# US 2022/0033129 A1 · Double-wall paperboard containers having aqueous barrier coatings > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2022/0033129 A1 - Document ID: US20220033129A1 - Status: Published application - Kind: A1 - Application number: 17/390,537 - Filed: 2021-07-30 - Published: 2022-02-03 - Earliest claimed: 2020-07-31 - Applicants: WestRock MWV, LLC - Inventors: Jiebin Pang; Timothy R. McNeal; Natasha G. Melton; Brian K. Knapp - Web page: https://patentgrep.com/patent/US20220033129A1 ## CPC - B65D 3/22: with double walls; with walls incorporating air-chambers; with walls made of laminated material {(for thermal insulating purposes B65D81/3818)} - D21H 27/32: with materials applied between the sheets (attaching together paper or cardboard sheets B31F5/00; adhesives C09J) - B31B 50/747: {Coating or impregnating blanks or webs} - B65D 3/06: essentially conical or frusto-conical - B65D 3/12: Flanged discs permanently secured, e.g. by adhesives or by heat-sealing - D21H 11/04: Kraft or sulfate pulp - D21H 19/385: {Oxides, hydroxides or carbonates} - D21H 19/40: siliceous, e.g. clays - D21H 19/58: Polymers or oligomers of diolefins, aromatic vinyl monomers or unsaturated acids or derivatives thereof - D21H 19/82: superposed {(D21H19/84 takes precedence)} - D21H 19/822: {two superposed coatings, both being pigmented} - D21H 19/84: on both sides of the substrate - D21H 27/10: Packing paper (packaging materials of special type or form B65D65/38) - B32B 7/14: applied in spaced arrangements, e.g. in stripes - B32B 29/005: {next to another layer of paper or cardboard layer} - B32B 2250/02: 2 layers - B32B 2250/26: All layers being made of paper or paperboard - B32B 2255/12: on paper layer - B32B 2255/26: Polymeric coating - B32B 2255/28: Multiple coating on one surface - B32B 2307/718: Weight, e.g. weight per square meter - B32B 2307/7246: Water vapor barrier - B32B 2307/7265: Non-permeable - B32B 2439/02: Open containers - B32B 2439/70: Food packaging - B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES - 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 - B31B: MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER (making wound articles, e.g. wound tubes, B31C; combined making and filling B65B) - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM ## Abstract A coated paperboard container includes an inner paperboard substrate, an outer paperboard substrate, a first aqueous barrier coating located on the inner paperboard substrate, and a second aqueous barrier coating located on the outer paperboard substrate. The inner paperboard substrate and the outer paperboard substrate are coupled with an adhesive. The first aqueous barrier coating and the second aqueous barrier coating include a pigment and a binder and the first aqueous barrier coating is heat sealable. ## Claims ### Claim 1 A coated paperboard container, comprising: an inner paperboard substrate; an outer paperboard substrate; a first aqueous barrier coating located on the inner paperboard substrate; and a second aqueous barrier coating located on the outer paperboard substrate. ### Claim 2 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and the outer paperboard substrate are coupled with an adhesive. ### Claim 3 (depends on 1) The coated paperboard container of claim 1 comprising a first base coating located between the inner paperboard substrate and the first aqueous barrier coating. ### Claim 4 (depends on 1) The coated paperboard container of claim 1 comprising a second base coating located between the outer paperboard substrate and the second aqueous barrier coating. ### Claim 5 (depends on 1) The coated paperboard container of claim 1 wherein the second aqueous barrier coating is located on an interior surface of the outer paperboard substrate. ### Claim 6 (depends on 1) The coated paperboard container of claim 1 wherein the second aqueous barrier coating is located on an exterior surface of the outer paperboard substrate. ### Claim 7 (depends on 1) The coated paperboard container of claim 1 wherein the first aqueous barrier coating is located on an inside surface of the inner paperboard substrate. ### Claim 8 (depends on 1) The coated paperboard container of claim 1 comprising a top coat layer located on an exterior surface of the outer paperboard substrate. ### Claim 9 (depends on 6) The coated paperboard container of claim 6 comprising a top coat layer located on the second aqueous barrier coating. ### Claim 10 (depends on 1) The coated paperboard container of claim 1 wherein the outer paperboard substrate comprises solid bleached sulfate. ### Claim 11 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate comprises solid bleached sulfate. ### Claim 12 (depends on 1) The coated paperboard container of claim 1 wherein the outer paperboard substrate has a basis weight ranging from about to about 140 lb/3000 ft2 to about 185 lb/3000 ft2. ### Claim 13 (depends on 1) The coated paperboard container of claim 1 wherein the paperboard substrate has a basis weight ranging from about to about 120 lb/3000 ft2 to about 200 lb/3000 ft2. ### Claim 14 (depends on 1) The coated paperboard container of claim 1 wherein: the first aqueous barrier coating comprises a first layer and a second layer, and the second aqueous barrier coating comprises a first layer and a second layer. ### Claim 15 (depends on 14) The coated paperboard container of claim 14 wherein: the first layer of the first aqueous barrier coating has a coat weight ranging from about 6.0 lb/3 msf to about 10.0 lb/3 msf, and the first layer of the second aqueous barrier coating has a coat weight ranging from about 6.0 lb/3 msf to about 10.0 lb/3 msf. ### Claim 16 (depends on 14) The coated paperboard container of claim 14 wherein: the first layer of the first aqueous barrier coating has a coat weight ranging from about 7.5 lb/3 msf to about 7.8 lb/3 msf, and the first layer of the second aqueous barrier coating has a coat weight ranging from about 7.5 lb/3 msf to about 7.8 lb/3 msf. ### Claim 17 (depends on 14) The coated paperboard container of claim 14 wherein: the second layer of the first aqueous barrier coating has a coat weight ranging from about 2.0 lb/3 msf to about 6.0 lb/3 msf, and the second layer of the second aqueous barrier coating has a coat weight ranging from about 2.0 lb/3 msf to about 6.0 lb/3 msf. ### Claim 18 (depends on 14) The coated paperboard container of claim 14 wherein: the second layer of the first aqueous barrier coating has a coat weight ranging from about 2.8 lb/3 msf to about 5.0 lb/3 msf, and the second layer of the second aqueous barrier coating has a coat weight ranging from about 2.8 lb/3 msf to about 5.0 lb/3 msf. ### Claim 19 (depends on 1) The coated paperboard container of claim 1 wherein the first aqueous barrier coating comprises binder and pigment. ### Claim 20 (depends on 1) The coated paperboard container of claim 1 wherein the second aqueous barrier coating comprises binder and pigment. ### Claim 21 (depends on 19) The coated paperboard container of claim 19 wherein the binder comprises styrene-acrylate. ### Claim 22 (depends on 20) The coated paperboard container of claim 20 wherein the binder comprises styrene-acrylate. ### Claim 23 (depends on 19) The coated paperboard container of claim 19 wherein the pigment comprises kaolin clay. ### Claim 24 (depends on 20) The coated paperboard container of claim 20 wherein the pigment comprises kaolin clay. ### Claim 25 (depends on 19) The coated paperboard container of claim 19 wherein the pigment comprises CaCO3. ### Claim 26 (depends on 20) The coated paperboard container of claim 20 wherein the pigment comprises CaCO3. ### Claim 27 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a 30-minute-water-Cobb rating of at most about 3.8 g/m2. ### Claim 28 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a 30-minute-water-Cobb rating of at most about 4.8 g/m2. ### Claim 29 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a 30-minute-water-Cobb rating of at most about 5.2 g/m2. ### Claim 30 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a 30-minute-water-Cobb rating of at most about 10.0 g/m2. ### Claim 31 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a water vapor transmission rate of at most about 200 g/m2-day. ### Claim 32 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a water vapor transmission rate of at most about 300 g/m2-day. ### Claim 33 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a water vapor transmission rate of at most about 400 g/m2-day. ### Claim 34 (depends on 1) The coated paperboard container of claim 1 wherein the inner paperboard substrate and outer paperboard substrate have a water vapor transmission rate of at most about 500 g/m2-day. ### Claim 35 A method of manufacturing a double-wall cup having an inner paperboard substrate coated with a first aqueous barrier coating and an outer paperboard substrate coated with a second aqueous barrier coating, the method comprising: forming a cup structure with the inner paperboard substrate; applying an adhesive to the cup structure; and overwrapping the cup structure with the outer paperboard substrate. ### Claim 36 (depends on 35) The method of claim 35 wherein the adhesive is glue. ### Claim 37 (depends on 35) The method of claim 35 wherein the inner paperboard substrate comprises solid bleached sulfate. ### Claim 38 (depends on 35) The method of claim 35 wherein the outer paperboard substrate comprises solid bleached sulfate. ### Claim 39 (depends on 35) The method of claim 35 wherein the first aqueous barrier coating comprises binder and pigment. ### Claim 40 (depends on 35) The method of claim 35 wherein the second aqueous barrier coating comprises binder and pigment. ### Claim 41 (depends on 39) The method of claim 39 wherein the binder comprises styrene-acrylate. ### Claim 42 (depends on 40) The method of claim 40 wherein the binder comprises styrene-acrylate. ### Claim 43 (depends on 35) The method of claim 35 wherein the second aqueous barrier coating is located on an interior surface of the outer paperboard substrate. ### Claim 44 (depends on 35) The method of claim 35 wherein in the second aqueous barrier coating is located on an exterior surface of the outer paperboard substrate. ### Claim 45 (depends on 35) The method of claim 35 wherein the first aqueous barrier coating is located on an inside surface of the inner paperboard substrate. ### Claim 46 A double wall cup comprising: an inner paperboard substrate; an outer paperboard substrate; a first aqueous barrier coating located on the inner paperboard substrate; a second aqueous barrier coating located on the outer paperboard substrate; and an adhesive located between the inner paperboard substrate and the outer paperboard substrate. ### Claim 47 (depends on 46) The double wall cup of claim 46 comprising a first base coating located between the inner paperboard substrate and the first aqueous barrier coating. ### Claim 48 (depends on 46) The double wall cup of claim 46 comprising a second base coating located between the outer paperboard substrate and the second aqueous barrier coating. ### Claim 49 (depends on 46) The double wall cup of claim 46 wherein the second aqueous barrier coating is located on an interior surface of the outer paperboard substrate. ### Claim 50 (depends on 46) The double wall cup of claim 46 wherein the second aqueous barrier coating is located on an exterior surface of the outer paperboard substrate. ### Claim 51 (depends on 46) The double wall cup of claim 46 wherein the first aqueous barrier coating is located on an inside surface of the inner paperboard substrate. ### Claim 52 (depends on 46) The double wall cup of claim 46 comprising a top coat layer located on an exterior surface of the outer paperboard substrate. ### Claim 53 (depends on 46) The double wall cup of claim 46 comprising a top coat layer located on the second aqueous barrier coating. ### Claim 54 (depends on 46) The double wall cup of claim 46 wherein the outer paperboard substrate comprises solid bleached sulfate. ### Claim 55 (depends on 46) The double wall cup of claim 46 wherein the inner paperboard substrate comprises solid bleached sulfate.