Low density paperboard articles

Abstract

The invention provides a low density paperboard material and associated method for use in producing an insulated container, and is especially well-suited for making cups. The paperboard material comprises a paperboard web including wood fibers and expanded microspheres, and has a relatively low density ranging from about 6 to about 10 lb/3 MSF/mil (0.38 to about 0.64 g/cm 3 ), a relatively high caliper ranging from about 24 to about 35 mil (609 to about 889 μm), and an internal bond strength of at least about 80×10 −3 ft-lbf (168×10 −3 kj/m 2 ), preferably at least 100×10 −3 lft-lbf (210×10 −3 kj/m 2 ). For applications such as cups the material is also coated on one or both sides with a barrier coating, preferably low density polyethylene, to limit liquid penetration into the web. The low density paperboard material of the invention is convertible for manufacture of containers, particularly cups, and exhibits insulative properties comparable to higher cost materials conventionally used to make cups. Also, the surface of the low density board may have a Sheffield smoothness of 300 SU or greater compared with the surface smoothness of 160 to 200 SU for conventional cupstock, the latter having been thought necessary for adequate print quality. However, it has been found that the low density board exhibits good printability on flexo printing machines despite its relatively rough surface, which is surprising and bonus effect realized along with the insulative and other properties of the board.

1 - 40 . (canceled) 
     
     
         41 . A paperboard material, comprising a paperboard web comprising wood fibers and expanded microspheres dispersed within the fibers; the web having an apparent density of from about 6.0 to about 10 lb/3 MSF/mil, an average internal bond of at least about 80×10 −3  ft-lbf, and a PPS10 of about 6.5 microns or less. 
     
     
         42 . The paperboard material according to  claim 41 , wherein the density of the web is at least about 6.5 lb/3 MSF/mil and the caliper of the web is at least about 28 mil. 
     
     
         43 . The paperboard material according to  claim 41 , wherein the average internal bond of the web is at least about 100×10 −3  ft-lbf. 
     
     
         44 . The paperboard material according to  claim 41 , wherein the average internal bond of the web is at least about 100×10 −3  ft-lbf. 
     
     
         45 . The paperboard material according to  claim 41 , comprising a barrier coating on at least one surface of the web. 
     
     
         46 . The paperboard material according to  claim 45 , wherein the barrier coating is present all surfaces of the web. 
     
     
         47 . The paperboard material according to  claim 46 , wherein the barrier coating has an average thickness of from about 0.5 to about 3.5 mil. 
     
     
         48 . The paperboard material according to  claim 45 , wherein the barrier coating has an average thickness of from about 0.5 to about 3.5 mil. 
     
     
         49 . The paperboard material according to  claim 45 , wherein the barrier coating comprises at least one member selected from the group consisting of polyethylene, EVOH, and polyethylene terephthalate. 
     
     
         50 . The paperboard material according to  claim 49 , wherein the barrier coating has an average thickness of from about 0.5 to about 3.5 mil. 
     
     
         51 . The paperboard material according to  claim 45 , wherein the barrier coating comprises a low density polyethylene. 
     
     
         52 . The paperboard material according to  claim 51 , wherein the barrier coating has an average thickness of from about 1 to about 3 mil. 
     
     
         53 . The paperboard material according to  claim 45 , wherein the barrier coating has an average thickness of from about 1 to about 3 mil. 
     
     
         54 . The paperboard material according to  claim 41 , wherein the material contains printing directly on at least one surface thereof. 
     
     
         55 . The paperboard material according to  claim 41 , wherein the web has a caliper of from about 24 to about 35 mil. 
     
     
         56 . The paperboard material according to  claim 41 , wherein the cellulosic fibers in the web comprise from about 20 to about 40% by weight dry basis softwood fibers and from about 60 to about 80% by weight dry basis hardwood fibers. 
     
     
         57 . The paperboard material according to  claim 41 , wherein the expanded microspheres in the web comprise synthetic polymeric microspheres. 
     
     
         58 . The paperboard material according to  claim 41 , wherein the expandable microspheres comprise from about 0.25 to about 10 wt. % of the total weight of the web on a dry basis. 
     
     
         59 . The paperboard material according to  claim 41 , wherein the expandable microspheres comprise from about 5 to about 7 wt. % of the total weight of the web. 
     
     
         60 . The paperboard material according to  claim 41 , wherein the expandable microspheres comprise from about 0.25 to about 5 wt. % of the total weight of the web.