# Patent

## Title
Basecoat and associated paperboard structure

## Abstract

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.

## Background
PRIORITY
The present patent application claims priority from U.S. Ser. No. 61/038,579 filed on Mar. 21, 2008, the entire contents of which are incorporated herein by reference.


FIELD
The present patent application is directed to coatings for paperboard and, more particularly, to basecoats as well as smooth paperboard structures formed with the disclosed basecoats.
BACKGROUND
Paperboard is used in various packaging applications. For example, aseptic liquid packaging paperboard is used for packaging beverage cartons, boxes and the like. Therefore, customers often prefer paperboard having a generally smooth surface with few imperfections to facilitate the printing of high quality text and graphics, thereby increasing the visual appeal of products packaged in paperboard.
Conventionally, paperboard smoothness is achieved by a wet stack calendering process in which the paperboard is rewetted and passed through a calendering device having two or more hard rolls. The wet stack calendering process smoothes the paperboard by compressing the fiber network to reduce the pits and crevices in raw stock paperboard (see FIG. 1). The result is a smooth paperboard with reduced board thickness and bulk and, therefore, reduced stiffness. However, stiffness is an important requirement for many paperboard applications, such as aseptic liquid packaging paperboard. Therefore, preparing a smooth yet stiff paperboard using the conventional wet stack calendering process requires increasing the basis weight of the paperboard, thereby substantially increasing the raw material cost.
Alternatively, manufacturers have attempted to smooth the surface of paperboard by coating the entire surface of the paperboard with a basecoat comprised of various pigments, such as clay, calcium carbonate, TiO2 and the like, then overcoating this base with a second and sometimes even a third coating, which is generally referred to as a topcoat. It was discovered that high quantities of relatively fine pigment particles applied to the surface of paperboard provided a more smooth surface without the need for wet stack calendering, thereby maintaining bulk. For example, as shown in FIG. 2, it was discovered that relatively high quantities (e.g., 10.6 pounds per 3000 ft2 or more) of relatively fine ground calcium carbonate, such as CARBITAL® 95 (Imerys Pigments, Inc. of Roswell, Ga.), applied to the rough surface of paperboard provided the greatest smoothness. Indeed, it has been understood that the more pigment applied to the surface of the paperboard the better the resulting smoothness. However, the use of relatively high quantities of pigments substantially increases the cost of preparing smooth and highly printable paperboard.
Accordingly, there is a need for a basecoat and associated paperboard structure that maintains paperboard bulk and provides the desired smoothness for high quality printing, while reducing manufacturing cost.
SUMMARY
In one aspect, the disclosed basecoat may include a pigment blend of a coarse ground calcium carbonate and a hyperplaty clay having an average aspect ratio of at least about 40:1.
In another aspect, a paperboard substrate may be coated with the disclosed basecoat to form a coated paperboard structure.
Other aspects of the disclosed basecoat and associated paperboard structure will become apparent from the following description, the accompanying drawings and the appended claims.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a photograph of an uncoated surface of an exemplary paperboard substrate (i.e., raw stock);
FIG. 2 is a photographic comparison of the surface of a paperboard substrate coated with various quantities (in pounds per 3000 ft2) of fine ground calcium carbonate according to the prior art;
FIG. 3 is a photographic comparison of the surface of a paperboard substrate coated with various quantities (in pounds per 3000 ft2) of the disclosed basecoat;
FIG. 4 is a graphical illustration of percent sediment void volume versus percent clay component for various pigment blends formulated with an extra course ground calcium carbonate;
FIG. 5 is a graphical illustration of percent sediment void volume versus percent clay component for various pigment blends formulated with a course ground calcium carbonate;
FIG. 6 is a graphical illustration of percent sediment void volume versus percent clay component for various pigment blends formulated with a fine ground calcium carbonate;
FIG. 7 is a first graphical comparison of Parker Print Surface smoothness versus coat weight;
FIG. 8 is a second graphical comparison of Parker Print Surface smoothness versus coat weight;
FIG. 9 is a side cross-sectional view of a paperboard substrate coated with the disclosed basecoat according to the disclosed method; and
FIG. 10 is a side cross-sectional view of the paperboard substrate of FIG. 9 shown at a second, greater magnification.



DETAILED DESCRIPTION
In one aspect, the disclosed basecoat may include a pigment blend of high aspect ratio clay and calcium carbonate. The pigment blend may be dispersed in a carrier, such as water, to facilitate application of the basecoat to an appropriate substrate, such as a paperboard substrate. Additional components, such as binders, stabilizers, dispersing agents and additional pigments, may be combined with the pigment blend to form the final basecoat without departing from the scope of the present disclosure.
As used herein, “paperboard substrate” broadly refers to any paperboard material that is capable of being coated with the disclosed basecoat. Those skilled in the art will appreciate that the paperboard substrate may be bleached or unbleached, and typically is thicker and more rigid than paper. Generally, a paperboard substrate has an uncoated basis weight of about 85 pounds per 3000 ft2 or more. Examples of appropriate paperboard substrates include corrugating medium, linerboard and solid bleached sulfate (SBS).
The clay component of the pigment blend of the disclosed basecoat may be any platy clay having a relatively high aspect ratio or shape factor (i.e., hyperplaty clay). As used herein, the terms “aspect ratio” and “shape factor” refer to the geometry of the individual clay particles, specifically to a comparison of a first dimension of a clay particle (e.g., the diameter or length of the clay particle) to a second dimension of the clay particle (e.g., the thickness or width of the clay particle). The terms “hyperplaty,” “high aspect ratio” and “relatively high aspect ratio” refer to aspect ratios generally in excess of 40:1, such as 50:1 or more, particularly 70:1 or more, and preferably 90:1 or more.
In one aspect, the clay component of the pigment blend may include a platy clay wherein, on average, the clay particles have an aspect ratio of about 40:1 or more. In another aspect, the clay component may include a platy clay wherein, on average, the clay particles have an aspect ratio of about 50:1 or more. An example of such a clay is CONTOUR® 1180 available from Imerys Pigments, Inc. of Roswell, Ga. In another aspect, the clay component may include a platy clay wherein, on average, the clay particles have an aspect ratio of about 90:1 or more. An example of such a clay is XP-6100 also available from Imerys Pigments, Inc. Additional examples of appropriate platy clays are disclosed in U.S. Pat. No. 7,208,039 to Jones et al., the entire contents of which are incorporated herein by reference.
In another aspect, the clay component of the pigment blend may include platy clay having a relatively high average particle size. In one particular aspect, the clay component may have an average particle size of about 4 microns or more. In a second particular aspect, the clay component may have an average particle size of about 10 microns or more. In a third particular aspect, the clay component may have an average particle size of about 13 microns or more.
The calcium carbonate component of the pigment blend of the disclosed basecoat may include a ground calcium carbonate. In one aspect, the calcium carbonate component may include a fine ground calcium carbonate. An example of such a fine ground calcium carbonate is CARBITAL® 95, available from Imerys Pigments, Inc. of Roswell, Ga., wherein about 95 percent of the calcium carbonate particles are less than about 2 microns in diameter. In another aspect, the calcium carbonate component may include a coarse ground calcium carbonate. An example of such a coarse ground calcium carbonate is CARBITAL® 60, also available from Imerys Pigments, Inc., wherein about 60 percent of the calcium carbonate particles are less than about 2 microns in diameter. In another aspect, the calcium carbonate component may include an extra coarse ground calcium carbonate. An example of such an extra coarse ground calcium carbonate is CARBITAL® 35, also available from Imerys Pigments, Inc., wherein only about 35 percent of the calcium carbonate particles are less than about 2 microns in diameter.
In another aspect, the calcium carbonate component of the pigment blend may have an average particle size of about 1 micron or more, such as about 1.5 microns and, more particularly, 3 microns or more.
Without being limited to any particular theory, it is believed that pigment blends that are formulated to provide relatively high percent sediment void volumes (i.e., bulkier particle packing) provide high smoothness at relatively low coat weights, thereby reducing raw material costs. Furthermore, it is believed that using a clay component having a relatively high aspect ratio and/or a relatively high average particle size and a calcium carbonate component having a relatively high average particle size yields relatively high and, therefore, desirable percent sediment void volumes. For example, sediment void volumes in excess of 45 percent may be desired, while sediment void volumes in excess of 47.5 percent may be more desired and sediment void volumes in excess of 50 percent may be even more desired.
One appropriate technique for measuring percent sediment void volume includes preparing a pigment blend sample having the desired weight percentage of the clay component to the calcium carbonate component. The pigment blend sample is then diluted with water to 50 percent by weight solids to provide a slurry. A 70 gram sample of the slurry is placed into a centrifuge tube and spun at about 8000 g for about 90 minutes. The sample is then removed from the centrifuge and the clear supernatant liquid is separated and weighed. The sediment is typically packed densely enough that the supernatant liquid is easy to pour off. Based upon the weight of the water removed, the weight of water still contained in the voids of the sediment may be calculated. Then, using particle densities, the weight of water in the voids may be converted into percent sediment void volume.
Referring to FIGS. 4-6, the percent sediment void volume for various pigment blends versus the percent by weight of the clay component in the pigment blend is provided. Specifically, FIGS. 4-6 compare the use of CARBITAL® 35 (extra coarse), CARBITAL® 60 (coarse) and CARBITAL® 95 (fine) as the calcium carbonate component and XP-6100 (aspect ratio over 90:1), CONTOUR® 1180 (aspect ratio about 50:1), CONTOUR® Xtrm (aspect ratio about 45:1) and KCS (aspect ratio about 10:1 (not a high aspect ratio clay)) as the clay component.
FIGS. 4-6 indicate that coarse ground calcium carbonate (FIGS. 4 and 5), particularly extra coarse ground calcium carbonate (FIG. 4), and high aspect ratio clays, particularly clays having an aspect ratio over 70:1, more particularly over 90:1 (XP-6100 clay), provide the highest percent sediment void volume.
Furthermore, the concave shape of the curves in FIGS. 4-6, particularly the curves associated with XP-6100 clay, indicates that maximum percent sediment void volume is achieved when the clay component is blended with the calcium carbonate component. For example, referring to FIG. 4, when extra coarse ground calcium carbonate and XP-6100 are used, maximum percent sediment void volume occurs between about 60 and about 90 percent by weight of the clay component.
Still furthermore, the concave shape of the curves indicates that certain blends of the clay component and the calcium carbonate component provide a percent sediment void volume that is similar, if not higher, than using 100 percent high aspect ratio clay. Therefore, the curves indicate that blending less expensive calcium carbonate with more expensive high aspect ratio clay may yield an equal, if not superior, coating material in terms of percent sediment void volume. Indeed, comparing FIG. 4 to FIG. 6 for example, the curves indicate that the coarser the calcium carbonate, the less high aspect ratio clay must be used to achieve higher percent sediment void volume. For example, referring to FIG. 4, when extra coarse ground calcium carbonate is blended with XP-6100 clay, a 45:55 blend of the clay component to the calcium carbonate component provides the same percent sediment void volume as 100 percent of the high aspect ratio clay.
Referring to FIGS. 7 and 8, the Parker Print Surface (“PPS”) smoothness values of paperboard coated with various basecoats on a pilot coater are presented with respect to the coat weight of the basecoat in pounds per ream (3000 ft2). Those skilled in the art will appreciate that PPS smoothness values taken from samples prepared with a pilot coater are generally higher than the PPS smoothness values obtained from samples prepared on a full scale mill. Nonetheless, the PPS smoothness values taken using a pilot coater are indicative of the improvement provided by the disclosed basecoats over prior art coatings. For reference, when a pilot coater is used, PPS smoothness values of about 7.0 microns or less are generally desired, PPS smoothness values of about 6.5 microns or less are preferred and PPS smoothness values of about 6.0 microns or less are more preferred.
Of particular interest, as shown in FIG. 7, basecoats including coarse or extra course calcium carbonate and high aspect ratio clay, particularly XP-6100 clay, provide relatively high percent sediment void volumes and present PPS smoothness values generally below about 7 microns at coat weights of about 9 pounds per ream or less on a paperboard substrate. Indeed, as shown by the positive slope of the curves in FIG. 7, improved smoothness (i.e., lower PPS smoothness value) of the resulting paperboard is directly correlated to lower coat weights. This data is contrary to the expectations of those skilled in the art, which would expect higher smoothness values at high coat weights.
Indeed, when a full scale mill was used, a basecoat including a 50:50 pigment blend of CARBITAL® 35 (ground calcium carbonate) and XP-6100 (high aspect ratio and high average particle size clay) yielded a PPS smoothness value of about 2 microns at a relatively low coat weight of 6 pounds per ream.
Accordingly, coating substrates such as paperboard with basecoats comprising ground calcium carbonate, particularly coarse or extra course ground calcium carbonate, and high aspect ratio clay, particularly clay having an aspect ratio in excess of about 70:1, more particularly high aspect ratio clay having a relatively high average particle size, yields a smooth paperboard structure without sacrificing bulk, and reduces manufacturing cost by combining more expensive platy clay with less expensive ground calcium carbonate, while requiring surprisingly low coat weights to achieve the desired smoothness.
Furthermore, those skilled in the art will appreciate that the type of high aspect ratio clay selected and the type of ground calcium carbonate selected, as well as the ratio of the clay component to the calcium carbonate component, may be dictated by cost considerations in view of the desired smoothness.
The disclosed basecoats may be applied to the surface of a substrate, such as paperboard (e.g., aseptic liquid packaging paperboard), in a quantity sufficient to fill the pits and crevices in the substrate without the need for coating the entire surface of the substrate. Therefore, the disclosed basecoat together with the disclosed method for applying the basecoat may be used to obtain high surface smoothness with a relatively small quantity of basecoat. Indeed, as discussed above, high surface smoothness may be achieved with an unexpectedly small quantity of the disclosed basecoat.
In one aspect, the basecoat is applied to the substrate using a blade coater such that the blade coater urges the basecoat into the pits and crevices in the substrate while removing the basecoat from the surface of the substrate. Specifically, as shown in FIGS. 9 and 10, the basecoat may be applied in a manner that is more akin to spackling, wherein substantially all of the basecoat resides in the pits and crevices in the surface of the substrate rather than on the surface of the substrate.
At this point, those skilled in the art will appreciate that when the disclosed basecoat is used in a blade coater the spacing between the moving substrate and the blade of the coater may be minimized to facilitate filling the pits and crevices in the surface without substantially depositing the basecoat on the surface of the substrate (i.e., forming a discontinuous film on the surface of the substrate). In other words, the blade of the coater may be positioned sufficiently close to the surface of the moving substrate such that the blade of the coater urges the basecoat into the pits and crevices in the surface of the substrate, while removing excess basecoat from the surface of the substrate.
EXAMPLE 1
A first pigment blend prepared according to an aspect of the present disclosure includes 50 percent by weight CARBITAL® 35 (coarse ground calcium carbonate) and 50 percent by weight XP-6100 (hyperplaty clay). In a stationary mixer, a coating formulation is prepared by combining the 50:50 pigment blend with water, latex binders and a thickening agent. The water is added in a quantity sufficient to form a slurry. Using a blade coater in the manner described above, the coating formulation is applied to raw paperboard stock having a basis weight of about 126 pounds per 3000 ft2 at the following coat weights: 6.7, 7.9, 8.9 and 11.3 pounds per 3000 ft2. Photographic results are shown in FIG. 3 and the PPS smoothness values are provided in FIG. 7 (data points marked with a circle).
Thus, as shown in FIG. 3, the disclosed basecoat and associated method provide optimum smoothness at relatively low coat weights. (Compare FIG. 2 to FIG. 3.) Specifically, the greatest smoothness is achieved at a coat weight of 6.7 pounds per 3000 ft2, with good smoothness achieved at 7.9 pounds per 3000 ft2, with less smoothness at 8.9 pounds per 3000 ft2, and even less smoothness at 11.3 pounds per 3000 ft2.
EXAMPLE 2
A second pigment blend prepared according to an aspect of the present disclosure includes 50 percent by weight OMYA HYDROCARB® 60 (coarse ground calcium carbonate available from Omya AG of Oftringen, Switzerland) and 50 percent by weight XP-6170 (hyperplaty clay available from Imerys Pigments, Inc.). In a stationary mixer, a coating formulation is prepared by combining the 50:50 pigment blend with water, latex and starch binders and a thickening agent. The water is added in a quantity sufficient to form a slurry. Using a blade coater in the manner described above, the coating formulation is applied to raw paperboard stock having a basis weight of about 106 pounds per 3000 ft2 at coat weights of 5.8 and 6.8 pounds per 3000 ft2, thereby providing paperboard structures with improved smoothness at relatively low coat weights.
Accordingly, at this point those skilled in the art will appreciate that basecoats formulated according to the present disclosure to include coarse ground calcium carbonate, particularly extra coarse ground calcium carbonate, and hyperplaty clay, particularly hyperplaty clays having aspect ratios in excess of about 70:1, and more particularly high aspect ratio clays having a relatively high average particle size (e.g., about 10 microns or more), provide increased surface smoothness at relatively low coat weights, particularly when applied to the substrate using the disclosed method.
While the pigment blends discussed above include platy clay and ground calcium carbonate, particularly coarse ground calcium carbonate, those skilled in the art will appreciate that alternative pigment blends may be used without departing from the scope of the present disclosure. For example, the pigment blend of the disclosed basecoat may include a platy clay and one or more additional inorganic pigments other than ground calcium carbonate, such as precipitated calcium carbonate, talc or kaolin clay.
Although various aspects of the disclosed basecoat and associated paperboard structure have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present patent application includes such modifications and is limited only by the scope of the claims.

## Claims

1. A paperboard structure comprising:
a paperboard substrate having a basis weight of at least 85 pounds per 3000 square feet; and
a basecoat applied to said paperboard substrate to form a layer on at least one surface of said paperboard substrate, said layer having a non-uniform cross-sectional thickness, wherein said cross-sectional thickness of said layer at each point on said paperboard substrate depends at least on a contour of said paperboard substrate at said point, said basecoat comprising a pigment blend including ground calcium carbonate and hyperplaty clay, wherein at most about 60 percent of said ground calcium carbonate has a particle size smaller than 2 microns, and wherein said hyperplaty clay has an average aspect ratio of at least about 40:1.

2. The paperboard structure of claim 1 wherein said average aspect ratio of said hyperplaty clay is at least about 70:1.

3. The paperboard structure of claim 1 wherein said average aspect ratio of said hyperplaty clay is at least about 90:1.

4. The paperboard structure of claim 1 wherein at most about 35 percent of said ground calcium carbonate has a particle size smaller than 2 microns.

5. The paperboard structure of claim 1 wherein said ground calcium carbonate comprises at least about 10 percent by weight of said pigment blend and at most about 60 percent by weight of said pigment blend.

6. The paperboard structure of claim 1 wherein said pigment blend consists essentially of said hyperplaty clay and said ground calcium carbonate.

7. The paperboard structure of claim 1 wherein said pigment blend has a sediment void volume of at least about 50 percent.

8. The paperboard structure of claim 1 wherein said paperboard substrate is formed as a web of fibers defining a plurality of pits in a surface thereof, and wherein said basecoat is received within said plurality of said pits without completely covering said surface.

9. The paperboard structure of claim 1 wherein said basecoat is applied to said paperboard substrate at a coat weight, per side, of at most about 9 pounds per 3000 square feet of said paperboard substrate.

10. The paperboard structure of claim 1 wherein said basecoat is applied to said paperboard substrate at a coat weight, per side, of at most about 8 pounds per 3000 square feet of said paperboard substrate.

11. The paperboard structure of claim 1 wherein said basecoat is applied to said paperboard substrate at a coat weight, per side, of at most about 7 pounds per 3000 square feet of said paperboard substrate.