Coated sheet material and method
AssigneeA*Ware Technologies, L.C.
InventorsDerric Overcash, Ronald L. Elsenbaumer
Life of this patent
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Abstract
A novel coated sheet material is made by: (a) coating a porous substrate sheet material with a barrier coating comprised of (i) a cross-linkable polymer resistant to penetration by water moister when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured, said barrier coating composition forming a barrier layer on said substrate sheet material; and (b) coating said barrier layer with a release coating composition. The coated sheet material may be used to make containers, wrappers and/or receptacles for food and other substances, including ovenable and dual-ovenable embodiments thereof.
Claims52
A coated sheet material comprised of:
- (a) a porous substrate sheet material comprised of cellulose material having at least two oppositely disposed surfaces;
- (b) a barrier coating on at least one surface of said substrate sheet material wherein said barrier coating is a blend comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured to form a barrier layer on said substrate sheet material;
- and
- (c) a release coating on said barrier layer wherein said release coating comprises a fatty acid complex of a metal ion in an oxidation state equal to or greater than 3, wherein said fatty acid complex of a metal ion is crosslinked to said water-dispersible, film-forming polymer in said barrier layer.
A coated sheet material for use in forming a food wrapper, container or receptacle, said coated sheet material being comprised of:
- (a) a substrate sheet material comprising cellulose having at least two oppositely disposed surfaces and having a basis weight of between about 20 pounds per 1000 square feet of sheet material and about 40 pounds per 1000 square feet of sheet material;
- (b) a barrier coating on at least one surface of said substrate sheet material wherein said barrier coating is a blend comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured to form a barrier layer on said substrate sheet material;
- and
- (c) a release coating on said barrier coating, wherein said release coating is comprised of a trivalent or tetravalent metal complex of a fatty acid, wherein said trivalent or tetravalent metal complex of a fatty acid is crosslinked to said water-dispersible, film-forming polymer in said barrier layer.
A coated sheet material for use in forming a food wrapper, container or receptacle, said coated sheet material being comprised of:
- (a) a substrate sheet material comprised of cellulose having at least two oppositely disposed surfaces and having a basis weight of between about 20 pounds per 1000 square feet of sheet material and about 40 pounds per 1000 square feet of sheet material;
- (b) a barrier coating on at least one surface of said substrate sheet material wherein said barrier coating is a blend comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a polyvinyl alcohol that is resistant to penetration by grease and oil when cured;
- and
- (c) a release coating on said barrier coating, wherein said release coating is comprised of a trivalent or tetravalent metal complex of a fatty acid wherein said trivalent or tetravalent metal complex of a fatty acid is crosslinked to said polyvinyl alcohol in said barrier layer.
A shaped article comprising a coated sheet material that is ovenable in a conventional oven at temperatures of about 400.degree. F. and that is comprised of:
- (a) a porous substrate sheet material comprised of cellulose material having at least two oppositely disposed surfaces;
- (b) a barrier coating on at least one surface of said substrate sheet material wherein said barrier coating is a blend comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured to form a barrier layer on said substrate sheet material;
- and
- (c) a release coating on said barrier layer wherein said release coating comprises a fatty acid complex of a metal ion in an oxidation state equal to or greater than 3, wherein said fatty acid complex of a metal ion is crosslinked to said water-dispersible, film-forming polymer in said barrier layer.
A method of making a coated sheet material, said method comprising the steps of:
- (a) coating one surface of a porous cellulose substrate sheet material having at least two oppositely disposed surfaces, with a barrier coating composition that is a blend solution or dispersion comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured, said barrier coating composition forming a barrier layer on said substrate sheet material;
- and
- (b) coating said barrier layer with a release coating composition comprised of a fatty acid complex of a metal ion in an oxidation state equal to or greater than 3, and crosslinking said fatty acid complex of a metal ion to said water-dispersible, film-forming polymer in said barrier layer, said release coating composition forming a release layer on said barrier layer.
A method of making a shaped article that is ovenable in a conventional oven at temperatures of about 400.degree. F., said method comprising the steps of:
- (a) coating one surface of a porous substrate sheet material comprising cellulose having at least two oppositely disposed surfaces, with a barrier coating composition that is a blend solution or dispersion comprised of:
- (i) a cross-linkable polymer that is resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer that is resistant to penetration by grease and oil when cured, said barrier coating composition forming a barrier layer on said substrate sheet material;
- (b) coating said barrier layer with a release coating composition wherein said release coating comprises a fatty acid complex of a metal ion in an oxidation state equal to or greater than 3, and crosslinking said fatty acid complex of a metal ion to said water-dispersible, film-forming polymer in said barrier layer, said release coating composition forming a release layer on said barrier layer;
- and
- (c) forming said substrate sheet material into a shaped article.
A method of protecting a food-contacting surface from penetration by grease, oil and water, wherein said method comprises the steps of:
- (a) on the food-contacting surface of a porous substrate sheet material comprising cellulose for use in a food wrapper, receptacle or container, coating said substrate sheet material with a barrier coating composition that is a blend solution or dispersion comprised of:
- (i) a cross-linkable polymer resistant to penetration by water moisture when cured, and (ii) a water-dispersible, film-forming polymer resistant to penetration by grease and oil when cured, said barrier coating composition forming a barrier layer on said substrate sheet material;
- and
- (b) coating said barrier layer with a release coating composition wherein said release coating comprises a fatty acid complex of a metal ion in an oxidation state equal to or greater than 3, and crosslinking said fatty acid complex of a metal ion to said water-dispersible, film-forming polymer in said barrier layer, said release coating composition forming a release layer on said barrier layer.
Dependencies are inferred from the claim text.