High gloss disposable pressware

Abstract

A high gloss, disposable pressed paperboard food container includes a glossy bilayer finish. The container is formed in a heated die set from a paperboard substrate provided with a first finish coating layer consisting essentially of a styrene-butadiene resin composition and a second, top coating finish layer consisting essentially of an acrylic resin composition applied to the first finish coating layer. The products of the invention typically exhibit a 60° gloss of greater than about 40 gloss units, as well as reduced moisture pickup and enhanced rigidity.

1 - 16 . (Canceled)  
     
     
         17 . A method of making a high gloss paperboard food container comprising the steps of: 
 (a) preparing a coated paperboard substrate said paperboard substrate being provided with a first finish coating layer consisting essentially of a styrene-butadiene resin composition and a second top finish coating layer consisting essentially of an acrylic resin composition applied to said first layer;    (b) scoring said paperboard substrate in a predetermined pattern suitable for forming said high gloss paperboard food container;    (c) cutting said scored paperboard substrate into a shape appropriate for forming said high gloss paperboard food container;    (d) heat pressing said paperboard blank into said high gloss paperboard food container wherein said container is provided with a plurality of pleats and said food container exhibits a surface gloss of at least about 40 gloss units at 60° as measured by test method ASTM D523-89.    
     
     
         18 . The method according to  claim 17 , wherein the forming surfaces of the heated die set are maintained a temperature of between about 250 to about 400 degrees F.  
     
     
         19 . The method according to  claim 18 , wherein said first finish coating is applied to said paperboard substrate in an amount of from about 0.25 pounds per 3,000 square foot ream to about 1.5 pounds per 3,000 square foot ream.  
     
     
         20 . The method according to  claim 17 , wherein said second top finish coating layer is applied to said paperboard substrate in an amount of from about 0.25 pounds per 3,000 square foot ream to about 1 pound per 3,000 square foot ream.  
     
     
         21 - 29 . (Canceled)  
     
     
         30 . A method of improving the wet rigidity of a disposable food container prepared from a paperboard blank in a heated die set, said paperboard blank being starch-sized and provided with a clay coating as well as a finish coating applied thereto and said disposable food container being provided with a plurality of pleats about its periphery; said method comprising providing said paperboard blank with a first finish coating layer consisting essentially of a styrene-butadiene resin composition applied to said clay coating and a second finish coating layer applied to said first finish coating layer consisting essentially of an acrylic resin composition.  
     
     
         31 . The method according to  claim 30 , wherein said first coating layer is applied to said paperboard blank in an amount of at least about 0.25 lbs per 3000 square foot ream of paperboard.  
     
     
         32 . The method according to  claim 30 , wherein said styrene-butadiene resin composition is a carboxylated styrene-butadiene resin composition.  
     
     
         33 . The method according to  claim 30 , wherein said paperboard blank is sized with from about 4 to about 15 lbs of starch per 3000 square feet of paperboard.  
     
     
         34 . The method according to  claim 30 , wherein the method is further operative to reduce the moisture pickup of said disposable food container.  
     
     
         35 . The method according to  claim 30 , wherein the method is further operative to increase the dry rigidity of said disposable food container.