Container with Repulpable Moisture Resistant Barrier

Abstract

This present invention is directed to a container adapted to hold and store moisture sensitive material such as for example, paper or electronic device. The container comprises a top wall, a bottom wall, and a plurality of side walls. Each of the top wall, bottom wall, and a plurality of side walls comprise a corrugated linerboard having an inner surface and an outer surface. At least one of the top wall, bottom wall, and side walls further comprises a coating applied to the linerboard. The coating is positioned at an inner surface of the linerboard to form a coated corrugated linerboard that is a moisture-resistant and resists penetration of water, water vapor or moisture into the container from ambient atmosphere thereby increasing the strength and shelf-life of the container under conditions of cyclic changes in ambient temperature and in ambient humidity. The coating has a coat weight from 1-10 wet #'s total per MSF (thousand square feet).

1 . A container adapted to hold and store moisture sensitive material, the container comprising a top wall, a bottom wall, and a plurality of side walls, wherein
 each of said top wall, bottom wall, and a plurality of side walls comprise a corrugated linerboard having an inner surface and an outer surface;   at least one of said top wall, bottom wall, and side walls further comprises a coating applied to said linerboard such that the coating is positioned at an inner surface of said linerboard to form a coated corrugated linerboard that is moisture-resistant and resists penetration of water, water vapor or moisture into the container from ambient atmosphere thereby increasing the strength and shelf-life of the container under conditions of cyclic changes in ambient temperature and in ambient humidity;   the container is readily recyclable and repulpable; and   the top wall, bottom wall, and side walls cooperate to form an interior space that is separated from the ambient atmosphere.   
     
     
         2 . The container of  claim 1 , wherein the coating has a coat weight from 1 to 10 wet #'s total per MSF (thousand square feet). 
     
     
         3 . The container of  claim 1 , wherein the coating has a coat weight that is less than 5 wet #'s total per MSF (thousand square feet). 
     
     
         4 . The container of  claim 1 , wherein the coating comprises a single layer. 
     
     
         5 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 40 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         6 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 20 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         7 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 10 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         8 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 180 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         9 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 100 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         10 . The container of  claim 1 , wherein the coated corrugated linerboard has a MVTR of less than 40 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         11 . The container of  claim 1 , wherein the coated corrugated linerboard has a Cobb value of less than 40 g/cm 2  in 30 minutes as measured by TAPPI Test Method T-441. 
     
     
         12 . The container of  claim 1 , wherein the coated corrugated linerboard has a Cobb value of less than 10 g/cm 2  in 30 minutes as measured by TAPPI Test Method T-441. 
     
     
         13 . The container of  claim 1  wherein the moisture sensitive material is paper. 
     
     
         14 . The container of  claim 1  wherein the moisture sensitive material is an electronic device. 
     
     
         15 . The container of  claim 1  wherein the coating is suitable for direct contact with edible material. 
     
     
         16 . The container of  claim 1  wherein the coating is a composition of at least one member selected from the group consisting of a styrene butadiene resin, acrylic polymer, pigment, and pulverized mica. 
     
     
         17 . A method of holding, storing, or shipping moisture sensitive material in a moisture-resistant, recyclable, and repulpable container, comprising
 placing the moisture sensitive material in an interior space of the container, wherein   the container is adapted to hold and store moisture sensitive material;   the container comprises a top wall, a bottom wall, and a plurality of side walls;   each of said top wall, bottom wall, and plurality of side walls comprise a corrugated linerboard having an inner surface and an outer surface;   at least one of said top wall, bottom wall, and side walls further comprises a coating applied to said linerboard such that the coating is positioned at an inner surface of said linerboard to form a coated corrugated linerboard that is moisture-resistant and resists penetration of water, water vapor or moisture into the container from ambient atmosphere thereby increasing the strength and shelf-life of the container under conditions of cyclic changes in ambient temperature and in ambient humidity;   the container is readily recyclable and repulpable; and   the top wall, bottom wall, and side walls cooperate to form an inside space that is separated from the ambient atmosphere.   
     
     
         18 . The method of  claim 17  wherein the moisture sensitive material is paper. 
     
     
         19 . The method of  claim 17 , wherein the coating has a coat weight from 1 to 10 wet #'s total per MSF (thousand square feet). 
     
     
         20 . The method of  claim 17 , wherein the coating has a coat weight that is less than 5 wet #'s total per MSF (thousand square feet). 
     
     
         21 . The method of  claim 17 , wherein the coating comprises a single layer. 
     
     
         22 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 40 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         23 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 20 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         24 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 10 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 72° F., 50% relative humidity. 
     
     
         25 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 180 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         26 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 100 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         27 . The method of  claim 17 , wherein the coated corrugated linerboard has a MVTR of less than 40 grams/m 2 /24 hours as measured by TAPPI Test Method T-448 om-89 at 90° F., 90% relative humidity. 
     
     
         28 . The method of  claim 17 , wherein the coated corrugated linerboard has a Cobb value of less than 40 g/cm 2  in 30 minutes as measured by TAPPI Test Method T-441. 
     
     
         29 . The method of  claim 17 , wherein the coated corrugated linerboard has a Cobb value of less than 10 g/cm 2  in 30 minutes as measured by TAPPI Test Method T-441.