US2016236498A1PendingUtilityA1

Packaging material having moisture barrier and methods for preparing same

49
Assignee: INT PAPER COPriority: Nov 5, 2010Filed: Apr 28, 2016Published: Aug 18, 2016
Est. expiryNov 5, 2030(~4.3 yrs left)· nominal 20-yr term from priority
Inventors:Dennis W. AndersonPatricia L. EwingTimothy J. BradfordMichael Murphy
D21H 19/10B32B 2307/75B41M 1/04Y10T428/31786B41M 5/502B32B 5/02B41M 5/506B32B 27/32B41M 7/0054Y10T428/31855B32B 2307/4023Y10T428/31551Y10T428/31902B32B 2307/734Y10T428/277D21H 27/10B41M 7/0045Y10T428/31906Y10T428/31895B32B 3/10B32B 27/10B32B 2307/724Y10T428/24851B05D 5/04Y10T428/266Y10T428/31511
49
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Claims

Abstract

An article in the form of a packaging material having a water vapor transportation rate of about 500 g/m 2 /day or less. The packaging material has a paper substrate and a print-receptive layer which is positioned over the outer surface of the paper substrate. The packaging material also has a moisture barrier layer positioned over the print-receptive layer. The moisture barrier layer is formed from one or more energy-cured polymers. Also, methods for preparing these packaging materials, including printed packaging materials.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . An article comprising a packaging material comprising:
 a paper substrate having an inner surface and an outer surface;   a print-receptive layer having an inner surface and an outer surface, wherein the print-receptive layer inner surface is positioned over the paper substrate outer surface and wherein the print-receptive layer outer surface has a Parker Print Smoothness value of about 1.5 or less;   a moisture barrier layer comprising one or more energy-cured polymers positioned over the print-receptive layer outer surface, wherein the packaging material has a water vapor transportation rate of about 500 g/m 2 /day or less, wherein the moisture barrier layer comprises one or more energy-cured polymers; and   a moisture barrier reinforcing layer comprising a polyolefin and positioned over the inner surface of the paper substrate.   
     
     
         2 . The article of  claim 1 , wherein the packaging material is recyclable. 
     
     
         3 . The article of  claim 1 , wherein the paper substrate comprises at least about 40% recyclable paper fibers. 
     
     
         4 . The article of  claim 1 , wherein the packaging material comprises ream wrap. 
     
     
         5 . The article of  claim 1 , which further comprises a curl control layer positioned between the inner surface of the paper substrate and the moisture barrier reinforcing layer. 
     
     
         6 . The article of  claim 5 , wherein the moisture barrier reinforcing layer is positioned on the curl control layer. 
     
     
         7 . The article of  claim 6 , which further comprises an inner surface paper sizing layer positioned on the inner surface, and wherein the curl control layer is positioned on the inner surface paper sizing layer. 
     
     
         8 . The article of  claim 1 , wherein the moisture barrier reinforcing layer is positioned on the inner surface of the paper substrate. 
     
     
         9 . The article of  claim 1 , which further comprises an outer surface paper sizing layer positioned on the outer surface, and wherein the print-receptive layer is positioned on the outer surface paper sizing layer. 
     
     
         10 . The article of  claim 1 , wherein the moisture barrier layer is positioned on the print-receptive layer. 
     
     
         11 . The article of  claim 1 , wherein the print-receptive layer is an ink-receptive layer. 
     
     
         12 . The article of  claim 1 , wherein the print-receptive layer is an ink-receptive layer has a Parker Print Smoothness value of about 1 or less. 
     
     
         13 . The article of  claim 1 , wherein the packaging material has a water vapor transportation rate of about 310 g/m 2 /day or less. 
     
     
         14 . The article of  claim 13 , wherein the packaging material has a water vapor transportation rate of about 155 g/m 2 /day or less. 
     
     
         15 . The article of  claim 13 , wherein the packaging material has a water vapor transportation rate of about 10 g/m 2 /day or less. 
     
     
         16 . The article of  claim 13 , wherein the packaging material has a water vapor transportation rate of from about 4 to about 2 g/m 2 /day or less. 
     
     
         17 . The article of  claim 1 , wherein the moisture barrier layer is positioned over the entire print-receptive outer surface. 
     
     
         18 . The article of  claim 1 , wherein the print-receptive layer comprises one or more printed areas. 
     
     
         19 . The article of  claim 1 , wherein the paper substrate comprises at least about 60% recyclable pulp fibers. 
     
     
         20 . The article of  claim 1 , wherein the paper substrate comprises from about 5 to about 95% softwood fibers, and from about 5 to about 95% hardwood fibers. 
     
     
         21 . The article of  claim 20 , wherein the paper substrate comprises from about 25 to about 75% softwood fibers, and from about 25 to about 75% hardwood fibers. 
     
     
         22 . The article of  claim 1 , wherein the paper substrate has a basis weight of from about 30 to about 100 lbs/3300 sq. ft and a caliper of from about 2 to about 5 mils. 
     
     
         23 . The article of  claim 22 , wherein the paper substrate has a basis weight of from about 45 to about 75 lbs/3300 sq. ft and a caliper of from about 3 to about 4 mils. 
     
     
         24 . The article of  claim 1 , wherein the print-receptive layer comprises. from about 10 to about 90 parts clay; from about 10 to about 30 parts calcium carbonate; from about 0.25 to about 10 parts starch; from about 20 to about 40 parts latex; and from about 0.01 to about 1 parts crosslinker. 
     
     
         25 . The article of  claim 24 , wherein the print-receptive layer is provided in a coat weight of from about 3 to about 15 lbs./3300 sq. ft. 
     
     
         26 . The article of  claim 25 , wherein the print-receptive layer is provided in a coat weight of from about 4 to about 12 lbs./3300 sq. ft. 
     
     
         27 . The article of  claim 1 , wherein the energy-cured polymers are obtained by curing one or more of the following energy-curable monomers: dipropylene glycol diacrylate; tripropylene glycol diacrylate; butanediol diacrylate; hexanediol diacrylate; alkoxylated hexanediol diacrylate; trimethyol propane triacrylate; alkoxylated trimethylol propane triacrylate; di(trimethylol propane triacrylate); glycerolpropoxy triacrylate; pentaerythritrol triacrylate; alkoxylated pentaerythritrol triacrylate; di(pentaerythritrol triacrylate); neopentaglycol diacrylate; alkoxylated neopentaglycol diacrylate; dipropylene glycol dimethacrylate; tripropylene glycol dimethacrylate; butanediol dimethacrylate; hexanediol dimethacrylate; alkoxylated hexanediol dimethacrylate; trimethyol propane trimethacrylate; alkoxylated trimethylol propane trimethacrylate; di(trimethylol propane methtriacrylate); glycerolpropoxy trimethacrylate; pentaerythritrol trimethacrylate; alkoxylated pentaerythritrol trimethacrylate; di(pentaerythritrol trimethacrylate); neopentaglycol dimethacrylate; alkoxylated neopentaglycoldimethacrylate; acrylated epoxy resins; bis acrylic esters of bisphenol A; acrylated polyurethanes; acrylated polyesters; or acrylated polyethers. 
     
     
         28 . The article of  claim 1 , wherein the energy-cured polymers are obtained by curing one or more of the following energy-curable monomers: urethane acrylates, aliphatic urethane acrylates, aliphatic urethane triacrylate/monomer blends, aliphatic urethane triacrylates blended with 1,6-hexanediol acrylates, hexafunctional urethane acrylates, siliconized urethane acrylates, aliphatic siliconized urethane acrylates, polyether acrylates, trimethylolpropane triacrylates, 2-phenoxyethyl acrylates, isobornyl acrylates, propoxylated glyceryl triacrylates, acrylate ester derivatives, methacrylate ester derivatives, acrylate ester derivatives, or tripropylene glycol diacrylate. 
     
     
         29 . The article of  claim 1 , wherein the energy-cured polymers are obtained by curing one or more of the following energy-curable monomers: trimethylolpropane ethoxy triacrylate, epoxy acrylate oligomers, or tripropylene glycol diacrylate. 
     
     
         30 . The article of  claim 1 , wherein the moisture barrier layer is provided at a coat weight of from about 2 to about 10 gsm. 
     
     
         31 . The article of  claim 30 , wherein the moisture barrier layer is provided at a coat weight of from about 3 to about 7 gsm. 
     
     
         32 . The article of  claim 1 , wherein the moisture barrier reinforcing layer comprises polyolefin comprising polyethylene or polypropylene. 
     
     
         33 . The article of  claim 1 , wherein the moisture barrier reinforcing layer comprises polyolefin in the form of a homopolymer, a copolymer, a random copolymer, a graph polymer or copolymer, or a block copolymer thereof. 
     
     
         34 . The article of  claim 1 , wherein the moisture barrier reinforcing layer comprises polyolefin comprising polyethylene. 
     
     
         35 . The article of  claim 1 , wherein the moisture barrier reinforcing layer comprises polyolefin comprising at least one polyethylene selected from the group consisting of high density polyethylene, high density cross-linked polyethylene, cross-linked polyethylene, medium density polyethylene, linear low density polyethylene, low density polyethylene, and very low density polyethylene. 
     
     
         36 . The article of  claim 1 , wherein the moisture barrier reinforcing layer is provided at a coat weight of from about 2 to about 10 gsm. 
     
     
         37 . The article of  claim 1 , wherein the moisture barrier reinforcing layer is provided at a coat weight of from about 3 to about 6 gsm. 
     
     
         38 . The article of  claim 1 , wherein the recyclable packaging material provides a brightness gain per yield loss value of at least about 0.3. 
     
     
         39 . The article of  claim 38 , wherein the recyclable packaging material provides a brightness gain per yield loss value of at least about 0.5. 
     
     
         40 . A method comprising the following steps:
 (a) providing a calendered printable material comprising:
 a paper substrate having an inner surface and an outer surface; 
 a print-receptive layer having an inner surface and a calendered outer surface positioned over the paper substrate outer surface, wherein the print-receptive layer inner surface is positioned over the paper substrate outer surface and wherein the calendered print-receptive layer outer surface has a Parker Print Smoothness value of about 1.5 or less; and 
 a moisture barrier reinforcing layer comprising a polyolefin positioned over the inner surface of the paper substrate; 
   (b) applying an energy-curable coating comprising one or more energy-curable monomers over the calendered print-receptive layer outer surface; and   (c) curing the energy-curable monomers to form a moisture barrier layer comprising one or more energy-cured polymers positioned over the calendered print-receptive layer outer surface to provide a printed packaging material having a water vapor transportation rate of about 500 g/m 2 /day or less.   
     
     
         41 . The method of  claim 40 , wherein the one or more energy-cured polymers are recyclable. 
     
     
         42 . The method of  claim 40 , wherein the printed packaging material is recyclable. 
     
     
         43 . The method of  claim 40 , wherein the energy-curable coating is applied over the entire print-receptive outer surface during step (b). 
     
     
         44 . The method of  claim 40 , wherein the energy-curable coating is applied over the entire calendered print-receptive layer outer surface during step (b). 
     
     
         45 . The method of  claim 40 , which comprises the following further step: (d) prior to step (c), depositing a print colorant on the calendered print-receptive layer outer surface to form one or more printed areas. 
     
     
         46 . The method of  claim 45 , wherein the print-receptive layer of step (a) is an ink-receptive layer, and wherein the print colorant deposited in step (d) is ink. 
     
     
         47 . The method of  claim 46 , wherein step (d) is carried out by flexographic printing of the ink on the print-receptive layer outer surface, and wherein step (b) is carried out by flexographic printing of the energy-curable coating on the print-receptive layer outer surface. 
     
     
         48 . The method of  claim 47 , wherein step (b) is carried out by flexographic printing of an energy-curable coating having a viscosity, as measured by the Zahn cup test, in the range of from about 10 to about 60 seconds. 
     
     
         49 . The method of  claim 48 , wherein step (b) is carried out by flexographic printing of an energy-curable coating having a viscosity in the range of from about 20 to about 60 seconds. 
     
     
         50 . The method of  claim 40 , wherein step (c) is carried out by photoinitiated curing of one or more photoinitiated-curable monomers. 
     
     
         51 . The method of  claim 40 , wherein step (c) is carried out by electron-beam curing of one or more electron beam-curable monomers. 
     
     
         52 . The method of  claim 40 , wherein step (c) is carried out by thermal curing of one or more thermally-curable monomers. 
     
     
         53 . The method of  claim 40 , wherein the calendered printable material further comprises a curl control layer positioned between the inner surface of the paper substrate and the moisture barrier reinforcing layer. 
     
     
         54 . The method of  claim 53 , wherein the moisture barrier reinforcing layer is positioned on the curl control layer. 
     
     
         55 . The method of  claim 54 , wherein the calendered printable material further comprises an inner surface paper sizing layer positioned on the inner surface, and wherein the curl control layer is positioned on the inner surface paper sizing layer. 
     
     
         56 . The method of  claim 40 , wherein the moisture barrier reinforcing layer is positioned on the inner surface of the paper substrate. 
     
     
         57 . A method comprising the following steps:
 (a) providing an unreeled printable material comprising:
 a paper substrate having an outer surface and inner surface; 
 a print-receptive layer having an inner surface and an outer surface, wherein the print-receptive layer inner surface is positioned over the paper substrate outer surface and wherein the print-receptive layer outer surface has a Parker Print Smoothness value of about 1.5 or less; and 
 a moisture barrier reinforcing layer comprising a polyolefin positioned over the inner surface of the paper substrate; 
   (b) depositing print colorant on the print-receptive layer outer surface to form one or more printed areas to provide a printed material;   (c) applying to the printed material an energy-curable coating comprising one or more energy-curable monomers over the print-receptive layer outer surface, including the printed areas, to provide a coated printed material; and   (d) curing the energy-curable monomers to form a moisture barrier layer comprising one or more energy-cured polymers positioned over the coated print-receptive layer outer surface to provide a printed packaging material having a water vapor transportation rate of about 500 g/m 2 /day or less;   wherein steps (a) through (d) are carried out as a single pass operation and without reeling up: the printed material of step (b) prior to carrying step (c); and the coated material of step (c) prior to carrying out step (d).   
     
     
         58 . The method of  claim 57 , wherein the paper substrate of step (a) comprises recyclable paper fibers, and wherein the printed packaging material provided in step (c) is a recyclable printed packaging material. 
     
     
         59 . The method of  claim 57 , wherein the energy-curable coating is applied over the entire print-receptive outer surface during step (c). 
     
     
         60 . The method of  claim 57 , wherein the print-receptive layer of step (a) is an ink-receptive layer, and wherein the print colorant of step (b) is ink. 
     
     
         61 . The method of  claim 60 , wherein step (b) is carried out by flexographic printing of the ink on the print-receptive layer outer surface, and wherein step (c) is carried out by flexographic printing of the energy-curable coating on the print-receptive layer outer surface. 
     
     
         62 . The method of  claim 61 , wherein step (c) is carried out by flexographic printing of an energy-curable coating having a viscosity, as measured by the Zahn cup test, in the range of from about 10 to about 60 seconds. 
     
     
         63 . The method of  claim 62 , wherein step (c) is carried out by flexographic printing of an energy-curable coating having a viscosity in the range of from 20 to about 60 seconds. 
     
     
         64 . The method of  claim 57 , wherein step (c) is carried out by photoinitiated curing of one or more photoinitiated-curable monomers. 
     
     
         65 . The method of  claim 57 , wherein step (c) is carried out by electron-beam curing of one or more electron beam-curable monomers. 
     
     
         66 . The method of  claim 57 , wherein step (c) is carried out by thermal curing of one or more thermally-curable monomers. 
     
     
         67 . The method of  claim 57 , which comprises the further step of: (e) reeling up the printed packaging material into a roll. 
     
     
         68 . The method of  claim 57 , wherein the unreeled printable material further comprises a curl control layer positioned between the inner surface of the paper substrate and the moisture barrier reinforcing layer. 
     
     
         69 . The method of  claim 68 , wherein the moisture barrier reinforcing layer is positioned on the curl control layer. 
     
     
         70 . The method of  claim 69 , wherein the unreeled printable material further comprises an inner surface paper sizing layer positioned on the inner surface, and wherein the curl control layer is positioned on the inner surface paper sizing layer. 
     
     
         71 . The method of  claim 57 , wherein the moisture barrier reinforcing layer is positioned on the inner surface of the paper substrate.

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