Heat-sealable paperboard structures and associated paperboard-based containers

A method for manufacturing a container comprising:

• cutting a paperboard structure to yield a blank having a first end opposed from a second end, the paperboard structure comprising:
• a paperboard substrate having a first major side and a second major side;
• a barrier coating layer on the first major side of the paperboard substrate, the barrier coating layer comprising a barrier coating binder and a barrier coating pigment at a first binder-to-pigment ratio of at least 1:2, by weight;
• a top coat on the first major side of the paperboard substrate, the top coat comprising a top coat binder and a top coat pigment at a second binder-to-pigment ratio ranging from 1:1 to 1:10, wherein the first binder-to-pigment ratio is greater than the second binder-to-pigment ratio, and wherein the barrier coating layer is positioned between the paperboard substrate and the top coat;
• and
• a heat-sealable harrier coating layer applied to the second major side of paperboard substrate, wherein the heat sealable barrier coating layer comprises heat-sealable barrier coating binder and heat-sealable barrier coating pigment, wherein the heat-sealable barrier coating binder comprises at least one of styrene-acrylate, styrene-butadiene rubber, ethylene acrylic acid, polyvinyl acetate, polyvinyl acrylic, and polyester dispersion;
• wrapping the blank around a mandrel;
• heat-sealing the first end of the blank to the second end of the blank, thereby yielding a side wall having an upper end portion and a lower end portion;
• and
• connecting a bottom wall to the lower end portion of the side wall.

A container comprising:

• a side wall having an upper end portion and a lower end portion, the side wall being formed from a paperboard structure comprising:
• a paperboard substrate having a first major side and a second major side;
• a barrier coating layer on the first major side of the paperboard substrate, the barrier coating layer comprising a barrier coating binder and a barrier coating pigment at a first binder-to-pigment ratio of at least 1:2, by weight;
• a top coat on the first major side of the paperboard substrate, the top coat comprising a top coat binder and a top coat pigment at a second binder-to-pigment ratio ranging from 1:1 to 1:10, wherein the first binder-to-pigment ratio is greater than the second binder-to-pigment ratio, and wherein the barrier coating layer is positioned between the paperboard substrate and the top coat, the top coat defining an exterior surface of the side wall;
• and
• a heat-sealable barrier coating layer applied to the second major side of the paperboard substrate, die heat-sealable barrier coating layer defining an interior surface of the side wall, wherein the heat sealable harrier coating layer comprises heat-sealable barrier coating binder and heat-scalable harrier coating pigment, wherein the heat-sealable barrier coating binder comprises at least one of styrene-acrylate, styrene-butadiene rubber, ethylene acrylic acid, polyvinyl acetate, polyvinyl acrylic, and polyester dispersion;
• and
• a bottom wall connected to the lower end portion of the side wall.

A container comprising:

• a side wall having an upper end portion and a lower end portion;
• and
• a bottom wall connected to the lower end portion of the side wall, the bottom wall being formed from a paperboard structure comprising:
• a paperboard substrate having a first major side and a second major side;
• a barrier coating layer on the first major side of the paperboard substrate, the barrier coating layer comprising a barrier coating binder and a harrier coating pigment at a first binder-to-pigment ratio of at least 1:2, by weight;
• a top coat era the first major side of the paperboard substrate, the top coat comprising a top coat binder and a top coat pigment at a second binder-to-pigment ratio ranging m 1:1 to 1:10, wherein the first binder-to-pigment ratio is greater than the second binder-to-pigment ratio, and wherein the barrier coating layer is positioned between the paperboard substrate and the top coat, the top coat defining an exterior surface of the bottom wall;
• and
• a heat-sealable barrier coating layer applied to the second major side of the paperboard substrate, the heat-sealable barrier coating layer defining an interior surface of the bottom wall, wherein the heat-sealable barrier coating layer comprises heat-sealable barrier coating binder and beat-sealable barrier coating pigment, wherein the heat-sealable barrier coating binder comprises at least one of styrene-acrylate, styrene-butadiene rubber, ethylene acrylic acid, polyvinyl acetate, polyvinyl acrylic, and polyester dispersion.