# US 11,299,855 B2 · Paperboard structure with at least one barrier coating layer > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 11,299,855 B2 - Document ID: US11299855B2 - Status: Granted - Kind: B2 - Application number: 16/267,865 - Filed: 2019-02-05 - Published: 2019-08-22 - Granted: 2022-04-12 - Earliest claimed: 2018-02-19 - Assignees: WestRock MWV, LLC - Applicants: WestRock MWV, LLC - Inventors: Jiebin Pang; Natasha G. Melton; Steven Parker; Teresa Krug - Web page: https://patentgrep.com/patent/US11299855B2 ## CPC - D21H 19/84: on both sides of the substrate - D21H 11/04: Kraft or sulfate pulp - D21H 19/38: characterised by the pigments - D21H 19/385: {Oxides, hydroxides or carbonates} - D21H 19/40: siliceous, e.g. clays - D21H 19/56: Macromolecular organic compounds or oligomers thereof obtained by reactions only involving carbon-to-carbon unsaturated bonds - D21H 19/60: Polyalkenylalcohols; Polyalkenylethers; Polyalkenylesters - D21H 19/72: Coated paper characterised by the paper substrate - D21H 19/822: {two superposed coatings, both being pigmented} - D21H 21/16: Sizing or water-repelling agents - D21H 23/22: Addition to the formed paper - 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 ## Abstract A paperboard structure that includes a paperboard substrate which includes a first major side and a second major side along with at least one barrier coating layer on the first major side. The barrier coating layer(s) may include a binder and a pigment, wherein the binder has a glass transition temperature of at least 20° C., wherein a ratio of the binder to the pigment is at least about 1:2 by weight. ## Claims ### Claim 1 A paperboard structure comprising: a paperboard substrate comprising a first major side and a second major side opposed from said first major side; and at least one barrier coating layer on said first major side, wherein said barrier coating layer comprises a hinder and a pigment, wherein said binder has a glass transition temperature of at least 20° C., wherein a ratio of said hinder to said pigment is at least 1:2 by weight, wherein at least 60 percent by weight of the pigment is comprised of particles having a particle size less than 2 microns, wherein the paperboard structure is heat-sealable when coated with a single layer of said barrier coating layer, and wherein the paperboard structure has a repulpability of at least 80 percent. ### Claim 2 (depends on 1) The paperboard structure of claim 1 wherein said glass transition temperature is at least 25° C. ### Claim 3 (depends on 1) The paperboard structure of claim 1 wherein said glass transition temperature is at least 30° C. ### Claim 4 (depends on 1) The paperboard structure of claim 1 wherein a ratio of said binder to said pigment is 1:2 to 9:1 by weight. ### Claim 5 (depends on 1) The paperboard structure of claim 1 wherein a ratio of said binder to said pigment is 1:1 to 4:1 by weight. ### Claim 6 (depends on 1) The paperboard structure of claim 1 wherein said binder comprises at least one of styrene-acrylate, styrene-butadiene rubber, ethylene acrylic acid, polyvinyl acetate, and polyester dispersion. ### Claim 7 (depends on 1) The paperboard structure of claim 1 wherein said pigment comprises clay. ### Claim 8 (depends on 1) The paperboard structure of claim 1 wherein said pigment comprises CaCO3. ### Claim 9 (depends on 1) The paperboard structure of claim 1 wherein said pigment comprises clay and CaCO3. ### Claim 10 (depends on 1) The paperboard structure of claim 1 wherein at least 70 percent by weight of the pigment is comprised of particles having a particle size less than 2 microns. ### Claim 11 (depends on 1) The paperboard structure of claim 1 wherein at least 80 percent by weight of said pigment is comprised of particles having a particle size less than 2 microns. ### Claim 12 (depends on 1) The paperboard structure of claim 1 wherein said pigment comprises at least one of: a coarse ground CaCO3 with a particle size of 60% less than 2 microns; a fine ground CaCO3 with a particle size of 90% less than 2 microns; and a fine ground CaCO3 with a mean particle diameter size of 0.4 microns. ### Claim 13 (depends on 1) The paperboard structure of claim 1 providing a 30-minute water Cobb test of less than 20 g/m2. ### Claim 14 (depends on 1) The paperboard structure of claim 1 providing a blocking rate of less than 3 at 40° C. and at 60 psi in a 24-hour period. ### Claim 15 (depends on 1) The paperboard structure of claim 1 further comprising a base coat layer between said paperboard substrate and said barrier coating layer. ### Claim 16 (depends on 15) The paperboard structure of claim 15 wherein said base coat layer comprises a binder and a pigment. ### Claim 17 (depends on 1) The paperboard structure of claim 1 further comprising a second barrier coating layer on said second major side. ### Claim 18 (depends on 1) The paperboard structure of claim 1 wherein said paperboard substrate has a caliper ranging from 4 points to 30 points. ### Claim 19 (depends on 18) The paperboard structure of claim 18 wherein said caliper ranges from 13 points to 18 points. ### Claim 20 (depends on 1) The paperboard structure of claim 1 wherein said paperboard substrate has a basis weight of 85 to 250 pounds per 3,000 square feet. ### Claim 21 (depends on 1) The paperboard structure of claim 1 having a repulpability of at least 85 percent. ### Claim 22 (depends on 1) The paperboard structure of claim 1 fluffier comprising a second barrier coating layer on said first major side. ### Claim 23 (depends on 1) The paperboard structure of claim 1 providing a 30-min water Cobb test of less than 6 g/m2. ### Claim 24 (depends on 22) The paperboard structure of claim 22 providing a 30-minute hot water Cobb test of less than 15 g/m2. ### Claim 25 (depends on 22) The paperboard structure of claim 22 providing a 30-minute hot coffee Cobb test of less than 15 g/m2. ### Claim 26 (depends on 22) The paperboard structure of claim 22 providing a 30-minute hot coffee Cobb test of less than 10 g/m2. ### Claim 27 (depends on 22) The paperboard structure of claim 22 providing a 30-minute hot coffee Cobb test of less than 8 g/m2. ### Claim 28 (depends on 22) The paperboard structure of claim 22 providing a blocking rate of less than 3 at 50° C. and at 60 psi in a 24-hour period. ### Claim 29 A method for manufacturing a paperboard structure comprising: preparing a harrier coating composition comprising a binder and a pigment, wherein said binder, when dried, has a glass transition temperature of at least 20° C., wherein a ratio of said binder to said pigment is at least 1:2 by weight, wherein at least 60 percent by weight of the pigment is comprised of particles having a particle size less than 2 microns; and applying a single layer of said barrier coating composition to a paperboard substrate to form a first barrier coaling layer, wherein said paperboard structure is heat-sealable after application of a single layer of said harrier coating composition, and wherein said paperboard structure has a repulpability of at least 80 percent. ### Claim 30 (depends on 29) The method of claim 29 further comprising applying a second barrier coating composition over said first harrier coating layer to form a second barrier coating layer. ### Claim 31 (depends on 29) The method of claim 29 further comprising drying said barrier coating composition. ### Claim 32 (depends on 29) The method of claim 29 further comprising applying a base coating to a first major side of the paperboard substrate.