Laminated paperboard packaging and method of manufacturing the same

Abstract

Embodiments of the present invention generally relate to a laminated composite paperboard packaging for containing ice cream and a method of manufacturing the same. In one embodiment of the present invention, a laminated packaging material comprises a layer of paperboard, a layer of an aqueous coating disposed on a first surface of the layer of paperboard, and a layer of a thermoplastic resin disposed on a second surface of the layer of paperboard, wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity.

1 . A laminated packaging material comprising:
 a layer of paperboard;   a layer of an aqueous coating disposed on a first surface of the layer of paperboard; and   a layer of a thermoplastic resin disposed on a second surface of the layer of paperboard;   wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity.   
   
   
       2 . The laminated packaging material of  claim 1 , wherein the layer of aqueous coating has a heat resistance up to about 450 degrees Fahrenheit and a water permeability of about 5 grams. 
   
   
       3 . The laminated packaging material of  claim 1 , wherein the layer of paperboard comprises at least one of kraft paper, high sized board, wood-pulp paper, manila paper, bleached paperboard, or combinations thereof. 
   
   
       4 . The laminated packaging material of  claim 1 , wherein the layer of paperboard has a density of between about 26 lb/MSF and about 90 lb/MSF. 
   
   
       5 . The laminated packaging material of  claim 1 , wherein the layer of a thermoplastic resin comprises low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (PP), or copolymers or combinations thereof. 
   
   
       6 . The laminated packaging material of  claim 1 , wherein the layer of an aqueous coating comprises at least one of polyvinylidene chloride (PVDC), styrene-butadiene rubber (SBR), a paraffin-based coating, or any combination thereof. 
   
   
       7 . The laminated packaging material of  claim 1 , wherein the layer of an aqueous coating comprises at least two distinct sublayers. 
   
   
       8 . The laminated packaging material of  claim 7 , wherein at least one sublayer comprises at least two distinct sub-sublayers. 
   
   
       9 . The laminated packaging material of  claim 1  further comprising an additive in at least one of the layers. 
   
   
       10 . A laminated packaging material comprising:
 a layer of paperboard;   a layer of linerboard;   a first layer of a thermoplastic resin disposed between a first surface of the layer of linerboard and a second surface of a layer of paperboard;   a layer of an aqueous coating disposed on a first surface of the layer of paperboard; and   a second layer of a thermoplastic resin disposed on a second surface of the layer of linerboard;   wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity.   
   
   
       11 . The laminated packaging material of  claim 10 , wherein at least one of the first layer of a thermoplastic resin and the second layer of a thermoplastic resin comprises low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (PP), any copolymer thereof, or any combination thereof. 
   
   
       12 . The laminated packaging material of  claim 10 , wherein the layer of an aqueous coating comprises at least one of polyvinylidene chloride (PVDC), styrene-butadiene rubber (SBR), a paraffin-based coating, or any combination thereof. 
   
   
       13 . The laminated packaging material of  claim 10 , wherein the layer of paperboard comprises kraft paper, high sized board, wood-pulp paper, manila paper, bleached paperboard, or any combination thereof. 
   
   
       14 . The laminated packaging material of  claim 10 , wherein the layer of paperboard has a density of between about 26 lb/MSF and about 90 lb/MSF. 
   
   
       15 . An ice-cream package comprising:
 a cylindrical sidewall; and   a bottom wall comprising:
 a layer of paperboard; 
 a layer of an aqueous coating disposed on a first surface of the layer of paperboard; and 
 a first layer of a thermoplastic resin disposed on a second surface of the layer of paperboard; 
 wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity; 
   wherein the bottom wall is bonded to the bottom portion of the cylindrical sidewall.   
   
   
       16 . The ice-cream package of  claim 15 , wherein the layer of aqueous coating has a heat resistance up to about 450 degrees Fahrenheit and a water permeability of about 5 grams. 
   
   
       17 . The ice-cream package of  claim 18 , wherein the layer of a thermoplastic resin comprises low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (PP), any copolymer thereof, or any combination thereof. 
   
   
       18 . The ice-cream package of  claim 15 , wherein the layer of an aqueous coating comprises at least one of wherein the layer of an aqueous coating comprises at least one of polyvinylidene chloride (PVDC), styrene-butadiene rubber (SBR), a paraffin-based coating, or any combination thereof. 
   
   
       19 . The ice-cream package of  claim 15 , wherein the bottom wall further comprises:
 a layer of linerboard disposed on the second surface of the first layer of a thermoplastic resin; and   a second layer of a thermoplastic resin disposed on a second surface of the layer of linerboard.   
   
   
       20 . A package comprising
 a container including a bottom wall and a side wall extending upwardly from the bottom wall and forming an inside portion above the bottom wall and   a laminated packaging material located in the inside portion of the side wall and arranged to cover the bottom wall and cooperate with the side wall to form an ice cream-storage region above the bottom wall, wherein the laminated packaging material includes   a layer of paperboard having a lower surface facing toward the bottom wall and an upper surface facing away from the bottom wall toward any ice cream extant in the ice cream-storage region,   a layer of thermoplastic resin disposed on the lower surface of the layer of paperboard to lie between the layer of paperboard and the bottom wall, and   a layer of an aqueous coating disposed on the upper surface of the layer of paperboard to lie between any ice cream extant in the ice cream-storage region and the layer of paperboard, and wherein the layers of an aqueous coating, paperboard, and thermoplastic resin cooperate to provide the laminated packaging material with a water vapor transmission rate of less than twenty grams per square meter per twenty-four hours in an environment of about 100° Fahrenheit and 90% humidity.   
   
   
       21 . The package of  claim 20 , wherein the laminated packaging material is mounted to form a gap between the layer of thermoplastic resin and the bottom wall of the container. 
   
   
       22 . The package of  claim 20 , wherein the layer of an aqueous coating comprises at least one of polyvinylidene chloride (PVDC), styrene-butadiene rubber (SBR), a paraffin-based coating, or any combination thereof. 
   
   
       23 . The package of  claim 22 , wherein the layer of an aqueous coating comprises at least two distinct sublayers. 
   
   
       24 . The package of  claim 23 , wherein a first of the at least two distinct sublayers is a base coating applied to the upper surface of the layer of paperboard and configured to provide means for filling any voids extant in the upper surface and a second of the at least two distinct sublayers is a functional coating applied to the base coating to locate the base coating between the functional coating and the upper surface and configured to provide means for providing at least one of a water-resistant, heat-resistant, scuff-resistant, and mold-resistant sublayer on the base coating, and wherein the base coating comprises one or more of SBR, clay-filled SBR, and PVDC. 
   
   
       25 . The package of  claim 22 , wherein the layer of an aqueous coating is characterized by a water permeability of less than about five grams as determined through the two-minute Cobb test and a heat resistance of at least 450° Fahrenheit. 
   
   
       26 . The package of  claim 20 , wherein the layer of an aqueous coating comprises at least two distinct sublayers. 
   
   
       27 . The package of  claim 26 , wherein a first of the at least two distinct sublayers is a base coating applied to the upper surface of the layer of paperboard and configured to provide means for filling any voids extant in the upper surface and a second of the at least two distinct sublayers is a functional coating applied to the base coating to locate the base coating between the functional coating and the upper surface and configured to provide means for providing at least one of a water-resistant, heat-resistant, scuff-resistant, and mold-resistant sublayer on the base coating, and wherein the base coating comprises one or more of SBR, clay-filled SBR, and PVDC. 
   
   
       28 . The package of  claim 20 , wherein the layer of an aqueous coating is characterized by a water permeability of less than about five grams as determined through the two-minute Cobb test and a heat resistance of at least 450° Fahrenheit. 
   
   
       29 . The package of  claim 28 , wherein the layer of paperboard comprises at least one of a Kraft paper, high-sized board, wood-pulp paper, manila paper, bleached paperboard, or combinations thereof and has a density of between about 26 lb/MSF and about 90 lb/MSF and wherein the layer of a thermoplastic resin comprises low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), polypropylene (PP), or copolymers or combinations thereof. 
   
   
       30 . The package of  claim 20 , further comprising a layer of linerboard disposed on the layer of thermoplastic resin and located between the layer of thermoplastic resin and the bottom wall of the container and a second layer of thermoplastic resin disposed on the layer of linerboard and located between the layer of linerboard and the bottom wall of the container. 
   
   
       31 . The package of  claim 30 , wherein the layer of an aqueous coating comprises at least two distinct sublayers. 
   
   
       32 . The package of  claim 31 , wherein a first of the at least two distinct sublayers is a base coating applied to the upper surface of the layer of paperboard and configured to provide means for filling any voids extant in the upper surface and a second of the at least two distinct sublayers is a functional coating applied to the base coating to locate the base coating between the functional coating and the upper surface and configured to provide means for providing at least one of a water-resistant, heat-resistant, scuff-resistant, and mold-resistant sublayer on the base coating, and wherein the base coating comprises one or more of SBR, clay-filled SBR, and PVDC.