Smooth and low density paperboard structures and methods for manufacturing the same
AssigneeWestRock MWV, LLC
InventorsSergio A. Giuste, Steven Parker, Terrell J. Green
Life of this patent
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Abstract
A method for manufacturing a paperboard structure includes passing a paperboard substrate through a hot-hard calender to yield a calendered paperboard substrate, the hot-hard calender including a nip defined by a thermo-roller and a counter roller, wherein a contact surface of the thermo-roller is heated to an elevated temperature. The method then includes applying a basecoat to the calendered paperboard substrate to yield a basecoated paperboard substrate, the basecoat includes a basecoat binder and a basecoat pigment blend. The method further includes applying a topcoat to the basecoated paperboard substrate.
Claims23
A method for manufacturing a paperboard structure comprising:
- passing a paperboard substrate through a hot-hard calender to yield a calendered paperboard substrate, said hot-hard calender comprising a nip defined by a thermo-roller and a counter roller, wherein a contact surface of said thereto-roller is heated to an elevated temperature of at least 250° F.;
- applying a basecoat to said calendered paperboard substrate to yield a basecoated paperboard substrate, said basecoat comprising a basecoat binder and a basecoat pigment;
- and
- applying a topcoat to said basecoated paperboard substrate,
- wherein said paperboard structure has a basis weight, a caliper thickness and a Parker Print Surf (PPS 10S) smoothness, said Parker Print Surf (PPS 10S) smoothness being at most 3 microns, said basis weight being at most Y2 pounds per 3000 ft2, wherein Y2 is a function of said caliper thickness (X) in points and is calculated as follows:
- Y2=3.71÷13.14X−0.1602X2.
Dependencies are inferred from the claim text.