Coated paperboard containers and methods

Abstract

A coated paperboard container includes a precursor paperboard substrate that includes a paperboard substrate and a barrier coating on the paperboard substrate. The coated paperboard container also includes an aqueous barrier coating on at least a portion of the barrier coating after the precursor paperboard container is formed with the barrier coating.

1 . A coated paperboard container, comprising:
 a precursor paperboard container comprising:
 a paperboard substrate; and 
 a barrier coating on the paperboard substrate; and 
   an aqueous barrier coating disposed on at least a portion of the barrier coating after formation of the paperboard substrate, having the barrier coating, into the precursor paperboard container.   
     
     
         2 . The coated paperboard container of  claim 1 , wherein:
 the paperboard substrate comprises a tubular structure having an interior surface and an exterior surface;   the barrier coating is on the interior surface; and   the aqueous barrier coating is disposed over the barrier coating on at least a portion of the interior surface such that the barrier coating is positioned between the interior surface and the aqueous barrier coating.   
     
     
         3 . The coated paperboard container of  claim 2 , wherein:
 the barrier coating is applied to the interior surface before formation of the tubular structure; and   the aqueous barrier coating is applied over the barrier coating after formation of the tubular structure.   
     
     
         4 . The coated paperboard container of  claim 3 , wherein the aqueous barrier coating is sprayed onto at least a portion of the interior surface over the barrier coating. 
     
     
         5 . The coated paperboard container of  claim 2 , wherein:
 the tubular structure comprises a seam;   the aqueous barrier coating is disposed over the barrier coating along the seam.   
     
     
         6 . The coated paperboard container of  claim 5 , wherein the aqueous barrier coating is further disposed over the barrier coating on a portion of the interior surface adjacent to the seam. 
     
     
         7 . The coated paperboard container of  claim 5 , wherein:
 the barrier coating is heat sealable; and   the seam is heat sealed using the barrier coating.   
     
     
         8 . The coated paperboard container of  claim 1 , further comprising:
 a tubular sidewall comprising an interior sidewall-surface;   a bottom wall connected to the sidewall and comprising an interior bottom-surface; and   a bottom seam formed between the sidewall and the bottom wall,   wherein:
 the barrier coating is on the interior sidewall-surface and the interior bottom-surface; and 
 the aqueous barrier coating is over the barrier coating along the bottom seam. 
   
     
     
         9 . The coated paperboard container of  claim 8 , wherein the sidewall and the bottom wall are heat sealed together by way of the barrier coating to form the bottom seam. 
     
     
         10 . The coated paperboard container of  claim 9 , wherein the aqueous barrier coating is over the barrier coating on at least a portion of the interior sidewall-surface adjacent to the bottom seam. 
     
     
         11 . The coated paperboard container of  claim 9 , wherein the aqueous barrier coating is over the barrier coating on at least a portion of the interior bottom-surface adjacent to the bottom seam. 
     
     
         12 . The coated paperboard container of  claim 9 , wherein the aqueous barrier coating is over the barrier coating on at least a portion of the interior sidewall-surface adjacent to the bottom seam and on at least a portion of the interior bottom-surface adjacent to the bottom seam. 
     
     
         13 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises a polymer material. 
     
     
         14 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises acrylic. 
     
     
         15 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises styrene acrylate. 
     
     
         16 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises styrene butadiene. 
     
     
         17 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises ethylene acrylic acid. 
     
     
         18 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises polyvinyl acrylic. 
     
     
         19 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises polyolefin. 
     
     
         20 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises polyester. 
     
     
         21 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises polylactic acid. 
     
     
         22 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises polyhydroxy alkanoate. 
     
     
         23 - 24 . (canceled) 
     
     
         25 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating comprises at least one of acrylic, styrene acrylate, styrene butadiene, ethylene acrylic acid, polyvinyl acrylic, polyolefin, polyester, polylactic acid, polyhydroxy alkanoate, epoxy, and polyurethane. 
     
     
         26 . (canceled) 
     
     
         27 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating has an area density of approximately 3 grams per square meter to approximately 18 grams per square meter. 
     
     
         28 . (canceled) 
     
     
         29 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating has an area density of approximately 8 grams per square meter to approximately 12 grams per square meter. 
     
     
         30 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating has coat weight of approximately 0.03 grams per container to approximately 0.3 grams per container. 
     
     
         31 . (canceled) 
     
     
         32 . The coated paperboard container of  claim 1 , wherein the aqueous barrier coating has coat weight of approximately 0.10 grams per container to approximately 0.15 grams per container. 
     
     
         33 . The coated paperboard container of  claim 1 , wherein the coated paperboard container is a cup. 
     
     
         34 . A coated paperboard container, comprising:
 a sidewall paperboard substrate comprising an interior sidewall-surface and a barrier coating on the interior sidewall-surface;   a bottom paperboard substrate comprising an interior bottom-surface and the barrier coating on the interior bottom-surface;   a bottom seam formed between the sidewall paperboard substrate and the bottom paperboard substrate; and   an aqueous barrier coating disposed over the barrier coating along the bottom seam.   
     
     
         35 - 63 . (canceled) 
     
     
         64 . A method of making a coated paperboard container, the method comprising steps of:
 applying a barrier coating to an interior sidewall-surface of a sidewall paperboard substrate;   applying the barrier coating to an interior bottom-surface of a bottom paperboard substrate;   connecting the sidewall paperboard substrate and the bottom paperboard substrate together to form a tubular structure; and   applying an aqueous barrier coating over the barrier coating along a bottom seam of the tubular structure formed between the sidewall paperboard substrate and the bottom paperboard substrate.   
     
     
         65 - 69 . (canceled)