavity of the container, forming an overlapped seam (not shown) in which the first longitudinal end is positioned inside the second longitudinal end. The seam may be sealed by, for example, connecting and heating a high- density polyethylene layer of the first longitudinal end to a high-density polyethylene layer of the second longitudinal end.

[0048] The bottom 144 may formed from the disclosed paperboard. Various techniques may be used to seal the bottom 144 to the sidewall 142. As one example, a lower end of the sidewall 142 may be shaped to form a circumferential recess 150. The bottom 144 may be placed into the recess 150 and sealed to the sidewall 142. Suitable techniques for sealing the bottom 144 to the sidewall 142 include hot air heat seal and ultrasound sealing.

[0049] The lid may be sealed to the sidewall 142. The paperboard lid 146 may be made from the disclosed paperboard, a different paperboard or a different material such as a film material (e.g., polymer; metal; metal-polymer combination). Various techniques may be used to seal the lid 146 to the sidewall 142. As one example, an upper end of the sidewall may be rolled over to form a flange 152 and the lid 146 may be sealed to the flange 152. The lid 146 may be sealed to the flange 152 by, for example, connecting and heating a high-density polyethylene layer of a paperboard lid 146 to a high-density polyethylene layer of the flange 152. As another example, a film lid 146 may be scaled to the flange 152, by, for example, a heat-seal or an adhesive, and a second lid may be provided to cover the film lid 146.

[0050] Fig. 7 is a cross sectional view of overlapped seam of a sidewall of the container of Fig. 4. As shown, sidewall component is completed by overlapping and sealing longitudinal ends of the sidewall blank to form an overlapped and sealed seam. In the case of Fig. 7, a tape 70 is applied to an innermost of the overlapped longitudinal end. The tape may function as a moisture barrier layer for the longitudinal end and may have heat sealing properties for sealing the longitudinal ends. For example, the tape may include polyethylene, such as low density polyethylene or high density polyethylene. However, the present description is not limited to using the tape 70 to seal the innermost longitudinal end and may include any other end sealing means. In another example, the seam may be sealed by folding the innermost longitudinal end and heating and connecting the high-density polyethylene layer at the first longitudinal end with the high-density polyethylene layer at the second longitudinal end.

[0051] The coated cellulosic substrate may be made into a coated cellulosic container using any available technique. Although various operations of making coated cellulosic container are described below, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

[0052] The coated cellulosic substrate may be cut into blanks by way of a cutting operation. The cutting operation may include any apparatus or system capable of cutting blanks from the coated cellulosic substrate. For example, the cutting operation may include a die cutting machine. The cutting operation may provide the blanks with the desired shape. The shape of the blanks may depend on the intended shape and configuration of the coated cellulosic container. Furthermore, in the case of cutting after a printing operation, the cutting operation may cut the blanks such that the printed indicia are positioned at the desired location.

[0053] The blanks may be formed into a coated cellulosic container by a forming operation.

The forming operation may shape and assemble one or more blanks into a coated cellulosic container having the desired shape and configuration. The forming operation may include any apparatus or system capable of forming one or more blanks into a coated cellulosic container having the desired shape and configuration. The forming operation may, for example, include a press mold or thermoforming mold.

[0054] In a specific example, the printed or unprinted container blanks may be formed into a paperboard container by a forming operation. For example, the sidewall blanks of Figs. 2 or 3 may be shaped by wrapping the sidewall blank around a mandrel to form a frustoconical-shaped sidewall. In an example, a sidewall blank may have a caliper thickness of 16 points. The sidewall may be completed by overlapping and sealing longitudinal ends of the shaped sidewall blank to form an overlapped and sealed seam. The seam may be sealed using any available technique.

[0055] In an example, the container may include a bottom. The bottom may be made from the coated cellulosic substrate, a different coated cellulosic substrate, or a non-cellulosic material. In an example, a bottom blank may have a caliper thickness of 13 points. The bottom may be sealed to the sidewall using any available technique. In an example, a lower end of the sidewall may be shaped to form a circumferential recess. The bottom may be placed into the circumferential recess and sealed to the sidewall.

[0056] In a non-limiting example, the container may include a lid. The lid may be made from the coated cellulosic substrate, a different cellulosic substrate, or a non-celluosic material, such as a film material (c.g., polymer; metal; mctal-polymcr combination), press-on lids (c.g., molded plastic lids) and the like. The lid may be sealed to the sidewall or may remain an unsealed lid. The lid may be sealed to the sidewall using any available technique and may depend on, among other possible factors, the type of lid being used.

[0057] During packaging, a food product (e.g., cold food product such as yogurt.) may be placed into the internal volume of the coated cellulosic container and the lid may be sealed to the sidewall of the coated cellulosic container, such as with a heat-seal, an adhesive or an interference fit. After placing the food product into the internal volume, the lid may be sealed using any available technique and may depend on, among other possible factors, the type of lid being used. [0058] Tn an example, an upper end of a sidewall may be rolled over to form a flange and the lid may be scaled to the flange.

[0059] In another example, a film material may be sealed, such as by way of lamination onto the sidewall to seal the paperboard container. A second non-sealing lid may be provided to cover the film material.

[0060] Although various operations of making coated cellulosic container are described above in a specific order and as independent operations performed by separate machines or systems, it will be understood that one or more operations may be performed in a different order, that one or more operations may be combined in a single operation, that one operation may be separated into multiple operations, or that one or more operations may be performed by a single machine or system.

[0061] Experimental Results

[0062] Testing of coated paperboard substrates and containers was conducted at 38 °C at 90% Room Humidity. For the experiment, raw edges of 16 ounce paperboard cups were sealed with silicone. The 16 oz cups were made using PMC1250 machine. Raw edge of cups were sealed with silicone and tested for any leaks. Five cups of each condition were filled with 300 ml (10.14 oz) of distilled water. Filled cups were sealed with a very low MVTR sealant film backed by Al foil by applying hot air and pressure. Filled and sealed cups were weighed using a 4 decimal point balance. Cups were stored in environmental chamber maintained at 2°C/45%RH. Cups were taken out and weighed in a conditioned room (23°C/50%RH) every 24 hours for two weeks. Cups were wiped before weighing to remove any condensate

[0063] Table 1 below shows water cobb and moisture vapor transmission rate values for one- and two-sided coated paperboard substrates and cups. The results show that when high density polyethylene is used as the moisture vapor barrier coating, the high density polyethylene may enable reducing the polymer layer thickness and hence plastic reduction for the resulting coated cellulosic container. TA B L E 1

[0064] Experimental aqueous overprint water barrier coatings were evaluated as follows. 1.5 mil PIS HDPE coated paperboard was chosen for screening of aqueous overprint water barrier coatings (WBC). The five WBC candidates that were evaluated were: WBC-1 (JainChem 320BC); WBC-2 (Actega AQ-9000); WBC-3 (Actega AQ-P83D); WBC-4 (C&A 1918MDE); and WBC-5 (C&A 1802D). The aqueous overprint water barrier coatings (WBC-1 to WBC-5) were applied using a lab proofer having anilox rollers to the clay coating side of coated paperboard opposite of the HDPE coated side. Different coat weights of aqueous overprint water barrier coatings were applied in term of BCM. Water Cobb tests were conducted on the side coated with the aqueous overprint water barrier coatings to understand its water barrier properties. The results arc shown in the graph of Fig. 9, which shows water resistance of the aqueous overprint water barrier coatings sufficient to resist penetration of external condensation.

[0065] Further, the disclosure comprises examples according to the following clauses:

[0066] Clause 1: A coated cellulosic substrate, comprising: a cellulosic substrate having a first major side and a second major side; a printable coating on the first major side of the cellulosic substrate; an aqueous overprint water barrier coating on the printable coating; and a moisture vapor barrier coating on the second major side of the cellulosic substrate.

[0067] Clause 2: The coated cellulosic substrate of Clause 1, wherein the cellulosic substrate is a paperboard substrate.

[0068] Clause 3: The coated cellulosic substrate of Clause 1 or Clause 2, wherein the cellulosic substrate is bleached.

[0069] Clause 4: The coated cellulosic substrate of Clause 1 or Clause 2, wherein the cellulosic substrate is unbleached.

[0070] Clause 5: The coated cellulosic substrate of any one of Clauses 1^1, wherein the cellulosic substrate has a caliper thickness in a range of 6 points to 36 points.

[0071] Clause 6: The coated cellulosic substrate of any one of Clauses 1^4, wherein the cellulosic substrate has a caliper thickness in a range of 7 points to 30 points.

[0072] Clause 7: The coated cellulosic substrate of any one of Clauses 1^4-, wherein the cellulosic substrate has a caliper thickness in a range of 9 points to 25 points.

[0073] Clause 8: The coated cellulosic substrate of any one of Clauses 1^4, wherein the cellulosic substrate has a caliper thickness in a range of 12 points to 20 points.

[0074] Clause 9: The coated cellulosic substrate of any one of Clauses 1^4, wherein the cellulosic substrate has a caliper thickness in a range of 15 points to 18 points. [0075] Clause 10: The coated cellulosic substrate of any one of Clauses 1 -9, wherein the cellulosic substrate has a basis weight ranging from 60 to 350 pounds per 3,000 square feet.

[0076] Clause 11: The coated cellulosic substrate of any one of Clauses 1-9, wherein the cellulosic substrate has a basis weight ranging from 100 to 300 pounds per 3,000 square feet.

[0077] Clause 12: The coated cellulosic substrate of any one of Clauses 1-9, wherein the cellulosic substrate has a basis weight ranging from 140 to 220 pounds per 3,000 square feet.

[0078] Clause 13: The coated cellulosic substrate of any one of Clauses 1-12, wherein the printable coating comprises a mixture of pigment and binder.

[0079] Clause 14: The coated cellulosic substrate of any one of Clauses 1-12, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises an inorganic pigment.

[0080] Clause 15: The coated cellulosic substrate of any one of Clauses 1-12, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises clay.

[0081] Clause 16: The coated cellulosic substrate of any one of Clauses 1-12, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises kaolin clay.

[0082] Clause 17: The coated cellulosic substrate of any one of Clauses 1-16, wherein the printable coating comprises a mixture of pigment and binder, wherein the binder comprises an emulsion polymer binder.

[0083] Clause 18: The coated cellulosic substrate of any one of Clauses 1-17, wherein the printable coating comprises a mixture of pigment and binder, wherein the amount of binder in the printable coating ranges from 5 to 25 parts by weight per 100 parts by weight of pigment.

[0084] Clause 19: The coated cellulosic substrate of any one of Clauses 1-17, wherein the printable coating comprises a mixture of pigment and binder, wherein the amount of binder in the printable coating ranges from 10 to 20 parts by weight per 100 parts by weight of pigment. [0085] Clause 20: The coated cellulosic substrate of any one of Clauses 1-19, further comprising a printed ink on the printable coating.

[0086] Clause 21: The coated cellulosic substrate of any one of Clauses 1-20, wherein the coat weight of aqueous overprint water barrier coating applied ranges from 5 to 50 BCM (billion cubic microns per square inch).

[0087] Clause 22: The coated cellulosic substrate of any one of Clauses 1-20, wherein the coat weight of aqueous overprint water barrier coating applied ranges from 5 to 10 BCM (billion cubic microns per square inch).

[0088] Clause 23: The coated cellulosic substrate of any one of Clauses 1-20, wherein the coat weight of aqueous overprint water barrier coating applied ranges from 10 to 20 BCM (billion cubic microns per square inch).

[0089] Clause 24: The coated cellulosic substrate of any one of Clauses 1-20, wherein the coat weight of aqueous overprint water barrier coating applied ranges from 20 to 50 BCM (billion cubic microns per square inch).

[0090] Clause 25: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 80 grams per square meter or less on the first major side of the cellulosic substrate.

[0091] Clause 26: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 70 grams per square meter or less on the first major side of the cellulosic substrate.

[0092] Clause 27: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 60 grams per square meter or less on the first major side of the cellulosic substrate.

[0093] Clause 28: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 50 grams per square meter or less on the first major side of the cellulosic substrate. [0094] Clause 29: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 40 grams per square meter or less on the first major side of the cellulosic substrate.

[0095] Clause 30: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 30 grams per square meter or less on the first major side of the cellulosic substrate.

[0096] Clause 31: The coated cellulosic substrate of any one of Clauses 1-24, wherein cellulosic substrate has a 30 minute Water Cobb test value of 20 grams per square meter or less on the first major side of the cellulosic substrate.

[0097] Clause 32: The coated cellulosic substrate of any one of Clauses 1-24, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 10 grams per square meter or less on the first major side of the cellulosic substrate.

[0098] Clause 33: The coated cellulosic substrate of any one of Clauses 1-32, wherein the moisture vapor barrier coating on the second major side comprises an aqueous coating.

[0099] Clause 34: The coated cellulosic substrate of any one of Clauses 1-32, wherein the moisture vapor barrier coating on the second major side comprises high density polyethylene.

[0100] Clause 35: The coated cellulosic substrate of any one of Clauses 1-32, wherein the moisture vapor barrier coating on the second major side comprises polyethylene having a density in a range of between 0.90 and 0.97 g/cm³.

[0101] Clause 36: The coated cellulosic substrate of any one of Clauses 1-32, wherein the moisture vapor barrier coating on the second major side comprises high density polyethylene having a density in a range of between 0.93 and 0.97 g/cm³.

[0102] Clause 37: The coated cellulosic substrate of any one of Clauses 1-32, wherein the moisture vapor barrier coating on the second major side comprises high density polyethylene having a density in a range of between 0.94 and 0.97 g/cm³. [0103] Clause 38: The coated cellulosic substrate of any one of Clauses 1-37, wherein the moisture vapor barrier coating on the second major side has a thickness ranging from 0.2 to 8 mils.

[0104] Clause 39: The coated cellulosic substrate of any one of Clauses 1-37, wherein the moisture vapor barrier coating on the second major side has a thickness ranging from 0.5 to 4 mils.

[0105] Clause 40: The coated cellulosic substrate of any one of Clauses 1-37, wherein the moisture vapor barrier coating on the second major side has a thickness ranging from 1 to 2 mils.

[0106] Clause 41: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 3 grams per square meter or less on the second major side of the cellulosic substrate.

[0107] Clause 42: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 2 grams per square meter or less on the second major side of the cellulosic substrate.

[0108] Clause 43: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 1.5 grams per square meter or less on the second major side of the cellulosic substrate.

[0109] Clause 44: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 1.4 grams per square meter or less on the second major side of the cellulosic substrate.

[0110] Clause 45: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 1.3 grams per square meter or less on the second major side of the cellulosic substrate.

[0111] Clause 46: The coated cellulosic substrate of any one of Clauses 1-40, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 1.2 grams per square meter or less on the second major side of the cellulosic substrate. [0112] Clause 47: The coated cellulosic substrate of any one of Clauses 1-46, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 100 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0113] Clause 48: The coated cellulosic substrate of any one of Clauses 1-46, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 50 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0114] Clause 49: The coated cellulosic substrate of any one of Clauses 1-46, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 25 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0115] Clause 50: The coated cellulosic substrate of any one of Clauses 1-46, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 10 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0116] Clause 51: The coated cellulosic substrate of any one of Clauses 1-50, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 9 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0117] Clause 52: The coated cellulosic substrate of any one of Clauses 1-50, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 8 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0118] Clause 53: The coated cellulosic substrate of any one of Clauses 1-50, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 7 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate. [0119] Clause 54: The coated cellulosic substrate of any one of Clauses 1-50, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 6 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0120] Clause 55: The coated cellulosic substrate of any one of Clauses 1-50, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 5 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

[0121] Clause 56: A coated cellulosic container comprising: a sidewall component having a first end and a second end; and a bottom component enclosing the first end of the sidewall component, wherein at least one of the sidewall component and bottom component comprises the coated cellulosic substrate of any one of Clauses 1-55.

[0122] Clause 57: The coated cellulosic container of Clause 56, further comprising a lid component enclosing the second end of the sidewall component.

[0123] Clause 58: The coated cellulosic container of Clause 56, further comprising a lid component enclosing the second end of the sidewall component and a food product contained in an internal volume of the coated cellulosic container.

[0124] Although various examples of the disclosed coated cellulosic substrates and coated cellulosic containers have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.

Claims

What is claimed is:

1. A coated cellulosic substrate, comprising: a cellulosic substrate having a first major side and a second major side; a printable coating on the first major side of the cellulosic substrate; an aqueous overprint water barrier coating on the printable coating; and a moisture vapor barrier coating on the second major side of the cellulosic substrate.

2. The coated cellulosic substrate of Claim 1, wherein the cellulosic substrate is a paperboard substrate.

3. The coated cellulosic substrate of Claim 1 or Claim 2, wherein the printable coating comprises a mixture of pigment and binder.

4. The coated cellulosic substrate of any one of Claims 1-3, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises an inorganic pigment.

5. The coated cellulosic substrate of any one of Claims 1-4, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises clay.

6. The coated cellulosic substrate of any one of Claims 1-4, wherein the printable coating comprises a mixture of pigment and binder, wherein the pigment comprises kaolin clay.

7. The coated cellulosic substrate of any one of Claims 1-4, wherein the printable coating comprises a mixture of pigment and binder, wherein the binder comprises an emulsion polymer binder.

8. The coated cellulosic substrate of any one of Claims 1-7, wherein the printable coating comprises a mixture of pigment and binder, wherein the amount of binder in the printable coating ranges from 5 to 25 parts by weight per 100 parts by weight of pigment.

9. The coated cellulosic substrate of any one of Claims 1-8, further comprising a printed ink on the printable coating.

10. The coated cellulosic substrate of any one of Claims 1-9, wherein the coat weight of aqueous overprint water barrier coating applied ranges from 5 to 50 BCM (billion cubic microns per square inch).

11. The coated cellulosic substrate of any one of Claims 1-10, wherein the cellulosic substrate has a 30 minute Water Cobb test value of 80 grams per square meter or less on the first major side of the cellulosic substrate.

12. The coated cellulosic substrate of any one of Claims 1-11, wherein the moisture vapor barrier coating on the second major side comprises an aqueous coating.

13. The coated cellulosic substrate of any one of Claims 1-11, wherein the moisture vapor barrier coating on the second major side comprises high density polyethylene.

14. The coated cellulosic substrate of any one of Claims 1-11, wherein the moisture vapor barrier coating on the second major side comprises polyethylene having a density in a range of between 0.90 and 0.97 g/cm³.

15. The coated cellulosic substrate of any one of Claims 1-14, wherein the moisture vapor barrier coating on the second major side has a thickness ranging from 0.2 to 8 mils.

16. The coated cellulosic substrate of any one of Claims 1-15, wherein the coated cellulosic substrate has a 30 minute Water Cobb test value of 3 grams per square meter or less on the second major side of the cellulosic substrate.

17. The coated cellulosic substrate of any one of Claims 1-16, wherein the coated cellulosic substrate has a moisture vapor transmission rate of 100 grams per square meter per day or less at 38 °C and 90% relative humidity on the second major side of the cellulosic substrate.

18. A coated cellulosic container comprising: a sidewall component having a first end and a second end; and a bottom component enclosing the first end of the sidewall component, wherein at least one of the sidewall component and bottom component comprises the coated cellulosic substrate of any one of Claims 1-17.

19. The coated cellulosic container of Claim 18, further comprising a lid component enclosing the second end of the sidewall component.

20. The coated cellulosic container of Claim 18, further comprising a lid component enclosing the second end of the sidewall component and a food product contained in an internal volume of the coated cellulosic container.