1. Field of the Invention
Embodiments of the present invention generally relate to a laminated paperboard packaging. More specifically, embodiments of the present invention relate to a laminated composite paperboard packaging for containing ice cream and a method of manufacturing the same.
2. Description of the Related Art
The packaging industry has quickly become one of the world's largest industries, accounting for almost one half-trillion dollars annually worldwide. Commonly-utilized packaging materials include plastic, paper, glass, cardboard, and other materials.
However, many of the current commonly-used packaging materials suffer mechanical failures and many other threats to the integrity of the structure during the course of normal operating conditions, such as saturation, which leads to deterioration of the integrity of the packaging material, and an eventual failure of the package to achieve its intended purpose. Previous attempts to solve the problem of saturation have come in the form of subpar water-resistant coatings, such as a form of polyethylene, to function as a water barrier and prevent a packaged product, such as ice cream, from soaking through its packaging.
Additionally, attempted solutions to this problem are not strong enough to maintain the structural integrity of the packaging material as the thin structures embodied in known containers are subjected to long term wear on the packaging. For example, one type of known ice cream container has a bottom wall which is coated on either the inside surface or both the inside surface and the outside surface by a layer of polyethylene, which is intended to serve as a water-resistant coating and as a heat-sealable surface. However, the polyethylene coating does not effectively resist the diffusion of water into the paper after a significant period of time. Additionally, polyethylene offers little resistance to heat, making the packaged ice cream or frozen novelty more susceptible to certain conditions, especially normal environmental temperatures.
Therefore, there is a need for an improved laminated paperboard packaging material.
Embodiments of the present invention generally relate to a laminated composite paperboard packaging for containing ice cream and a method of manufacturing the same. In one embodiment of the present invention, a laminated packaging material comprises a layer of paperboard, a layer of an aqueous coating disposed on a first surface of the layer of paperboard, and a layer of a thermoplastic resin disposed on a second surface of the layer of paperboard, wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity.
In another embodiment of the present invention, a laminated packaging material comprises a layer of paperboard, a layer of linerboard, a first layer of a thermoplastic resin disposed between a first surface of the layer of linerboard and a second surface of a layer of paperboard, a layer of an aqueous coating disposed on a first surface of the layer of paperboard, and a second layer of a thermoplastic resin disposed on a second surface of the layer of linerboard, wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity.
In yet another embodiment, an ice-cream package comprises a cylindrical sidewall, and a bottom wall comprising: a layer of paperboard, a layer of an aqueous coating disposed on a first surface of the layer of paperboard, and a first layer of a thermoplastic resin disposed on a second surface of the layer of paperboard, wherein the laminated packaging material has a water vapor transmission rate of less than 20 grams per square meter per twenty-four hours in an environment of about 100 degrees Fahrenheit and 90% humidity, wherein the bottom wall is bonded to the bottom portion of the cylindrical sidewall.
So the manner in which the above recited features of the present invention can be understood in detail, a more particular description of embodiments of the present invention, briefly summarized above, may be had by reference to embodiments, which are illustrated in the appended drawings. It is to be noted, however, the appended drawings illustrate only typical embodiments of embodiments encompassed within the scope of the present invention, and, therefore, are not to be considered limiting, for the present invention may admit to other equally effective embodiments, wherein:
The headings used herein are for organizational purposes only and are not meant to be used to limit the scope of the description or the claims. As used throughout this application, the word “may” is used in a permissive sense (i.e., meaning having the potential to), rather than the mandatory sense (i.e., meaning must). Similarly, the words “include”, “including”, and “includes” mean including but not limited to. To facilitate understanding, like reference numerals have been used, where possible, to designate like elements common to the figures.
Embodiments of the present invention generally relate to a laminated paperboard packaging. More specifically, embodiments of the present invention relate to a laminated composite paperboard packaging for containing ice cream and a method of manufacturing the same.
The layer of paperboard 102 may comprise any material suitable for embodiments of the present invention. In one embodiment, the layer of paperboard 102 comprises at least one of a paper product, such as kraft paper, high sized board, wood-pulp paper, manila paper, bleached paperboard, or any combination thereof. The layer of paperboard 102 is generally strong enough material to withstand conditions such as saturation and weight load while exhibiting minimal signs of structural failure.
The layer of paperboard 102 generally comprises a weight between about 26 pounds (lb) per thousand square feet (MSF) and about 90 lb/MSF. The weight of the layer of paperboard 102 used is typically dependent on the end user's requirements and the manufacturer's capabilities. In certain embodiments of the present invention, paper grades may be represented in pounds per 3MSF, or pounds per three thousand square feet. In one embodiment, the layer of paperboard 102 comprises a paper grade of about 40 lb/3 MSF, representing 40 pounds per 3,000 square feet (or 13 lb/MSF). In additional embodiments of the present invention, the weight of the paperboard may range between about 30 lb/3 MSF and about 90 lb/MSF.
The layer of an aqueous coating 104 is disposed on the first side of the layer of paperboard 102 to provide a superior water-resistant barrier. In one embodiment of the present invention, the layer of an aqueous coating 104 may comprise polyvinylidene chloride (PVDC), styrene-butadiene rubber (SBR), paraffin-based coatings, or any other aqueous coating material feasible in the context of the present invention.
In accordance with embodiments of the present invention, the layer of an aqueous coating 104 has a water permeability of less than about 5 grams as determined through the two minute Cobb test. Additionally, in accordance with embodiments of the present invention, a layer of an aqueous coating of a laminated packaging material has a heat resistance of at least 450 degrees Fahrenheit. Together, these properties allow embodiments of the present invention to be highly resistant to water permeation and heat, allowing these embodiments to be much less susceptible to hazardous mechanical conditions, and thus, making them much more resistant to structural failure.
Generally, the layer of an aqueous coating 104 is formed in a one-step or a two-step application process. In one embodiment of the present invention, an aqueous coating comprises at least two distinct sublayers.
In one embodiment of the present invention, a two-step process first comprises the step of applying a base coating to fill in any voids which may be present in the layer of paperboard 102 and allow the layer of paperboard 102 to readily accept another coating. A base coating may comprise SBR, clay-filled SBR, PVDC, any polymeric coating feasible in the context of the present invention, any paraffin-based coating feasible in the context of the present invention, or any combination thereof.
In another embodiment, a two-step process then comprises the step of applying a functional coating on top of the base coating. A functional coating may comprise any coating which provides an added value, such as water-resistance, heat-resistance, scuff-resistance, mold-resistance, and any other functionality which is feasible in the context of the present invention.
In one embodiment of the present invention, the functional coating may be applied as a dual coat and act as a base coat to eliminate potential compatibility issues between the base coating and the functional coating when they are dissimilar in composition. In this manner, the functional coating may comprise at least two distinct sublayers.
In one embodiment of the present invention, the layer of a thermoplastic resin 106 may comprise any form of polyethylene—that is, low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), high-density polyethylene (HDPE), or any other form of polyethylene—or polypropylene, any other thermoplastic resin which is feasible in the context of the present invention, any copolymer thereof, or any combination thereof. The layer of a thermoplastic resin 106 functions as a barrier to outside substances, as well as acting as a heat-sealable surface which is able to be melted with application of heat and bonded to a surface to form a container or other structure.
In accordance with one embodiment of the present invention, a laminated packaging material may further comprise an additive. Such additives may include, but are not limited to, pigments, chemical- and/or radiation-resistant additives, any other additive suitable for embodiments of the present invention, or any combination thereof.
Generally, in accordance with embodiments of the present invention, the laminated packaging material 100 has a water vapor transmission rate of less than about 30 grams per square meter per twenty-four hours, as determined through standard testing procedures in an environment at approximately 100 degrees Fahrenheit and about 90% humidity. In alternative embodiments of the present invention, the laminated packaging material 100 has a water vapor transmission rate of less than about 20 grams per square meter per twenty-four hours.
Referring now to
Generally, to create a laminated packaging material 100, a lamination process may be performed in any sequence. In one embodiment, the layer of paperboard 102 and the layer of linerboard 202 are laminated together by a first layer of a thermoplastic resin 106. A layer of an aqueous coating 104 is subsequently extruded on the exposed surface of the layer of paperboard 102. Finally, a second layer of a thermoplastic resin 204 is extruded on the exposed surface of the layer of linerboard 202.
In accordance with one embodiment of the present invention, the laminated packaging material complies fully with guidelines for indirect food additives set by the United States Food and Drug Administration (FDA) and outlined in Title 21 of the United States Code of Federal Regulations, Subpart B, Section 176 et seq.
Referring now to
The bonding of the bottom wall 312 to the bottom portion 306 of the cylindrical sidewall 302 may be achieved in a number of different ways. In one embodiment of the present invention, a layer of the bottom wall 312 is melted to the bottom portion 306 of the cylindrical sidewall 302. The layer which is melted to form the bond may be the second layer of a thermoplastic resin or the layer of an aqueous coating.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof.
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/915,125, filed May 1, 2007, entitled “Laminated Paperboard Ice Cream Packaging,” the disclosure of which is incorporated herein by reference in its entirety.
Number | Date | Country | |
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60915125 | May 2007 | US |