Paperboard-based beverage container

Abstract

A container including at least one wall that defines an internal volume and an opening into the internal volume, the wall defining an internal surface and an external surface and being formed as a layered structure that includes a first layer, a second layer that includes paperboard and defines the external surface, and an adhesive layer disposed between the first layer and the second layer, wherein at most 0.15 grams of surface condensation forms on the wall per 300 square centimeters of the external surface during a 20-minute interval, the 20-minute interval beginning upon filling 75 percent of the internal volume with a liquid maintained at a temperature of about 32° F. while the filled container is exposed to an ambient temperature of about 73° F. and about 50 percent relative humidity.

What is claimed: 
     
         1 . A method for making a beverage container comprising the steps of:
 providing a first layer of paperboard and a second layer of paperboard;   positioning an adhesive material between said first layer and said second layer to form a layered structure, said adhesive material having a pseudoplasticity index in the range of about 0.3 to about 0.5;   shaping said layered structure to define an internal volume and an opening into said internal volume, said layered structure having an internal surface and an external surface; and   drying said adhesive material.   
     
     
         2 . The method of  claim 1  wherein said second layer has an average porosity of 20 to 1000 Gurley units. 
     
     
         3 . The method of  claim 1  wherein said second layer has an average porosity of 20 to 150 Gurley units. 
     
     
         4 . The method of  claim 1  wherein said adhesive material is provided as a foam. 
     
     
         5 . The method of  claim 4  wherein 10 to 60 percent of said foam is comprised of open voids. 
     
     
         6 . The method of  claim 1  wherein said adhesive material includes sawdust and a binder. 
     
     
         7 . The method of  claim 6  wherein said sawdust has an average particle size of at least 100 microns. 
     
     
         8 . The method of  claim 6  wherein said sawdust has an average particle size of at least 1000 microns. 
     
     
         9 . The method of  claim 6  wherein said binder comprises latex. 
     
     
         10 . The method of  claim 6  wherein said binder comprises starch. 
     
     
         11 . The method of  claim 1  wherein said adhesive material comprises 2 to 70 percent by weight filler and 8 to 70 percent by weight organic binder. 
     
     
         12 . The method of  claim 11  wherein said filler comprises an organic filler. 
     
     
         13 . The method of  claim 12  wherein said organic filler is selected from the group consisting of sawdust, ground wood, cellulose pulp, pearl starch, gluten feed, corn seed skin, kenaf core and combinations thereof. 
     
     
         14 . The method of  claim 12  wherein said organic filler comprises a hard organic filler. 
     
     
         15 . The method of  claim 11  wherein said adhesive material further comprises 1 to 15 percent by weight sodium silicate. 
     
     
         16 . The method of  claim 11  wherein said adhesive material further comprises 0.5 to 10 percent by weight plasticizer. 
     
     
         17 . The method of  claim 11  wherein said adhesive material has an equilibrium moisture content of about 10 to 15 percent by weight. 
     
     
         18 . The method of  claim 1  wherein said adhesive material forms an adhesive layer between said first layer and said second layer, and wherein said adhesive layer has a thickness of 0.05 to 5 millimeters. 
     
     
         19 . The method of  claim 1  wherein said second layer includes an inner surface and an outer surface, said outer surface defining said external surface, and wherein inner surface has a first Hercules sizing and said outer surface has a second Hercules sizing, said second Hercules sizing being greater than said first Hercules sizing. 
     
     
         20 . The method of  claim 1  wherein said adhesive material comprises organic filler and organic binder. 
     
     
         21 . The method of  claim 1  wherein said adhesive material spaces said first layer at least 0.5 millimeters away from said second layer. 
     
     
         22 . A method for making a beverage container comprising the steps of:
 providing a first layer of paperboard and a second layer of paperboard;   positioning an adhesive material between said first layer and said second layer to form a layered structure, said adhesive material having a pseudoplasticity index in the range of about 0.3 to about 0.5;   shaping said layered structure to define an internal volume and an opening into said internal volume, said layered structure having an internal surface and an external surface; and   drying said adhesive material,   wherein at most 0.15 grams of condensation forms on said external surface per 300 square centimeters of said external surface during a 20-minute interval, said 20-minute interval beginning upon filling 75 percent of said internal volume with a liquid maintained at a temperature of about 32° F. while said filled container is exposed to an ambient temperature of about 73° F. and about 50 percent relative humidity.