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US20250382746A1 - Single coated paperboard - Google Patents

Single coated paperboard

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Publication number
US20250382746A1
US20250382746A1 US18/879,374 US202318879374A US2025382746A1 US 20250382746 A1 US20250382746 A1 US 20250382746A1 US 202318879374 A US202318879374 A US 202318879374A US 2025382746 A1 US2025382746 A1 US 2025382746A1
Authority
US
United States
Prior art keywords
coating
paperboard
coating layer
coated paperboard
methods
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
US18/879,374
Other languages
English (en)
Inventor
Therese Hagg
Johan A. Larsson
Andreas Nordell
Krister Sall
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Billerud AB
Original Assignee
Billerud AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=82748243&utm_source=google_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20250382746(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by Billerud AB filed Critical Billerud AB
Publication of US20250382746A1 publication Critical patent/US20250382746A1/en
Pending legal-status Critical Current

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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
    • D21H19/36—Coatings with pigments
    • D21H19/38—Coatings with pigments characterised by the pigments
    • D21H19/385—Oxides, hydroxides or carbonates
    • 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
    • D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/58—Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof
    • 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
    • D21H19/56—Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/60—Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters
    • 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
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16—Sizing or water-repelling agents
    • 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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/10—Packing paper
    • 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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply

Definitions

  • Pigment-coated paperboard is commonly provided with at least two coating layers, including a base coating and a top coating, in order to induce certain surface properties.
  • the base coating is used to prime the surface while the top coating is used to adapt the surface properties to specific applications.
  • a barrier coating might also be added.
  • the pigment-coated paperboard is covered with a layer of polyethylene (PE) such that a laminate is formed.
  • PE polyethylene
  • the purpose of the PE layer is normally to provide a barrier and/or to facilitate heat-sealing when a package is formed from the laminate.
  • the laminate it is important that the PE layer adheres firmly to the pigment coating, i.e., that delamination is avoided.
  • the present inventors have realized that there is a need to reduce the cost of paperboard manufacturing while maintaining other properties, such as PE-adhesion and surface roughness, at an acceptable level.
  • the present disclosure provides a coated paperboard comprising a paperboard substrate and a coating layer applied directly to a surface of a first side of the paperboard substrate, wherein:
  • Pigment-based coating refers to a coating comprising at least 75% by dry weight of pigment.
  • the coating layer is present on one side of the paperboard substrate and is present as a single layer with no other pigment-based coating layers on said side.
  • the paperboard according to the present disclosure has an improved PE-adhesion, which is advantageous since it prevents delamination during forming of packages from the paperboard.
  • the calcium carbonate pigments of the present disclosure are relatively large and give rise to a coated paperboard having lower surface roughness than what is obtained with single layer coatings comprising finer calcium carbonate pigments.
  • the coating layer is the only pigment-based coating applied to any side of the coated paperboard.
  • the coating layer is applied by dispersion coating and the coated paperboard comprises no other coating layer applied by dispersion coating on the same side of the paperboard as the coating layer.
  • the polymeric binder is a styrene-based copolymer such as a styrene-butadiene copolymer or a styrene-acrylate copolymer.
  • the calcium carbonate pigment is a ground calcium carbonate (GCC).
  • GCC ground calcium carbonate
  • the coat weight of the coating layer is at least 10 g/m 2 , preferably at least 12 g/m 2 .
  • a suitable upper limit for the coat weight is 18 g/m 2 or 20 g/m 2 .
  • the coat weight of the coating layer is 12-16 g/m 2 .
  • the single coating layer can be applied in a coat weight similar to the coat weight of the base coating layer in conventional coated paperboards comprising at least two coating layers.
  • the coating layer is present as a single pigment-based coating layer, it is possible to reduce the total amount of coating used compared to conventional coating materials comprising at least two coating layers and thereby reduce the cost.
  • production of a single-coated product requires one coater and is hence less costly from an investment and operational perspective.
  • the grammage according to ISO 536:2019 of the paperboard substrate may for example be between 100 and 400 g/m 2 , e.g. between 120 and 300 g/m 2 , such as between 125 and 260 g/m 2 .
  • the coated paperboard is a liquid packaging board.
  • the paperboard substrate of the liquid packaging board comprises at least two, such as at least three layers and each layer comprises hydrophobic size.
  • the hydrophobic size may be alkenyl succinic anhydride (ASA), alkyl ketene dimer (AKD) and/or rosin size, and each layer of the paperboard substrate may comprise at least 1.5 kg/tonne fibre of the hydrophobic size.
  • each layer comprises at least one of AKD and ASA.
  • the hydrophobic size is preferably added as internal sizing.
  • FIG. 1 shows surface properties of samples of coated paperboard produced in a pilot trial.
  • FIG. 2 shows surface properties of samples of coated paperboard produced in a (full-scale) machine trial.
  • FIG. 3 shows the PE-adhesion values of samples of coated paperboard produced in the (full-scale) machine trial.
  • the present disclosure relates to a coated paperboard comprising a paperboard substrate and a coating layer applied directly to a first surface of said paperboard substrate.
  • the paperboard substrate comprises at least two layers, such as at least three layers wherein the top layer of the paperboard substrate is provided with the pigment coating.
  • the top layer of the paperboard substrate is typically bleached.
  • Each layer of the paperboard substrate may comprise hydrophobic size such as ASA, AKD and/or rosin size. The amount of added hydrophobic size may be 1.5 kg/tonne fibre.
  • the paperboard substrate may comprise other conventional additives such as fillers and colouring agents, however, it is not necessary.
  • the coating layer comprises a polymeric binder and a calcium carbonate pigment.
  • the polymeric binder can be a synthetic binder and/or a biobased binder.
  • the polymeric binder is preferably a styrene-based copolymer such as a styrene-butadiene copolymer or a styrene-acrylate copolymer.
  • the styrene-acrylate copolymer is preferred, e.g. form an environmental perspective.
  • the calcium carbonate pigment has a particle size distribution (% ⁇ 2 ⁇ m) between 50 and 70.
  • % means percent by weight.
  • the calcium carbonate pigment has a weight median particle size d 50 of 1.1-1.7 ⁇ m, such as 1.2-1.6 ⁇ m.
  • Particle size distribution values can be determined using a SediGraph 5100 or 5120 device from the company Micromeritics, USA.
  • a particle size distribution (% ⁇ 2 ⁇ m) between 50 and 70 means that between 50 wt. % and 70 wt. % of the particles has an equivalent spherical diameter below 2 ⁇ m.
  • % ⁇ 2 ⁇ m is a cut-off value commonly used in the field to define the particle size of a pigment product.
  • “60” represents the weight percentage of particles having a diameter below 2 ⁇ m.
  • “90” represents the weight percentage of particles having a diameter below 2 ⁇ m.
  • the calcium carbonate pigment is ground calcium carbonate (GCC).
  • the coating layer comprises the polymeric binder and the calcium carbonate pigment in a dry weight ratio between 10:100 and 17:100, preferably 12:100-17:100.
  • the polymeric binder and the calcium carbonate pigment together, amount to at least 85% of the dry weight of the coating layer, preferably at least 90% of the dry weight of the coating layer, more preferably at least 95% of the dry weight of the coating layer.
  • the coating layer only comprises a binder, calcium carbonate pigment and optionally a rheology modifier, in dry form.
  • the coating layer is applied directly to a first surface of the paperboard substrate. Said surface is preferably the print side of the paperboard substrate. There is no additional pigment-based coating layer present between the paperboard substrate and the coating layer, hence no “base coating” layer is applied.
  • the coating layer of the present disclosure is a single coating layer that serves the purposes of both a “base coating” layer and a “top coating” layer.
  • the coating layer is the only pigment-based coating applied to any side of the coated paperboard.
  • the coated paperboard may have a PPS roughness of less than 3.8 ⁇ m, such as 0.5-3.7 ⁇ m.
  • the coating layer may further comprise a rheology modifier (RM) such as acrylic copolymer emulsions, which may facilitate the application of said coating layer to the paperboard substrate.
  • RM rheology modifier
  • the amount of rheology modifier is typically 0.05-2% such as 0.1%-1% of the dry weight of the coating.
  • the coat weight of the coating layer is at least 10 g/m 2 (e.g. 10-20 g/m 2 , such as 10-18 g/m 2 ), preferably at least 12 g/m 2 (e.g. 12-20 g/m 2 , such as 12-18 g/m 2 ).
  • the single coating layer can be applied in a coat weight similar to the coat weight of the base coating layer in conventional coated paperboards comprising at least two coating layers.
  • the coating layer is present as a single pigment-based coating layer, it is possible to reduce the total amount of coating used compared to conventional coating materials comprising at least two coating layers and thereby reduce the cost.
  • production of a single-coated product requires one coater and is hence less costly from an investment and operational perspective.
  • the coating layer may be applied to the first surface of the paperboard substrate by dispersion coating, wherein the dispersion coating comprises a latex binder and a calcium carbonate pigment in an aqueous medium.
  • the coating layer is preferably the only coating layer applied by dispersion coating on the first surface.
  • the coated paperboard is a liquid packaging board.
  • a pilot trial was performed by coating uncoated paperboard (LPB) substrates.
  • the paperboard substrate had a grammage of ⁇ 220 g/m 2 and comprised three layers, wherein the top layer was bleached. All layers comprised hydrophobic size (AKD+rosin size).
  • a reference paperboard was prepared by coating the paperboard substrate with a base coating and a top coating, having a total coat weight of 20 g/m 2 .
  • the calcium carbonate pigments were Hydrocarb 90 (“HC 90”) having a d 50 of 0.7 ⁇ m, Covercarb 75 (“CC 75”) having a d 50 of 0.63 ⁇ m and Hydrocarb 60 (“HC 60”) having a d 50 of 1.4 ⁇ m and a particle size distribution (% ⁇ 2 ⁇ m) of 60.
  • the calcium carbonate pigments were all from Omya.
  • the clay pigment was a flaky kaolin pigment.
  • the polymeric binder was a styrene-acrylate binder used as a latex (SA latex).
  • SA latex styrene-acrylate binder used as a latex
  • the Parker Print Surf (PPS) roughness and the Bendtsen roughness were measured according to ISO 8791-4 and ISO 8791-2 respectively and the results can be-seen in FIG. 1 .
  • the concepts having a single coating structure all had higher PPS and Bendtsen roughness compared to the concepts having a double coating structure (concepts 1-3 and reference). This may be due to the concepts 4-6 only having one coating layer in comparison to the reference and concepts 1-3 having two coating layers.
  • the double coating concepts have higher coat weights (20 g/m 2 and 15.5 g/m 2 ) compared to the single coating concepts (14 g/m 2 ).
  • the single coating structures in this trial thus, seem to behave differently compared to double coating structures in the trial; changes in the different compositions, such as altering the particle size of the pigments or incorporating clay, give rise to different effects.
  • a machine trial was performed by coating uncoated paperboard (LPB) substrates.
  • the paperboard substrate had a grammage of ⁇ 220 g/m 2 and comprised three layers wherein the top layer was bleached. All layers comprised hydrophobic size (AKD+rosin size).
  • the coatings were applied using a blade coater and air dryer.
  • the Parker Print Surf (PPS) roughness and the Bendtsen roughness were measured according to ISO 8791-4 and ISO 8791-2 respectively and the results can be seen in FIG. 2 .
  • concept 6 had a higher PPS and Bendtsen roughness than the reference and concept 3. As stated above, this could possibly be attributed to concept 6 only having a single coating layer and a lower coat weight.
  • the paperboards in the machine trial were laminated with a layer of polyethylene (PE) on the coated side and the PE-adhesion was tested according to ISO 6133.
  • the PE-adhesion was tested on a 5 cm long strip of PE-laminated paperboard with a width of 15 mm.
  • the delamination of the PE-film from the paperboard was tested using a tensile tester and the results are averages of 8 samples.
  • the results for the PE-adhesion can be seen in FIG. 3 .
  • concept 6 which had the single coating and coarser pigments, had superior PE-adhesion compared to the reference and concept 3. It appears as if the single coating combined with the use of calcium carbonate pigment with larger average particle size give rise to an improved PE-adhesion.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Paper (AREA)
US18/879,374 2022-06-28 2023-06-28 Single coated paperboard Pending US20250382746A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
EP22181454.4 2022-06-28
EP22181454.4A EP4299832B1 (fr) 2022-06-28 2022-06-28 Carton revêtu unique
PCT/EP2023/067612 WO2024003119A1 (fr) 2022-06-28 2023-06-28 Carton à revêtement unique

Publications (1)

Publication Number Publication Date
US20250382746A1 true US20250382746A1 (en) 2025-12-18

Family

ID=82748243

Family Applications (1)

Application Number Title Priority Date Filing Date
US18/879,374 Pending US20250382746A1 (en) 2022-06-28 2023-06-28 Single coated paperboard

Country Status (5)

Country Link
US (1) US20250382746A1 (fr)
EP (2) EP4299832B1 (fr)
CN (1) CN119452135A (fr)
MX (1) MX2024015829A (fr)
WO (1) WO2024003119A1 (fr)

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
SE0102941D0 (sv) 2001-09-05 2001-09-05 Korsnaes Ab Publ Uncoated paperboard for packages
US20100040794A1 (en) 2006-11-15 2010-02-18 Francis Dobler Placental blood extractor
US8142887B2 (en) * 2008-03-21 2012-03-27 Meadwestvaco Corporation Basecoat and associated paperboard structure
SE534561C2 (sv) * 2009-04-03 2011-10-04 Korsnaes Ab Pigmentbestruken kartong för förpackningar, förpackning innefattande pigmentbestruken kartong, användning av sådan kartong, och ett förfarande i en process för tillverkning av kartong
US9732474B2 (en) * 2015-05-29 2017-08-15 International Paper Company Hydrophobic coated paper substrate for polymer emulsion topcoats and method for making same
US10961663B2 (en) 2017-01-25 2021-03-30 Westrock Mwv, Llc Paperboard with low coat weight and high smoothness
EP3388575A1 (fr) * 2017-04-12 2018-10-17 BillerudKorsnäs AB Carton recouvert de pigments présentant une meilleure adhésion de pe
US20190177920A1 (en) * 2017-12-11 2019-06-13 Graphic Packaging International, Llc Pigmented size press and surface size for coated paper and paperboard
WO2019139813A1 (fr) * 2018-01-12 2019-07-18 Westrock Mwv, Llc Compositions de revêtement et structures en carton associées
US11578462B2 (en) * 2018-04-27 2023-02-14 Westrock Mwv, Llc Anti-blocking high barrier paperboard structures
JP2022532203A (ja) * 2019-05-10 2022-07-13 ウエストロック・エム・ダブリュー・ヴイ・エルエルシー 平滑な、および低密度の板紙構造物、ならびに、それを製造するための方法

Also Published As

Publication number Publication date
MX2024015829A (es) 2025-04-02
EP4299832C0 (fr) 2024-08-07
WO2024003119A1 (fr) 2024-01-04
EP4547909A1 (fr) 2025-05-07
EP4299832B1 (fr) 2024-08-07
EP4299832A1 (fr) 2024-01-03
CN119452135A (zh) 2025-02-14

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