Patent US10619306

Low density paper and paperboard with two-sided coating
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US10619306

1. A paperboard comprising: (15) (3)

a solid bleached sulfate (SBS) paperboard substrate having a first side and a second side, wherein said substrate has a basis weight of at least 65 pounds per 3000 ft2; and

a first coating applied to said first side and a second coating applied to said second side to form a coated structure, said coated structure having a basis weight, a caliper thickness and a Parker Print Surf smoothness, said Parker Print Surf smoothness of said coated structure being at most 2 microns and said basis weight of said coated structure being less than Y1 pounds per 3000 ft2;

wherein Y1 is a function of said caliper thickness (X) in points and is calculated as follows:
Y1=29.15+11.95X−0.07415X2.

2. The paperboard of claim 1 wherein at least one of said first coating and said second coating includes starch. (0)

3. The paperboard of claim 1 wherein at least one of said first coating and said second coating includes coarse ground calcium carbonate and high aspect ratio clay. (0)

4. The paperboard of claim 1 wherein said basis weight of said coated structure is less than Y2 pounds per 3000 ft2, wherein Y2 is calculated as follows: (0) (1)

5. The paperboard of claim 1 wherein said basis weight of said coated structure is less than Y3 pounds per 3000 ft2, wherein Y3 is calculated as follows: (0) (1)

6. The paperboard of claim 1 wherein said basis weight of said coated structure is less than Y4 pounds per 3000 ft2, wherein Y4 is calculated as follows: (0) (1)

7. The paperboard of claim 1 wherein said Parker Print Surf smoothness is at most 1.7 microns. (0)

8. The paperboard of claim 1 wherein said Parker Print Surf smoothness is at most 1.5 microns. (0)

9. The paperboard of claim 1 wherein at least one of said first coating and said second coating comprises an inorganic pigment. (0)

10. The paperboard of claim 1 wherein said substrate is a single-ply substrate. (0)

11. The paperboard of claim 1 wherein said substrate consists essentially of chemical pulp. (0)

12. The paperboard of claim 1, wherein said first coating comprises a pigment blend including a hyperplaty clay component and a ground calcium carbonate component, wherein at most 60 percent of said ground calcium carbonate component has a particle size smaller than 2 microns. (0)

13. The paperboard of claim 1 wherein said substrate is substantially free of chemical bulking agents. (0)

14. The paperboard of claim 1 wherein said basis weight of said coated structure is at least Y₅pounds per 3000 ft², wherein Y₅is a function of said caliper thickness (X) in points and is calculated as follows: (0) (1)

15. The paperboard of claim 1 wherein at least one of said first coating and said second coating comprises a hyperplaty clay component having an average aspect ratio of at least 40:1. (0)

16. The paperboard of claim 1 wherein at least one of said first coating and said second coating comprises a topcoat and a basecoat, said basecoat being positioned between said topcoat and said substrate. (1) (0)

18. A paperboard comprising: (2) (4)

a solid bleached sulfate (SBS) paperboard substrate having a first side and a second side, wherein said substrate has a basis weight of at least 65 pounds per 3000 ft², and wherein said substrate is substantially free of chemical bulking agents; and

a first coating applied to said first side and a second coating applied to said second side to form a coated structure, at least one of said first coating and said second coating comprising an inorganic pigment, said coated structure having a basis weight, a caliper thickness and a Parker Print Surf smoothness, said Parker Print Surf smoothness of said coated structure being at most 2 microns and said basis weight of said coated structure being less than Y₁pounds per 3000 ft²and more than Y5 pounds per 3000 ft²,

wherein Y₁is a function of said caliper thickness (X) in points and is calculated as follows:
Y₁=29.15 +11.95X −0.07415X², and

wherein Y₅is a function of said caliper thickness (X) in points and is calculated as follows:
Y₅=26.15 +10.83X −0.06815X².

19. The paperboard of claim 18 wherein said basis weight of said coated structure is less than Y₂pounds per 3000 ft², wherein Y₂is calculated as follows: (0) (1)

20. The paperboard of claim 18 wherein said basis weight of said coated structure is less than Y₃pounds per 3000 ft², wherein Y₃is calculated as follows: (0) (1)

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Patent US10619306

Low density paper and paperboard with two-sided coating

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