Meadwestvaco Corporation

Westrock Mwv, LLC

Gary P Fugitt

Steven G Bushhouse

Wei-Hwa Her

Scott E Ginther

Jason Richard Hogan

Steven Parker

Terrell J Green

Steve G Bushhouse

Anthony V Lyons

Steven Paul Metzler

Sven Samuel Arenander

Terry Clark

Roger W Wygant

John W Stolarz, Jr

James P E Jones

Robert W Carlson

Stanley H McGrew, Jr

Jr Stanley H Mcgrew

Steven P Metzler

A coated paper or paperboard structure includes a paper or paperboard substrate and a basecoat applied to the paper or paperboard substrate to yield a basecoat outer surface. The basecoat includes a water-soluble polymer binder and pigment.

Coated paper and paperboard structures

Coatings are disclosed which provide single-layer-coated paperboard having good smoothness and printability. Low density organic pigments (LDOP) are used in some of the coatings. Certain coatings when applied as single-layer coatings at 6 lb/3000 ft(9.8 g/m) and higher gave Parker PrintSurf values less than 2.5 microns. Certain coatings when applied as base coats and then top coated gave PrintSurf values less than 2.0 microns for uncalendered samples.

Paperboard with low coat weight and high smoothness

Paper and paperboard coatings are disclosed using a modified clay which is characterized by an average shape factor less than 60, a sediment void volume greater than 48%, and containing less than 30% by mass of particles less than 1 micron in diameter.

Coatings using clays with low packing density

A paper or paperboard including a cellulose substrate and a coating applied to each side of the paperboard substrate to form a coated structure, the coated structure having a basis weight, a caliper thickness and a Parker Print Surf smoothness, the Parker Print Surf smoothness being at most about 2 microns, the basis weight being less than about Y1 pounds per 3000 ft2, wherein Y1 is a function of the caliper thickness (X) in points and is calculated as follows:1=29.15+11.95&#x2212;0.074152.

Low density paper and paperboard with two-sided coating

A basecoat including a pigment blend that includes a ground calcium carbonate component and a hyperplaty clay component, wherein the ground calcium carbonate component has a coarse particle size distribution, and wherein the hyperplaty clay component has an average aspect ratio of at least 40:1.

Basecoat and associated paperboard structure

A paper or paperboard including a cellulose substrate and a coating applied to each side of the paperboard substrate to form a coated structure, the coated structure having a basis weight, a caliper thickness and a Parker Print Surf smoothness, the Parker Print Surf smoothness being at most about 2 microns, the basis weight being less than about Ypounds per 3000 ft2, wherein Yis a function of the caliper thickness (X) in points and is calculated as follows: Y=29.15+11.95X&#x2212;0.07415X2.

A paperboard structure including a paperboard substrate having a first major surface and a second major surface and a basecoat applied to the first major surface and/or the second major surface, the basecoat including a pigment component, the pigment component including all pigments in the basecoat, wherein the pigment component has a median particle size between about 3 and about 8 micrometers, and wherein at most about 15 percent by weight of the pigment component has a particle size smaller than 1 micrometer.

Basecoat composition and associated paperboard structure

A basecoat including a pigment blend including a calcined clay component and a hyper-platy clay component, wherein the hyper-platy clay component has a shape factor of at least about 40:1, and wherein the pigment blend has a sediment void volume of at least about 50 percent.

Basecoat and associated paperboard structure including a pigment blend of hyper-platy clay and calcined clay

A basecoat composition including a carrier component and a pigment component dispersed in the carrier component, the pigment component including all pigments in the basecoat composition, wherein the pigment component has a median particle size between about 3 and about 8 micrometers, and wherein at most about 15 percent by weight of the pigment component has a particle size smaller than 1 micrometer.

A method for treating a substrate is described. In accordance with one aspect, the method includes applying a polymer coating to a substrate, and bringing the polymer coating into contact with a heated surface in a pressure nip while the coating is still in a wet state. Optionally the polymer coating may include a crosslinkable material, and a crosslinking agent may be used to promote crosslinking. The polymer coating replicates the heated surface. A product produced in accordance with the described method is also disclosed. The product is characterized by having subsurface voids within the coating.

Method for treating a substrate

A basecoat including a pigment blend, the pigment blend including at least a calcined clay and a hyper-platy clay, the hyper-platy clay having a shape factor of at least about 40:1.

A method for coating paperboard including the steps of preparing a paperboard substrate having a basis weight of at least about 85 pounds per 3000 ft, with the proviso that the paperboard substrate is not subjected to a wet stack calendering process, applying a basecoat to at least one surface of the paperboard substrate to form a coated paperboard structure, the basecoat including at least one pigment, the pigment having a sediment void volume of at least about 45 percent, and applying a top coat over the basecoat of the coated paperboard structure to form a top-coated paperboard structure having an outermost coating surface, wherein the outermost coating surface has a Parker Print Surf smoothness of at most about 3 microns.

Method for coating dry finish paperboard

A basecoat including a pigment blend of a coarse ground calcium carbonate and a hyperplaty clay having an average aspect ratio of at least about 40:1.

Growing community of inventors

Pittsboro, NC, United States of America

Gary P Fugitt