Coated cardboard and a method of producing the same
A coated food cardboard that is comprised of a cardboard layer and a coating layer at least on one side of it, and a method of producing it. Between the coating layer and the cardboard surface is formed by dispersion coating a barrier layer that is comprised of binder and slate-like pigments. The layer is formed of a dispersion that is prepared by dispersing slate-like pigment in water and mixing this with a non-hydrophobic binder. The cardboard has excellent barrier properties and it can be used, for example, in such a pigment coated cardboard, in particular fresh fibre cardboard that has good properties of mineral oil migration and fat penetration prevention.
The present invention relates to a cardboard according to the preamble of claim 1.
Such a product comprises a fibre layer that has two opposite surfaces, in which case there is a coating layer at least on its first surface.
The present invention also relates to a method, according to the preamble of claim 13, of producing a cardboard that comprises barrier properties, and the use according to claim 27.
Barriers are used in paper and cardboard products to prevent unwanted substances to penetrate through the material. Such unwanted substances can be for example: water, water vapour, oxygen, fat, flavourings and components of mineral oil. In particular, it has become important to prevent the penetration of the latter ones, because it has been found that from a recycled fibre cardboard that is placed directly against the food, such as cereals, mineral oil components, that are harmful to health and sourced from for example printing inks, migrate into the food. It has also been suspected that such a migration can take place indirectly from the outer package that comprises recycled fibre, through the fresh fibre cardboard of the inner package, into the food.
In cardboards, barriers that are extruded or applied as dispersions are generally used. The barrier is applied either onto the back side or the surface of the cardboard. Barrier application is usually carried out as an off-line operation, where the cardboard manufactured at the cardboard mill is lengthwise cut into suitable rolls, packed, transported to the processing plant, coated with a barrier at the processing plant, packed and sent to the customer.
With regard to the art, reference is made to publications WO 2013164646 A1, U.S. Pat. No. 6,545,079 B1, EP 2777934 A1 and U.S. Pat. No. 6,531,196 B1.
Known solutions are associated with problems. Barrier application as an off-line operation significantly increases production costs of the barrier coated cardboard, compared to cardboard which is not barrier coated, and reduces its competitiveness.
In barrier material applied as a dispersion, “pinholes”, i.e. holes that are invisible to the eye, easily appear in the barrier layer, which holes ruin the barrier function. These pinholes may arise, for example, due to a rough base cardboard or instability of the application method. Also, off-line coating, as a separate operation, increases the risk of quality problems.
Application of the barrier as a separate layer onto either surface of the cardboard, immediately affects the other operating characteristics of the cardboard. If, for example, a barrier is applied onto the back side of a folding boxboard, it seals the surface pore structure and prevents the penetration of dispersion or hot melt adhesives. As a result, the production of conventional cardboard boxes requires the use of expensive special solutions, such as perforations and special adhesives.
If a barrier is applied, for example, onto the surface of a folding boxboard, the barrier prevents the printing inks from penetration, for example, in offset, gravure, flexo and ink jet printing. A separate barrier layer also increases the risk of poor toner adhesion in electrophotographic printing methods of digital printing.
A barrier that is applied onto either side of the surface of a cardboard can also cause blocking of the cardboard when reeling. In such a case, the cardboard layers on the machine reel adhere to each other, causing serious quality and runability problems.
When hydrophobic barrier materials are used, the cardboard recirculation back to the process is aggravated due to poor pulpability.
It is an aim of the present invention to eliminate at least some of the problems of the prior art and to provide an entirely novel solution of producing cardboard having barrier properties.
The invention is based on the idea that a barrier layer is formed by dispersion coating onto the fibre layer of the cardboard, which layer is comprised of a binder and slate-like pigments. The barrier layer is arranged between the surface and at least one coating layer. Case-specifically, there may be a surface-sizing layer or a coating layer between the surface and the barrier layer, respectively. Preferably, the surface-sizing agent layer or the coating layer, respectively, is formed onto the surface of the cardboard layer, prior to the application of the barrier layer onto the surface.
Cardboard thus obtained can be used in food packaging, in particular it can be used in pigment coated cardboard, such as fresh fibre cardboard, which has excellent properties of mineral oil migration and fat penetration prevention.
More specifically, the cardboard according to the present invention is mainly characterized by what is stated in the characterizing part of claim 1.
The method according to the present invention is, in turn, characterized by what is stated in the characterizing part of claim 13.
The use according to the present invention is, in turn, characterized by what is stated in claim 27.
The present solution provides considerable advantages. Thus, according to the present invention, it is possible to apply online at the cardboard machine a barrier layer onto the surface side of the cardboard, before the pigment coating or before the second or last pigment coating, in which case excess handling and transport costs are eliminated.
With the barrier solution of the present invention it is possible to reduce the penetration rate of organic solvent vapour through the cardboard to even less than 10%, compared to cardboard without the barrier.
The barrier has good ability to prevent mineral oil migration and fat penetration.
Conventional pigment coated fresh fibre cardboard has been observed in laboratory tests to reduce, by at least 20% of the maximum potential, the total indirect mineral oil migration taking place from the outer package through the inner package cardboard. By adding to the cardboard the barrier solution according to this invention, it is possible to reduce the indirect mineral oil migration even to 1.5% of the maximum potential.
Since the barrier layers in the barrier solution described in the present invention are between the fibre layer and the pigment coating layers, that are typically on the surface of the cardboard, and both outer surfaces have properties similar to the corresponding surface of conventional cardboard:
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- side gluing with dispersion or hotmelt adhesives does not require unorthodox solutions,
- printing properties do not differ from conventional, and
- when reeling at the cardboard machine, blocking of cardboard does not occur due to the effect of the barrier.
Since the barrier can be applied online at the cardboard machine, the present invention enables delivery of the barrier product directly from the cardboard mill to the customer, without a separate external subcontractor needed to apply the barrier, which will bring significant savings in logistics costs.
Although, in one preferred embodiment, the barrier is brought to a cardboard surface that comprises chemical pulp fibre, it is also possible to form the described barrier onto a surface that comprises mechanical pulp.
The cardboard produced according to the present invention, is entirely pulpable and can be recycled to the cardboard mill process, like ordinary cardboard. In this regard, it clearly differs from, for example, conventional barrier cardboard brands that comprise extrusion films.
In a first embodiment, a barrier dispersion is prepared by dispersing a slate-like kaolin pigment in water and mixing this with either cooked or cold soluble conventional surface-sizing starch slurry.
In another embodiment, the dispersion is applied directly at the cardboard machine.
In a third embodiment, the dispersion is applied directly at the cardboard machine, after surface-sizing and preferably before any pigment coating.
In a fourth embodiment, the dispersion is applied as two separate layers directly at the cardboard machine, after the surface-sizing and before the pigment coating. The first layer is applied with a film size press, for example, in which case a contour type barrier coating layer is achieved, that follows the surface shapes and the roughness. By applying a second layer, any pin-holes in the first coating layer are blocked, in which case the total thickness of the barrier layer increases and the surface becomes smooth.
In the following, preferred embodiments are described with reference to the accompanying photographs.
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the electron microscopic picture in
In the following description, the terms “spread” and “apply” are used interchangeably.
As seen from the above, the present cardboard product is a coated food cardboard. Such a product comprises a fibre layer (cardboard layer) and a coating layer on at least one side of it.
The fibre matrix of the cardboard may comprise bleached or unbleached hardwood pulp, bleached or unbleached softwood pulp, bleached or unbleached mechanical pulp, bleached or unbleached chemi-mechanical pulp or recirculated broke pulp used in cardboard production, or mixtures thereof. In particular, mutual mixtures of the above described bleached and unbleached pulps, respectively, and mechanical or chemi-mechanical pulps, are possible. Recirculated broke pulp may also be used in any of the abovementioned pulps, mechanical pulps and chemi-mechanical pulps.
An example of a multilayer cardboard is a product that comprises in combination
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- a first fibre layer having an outer surface and an inner surface,
- a second fibre layer, that is arranged at a distance from the first fibre layer and having an outer surface and an inner surface, in which case the inner surface of the second fibre layer is arranged on the inner side of the first fibre layer, and
- a third fibre layer, that is arranged between the first and the second fibre layer, the fibre layers forming the fibre matrix of the cardboard, and a tracer containing surface-sizing layer being arranged on the outer surface of the first fibre layer, that forms the cardboard back.
In such a product, which in principal corresponds to a conventional folding boxboard, at least one of the first and second fibre layers comprises chemical cellulose pulp.
The first and the second fibre layer may comprise bleached or unbleached softwood and/or hardwood pulp. A third fibre layer comprises mechanical or chemi-mechanical pulp, unbleached or bleached softwood or hardwood pulp or broke pulp that is recirculated in the cardboard production.
Usually, the grammage of the cardboard layer is approximately 40-750 g/m2, most suitably approximately 90-500 g/m2, in particular approximately 110-400 g/m2.
As an example, it may be mentioned that the grammage of a typical folding boxboard is approximately 150-350 g/m2. Usually, a folding boxboard comprises 2-10 layers, in which case the grammage of the surface layer is approximately 40-80 g/m2 and of the back 25-50 g/m2.
Since the present solution is applied particularly as an online application, the cardboard layer to be treated is preferably in the form of a cardboard web, and the barrier layer is brought to the cardboard web coming from the dewatering of the cardboard machine. It is of course also possible to apply the barrier layer onto a sheet-like cardboard.
If desired, and as indicated above, the surface of the cardboard can be sized in order to modify its surface properties, for example to seal the surface and to reduce the moisture absorption, before the barrier layer is applied onto the cardboard layer. Such a surface sizing is in one embodiment combined with online application of the present barrier composition.
The surface-sizing layer typically comprises a synthetic, water-soluble polymer or a natural polymer or a derivative thereof. Surface-sizing agents may be divided into several groups, in which case the main division is between the cationic and anionic surface-sizing agents.
In addition to these, to a certain extent also reactive sizing agents, such as alkyl-ketene dimer (AKD), that are otherwise mainly used in beater-sizing, are used in the surface-sizing. Also, perfluorinated substances, such perfluorinated phosphate and perfluorinated alkyl polymers may be used.
Cationic surface-sizing agents are cationic starches and starch derivatives, and corresponding carbohydrate based biopolymers. Examples of synthetic polymers are, for example, styrene/acrylate copolymers (SA), polyvinyl alcohols, polyurethanes and alkylated urethanes.
Anionic surface-sizing agents include anionic starches and starch derivatives, and corresponding carbohydrate based biopolymers, among others carboxymethylcellulose and its salts, and alkylcelluloses such as methyl and ethyl cellulose. Examples of synthetic polymers are styrene/maleic acid copolymer (SMA), di-isobutylene/maleic acid anhydride, styrene-acrylate copolymers, acrylonitrile/acrylate copolymers and polyurethanes and corresponding latex products that comprise the same chemical functionalities.
Many of the above-mentioned are supplied as viscous solutions, that are formed of sodium or ammonium salts of the corresponding polycarboxylic acids.
The percentage of the surface-sizing agent in the solution is generally approximately 0.01-25% by weight, typically approximately 1-15% by weight. The amount of the surface-sizing agent (grammage) is generally approximately 0.1-10 g/m2, particularly approximately 0.2-5 g/m2, for example approximately 0.3-3g/m2.
The barrier layer is formed onto the cardboard layer, either directly or after application of the surface-sizing agent. This layer comprises a binder and a slate-like mineral pigment. Most suitably, the barrier layer is formed with a dispersion coating.
Preferably, the pigment together with the binder, form a network structure that is capable of slowing down the penetration of molecules of unwanted substances, through the barrier layer.
In one preferred embodiment, the barrier layer comprises non-hydrophobic binder. Examples of suitable binders include starch, such as cooked or cold soluble surface sizing starch slurry, polyvinyl alcohol, ethylene vinyl alcohol, and mixtures thereof. It has been found that the non-hydrophobic binder is particularly advantageous because it allows applying of coating paste onto the barrier layer, in such a way that the coating layer adheres to and remains on the surface of the barrier layer.
In one embodiment, the barrier layer comprises of its dry weight 5-70% mineral pigment and 95-30% binder, in particular it comprises of its dry weight approximately 15-60% mineral pigment and 85-40% binder, possibly together with dispersion additives.
As examples of the slate-like mineral pigments of the barrier layer may be mentioned kaolin, talc and mixtures thereof.
In one embodiment, the barrier layer is formed of a dispersion that is prepared by dispersing the slate-like pigment in water and mixing this with a non-hydrophobic binder.
According to a more preferred embodiment, the barrier layer is formed of a dispersion, that is prepared by dispersing a slate-like pigment in water, in particular in order to generate a pigment dispersion that has a solids content of over 50%. The dispersion thus obtained is preferably combined with the binder by mixing, in which case the pigment percentage of the dry matter of the dispersion that is used to form the barrier layer, is approximately 5-70%, in particular approximately 15-60%.
In one preferred embodiment, the dispersion is applied at the cardboard machine, i.e. as an online application, after possible surface-sizing and before the pigment coating.
This embodiment will provide interesting effects. Thus, the surface size will close the fibrous surface of the web thereby preventing excessive penetration of the binder of the barrier composition into the web. Instead, the binder remains in the barrier layer. Further, the barrier layer forms a smooth layer after a preceding surface sizing step, and this will further reduce the risk of formation of pin-holes. A smooth barrier layer, obtained as discussed, will also form a smooth base layer for one or several pigment coating layers. In combination, the pigment coating layers will be smooth and they will further improve the barrier effect of the barrier layer, as well as provide for a good printing surface. Good haptic and visual properties will also be attained.
The dispersion may be applied as a single application, but it can also be applied in several layers on top of each other. In a preferred embodiment, the dispersion is applied as at least two separate layers.
In one embodiment, the first dispersion layer is applied with a film size press, in which case a contour type barrier layer is achieved, that follows the surface shapes and the roughness.
A second layer is applied onto the first layer. It can be applied, for example, by using a blade or rod, and the application can therefore be carried out, for example, with a blade coating unit or a rod coating unit.
After the application of the second dispersion layer, or other dispersion layers, in one alternative, the barrier layers are left undoctored.
In a preferred embodiment, after the application of the second dispersion layer, or other dispersion layers, the layers are doctored with a rotating or static, smooth or grooved rod, an air knife, or a metallic or ceramic blade. It is also possible to proceed in this way, in case the dispersion coating is brought onto the surface of the cardboard by single application.
Preferably, the dispersion layer is applied from a pigment slurry having a relatively high dry matter content. In one embodiment, the dry matter content of the pigment is 10-40%, in particular 12-39.5%, calculated on the weight of the slurry.
A typical grammage of the barrier layer is approximately 1-50 g/m2, particularly approximately 5-40 g/m2, most suitably approximately 10-30 g/m2, per side or page of the cardboard.
The barrier layer increases the weight of the product only to a small extent, typically by approximately 5-30%, compared to a product without a barrier layer.
In a dispersion that is suitable for forming a barrier layer, it is possible to use conventional additives and auxiliary agents, such as dispersing agents (for example sodium salt of polyacrylic acid), substances that affect the viscosity of the mixture (for example CMC, hydroxyethyl cellulose, polyacrylates, alginates, benzoate), so-called slip agents, hardeners used for improving water repulsion, optical auxiliary agents, anti-foaming agents, pH adjusting agents and preservatives, in the coating composition. Examples of the slip agents include sulphonate oils, esters, amines, calcium and ammonium stearates; the agents that improve water repulsion include glyoxal; the optical auxiliary agents include derivatives of diamino stilbene sulphonic acid; the anti-foaming agents include phosphate esters, silicones, alcohols, ethers, vegetable oils; the pH controlling agents include sodium hydroxide, ammonia; and finally the preservatives include formaldehyde, phenol and quaternary ammonium salts.
After the application of the barrier layer, the cardboard web or sheet to be coated is brought to the front coater.
Based on the above, also the following applications can be mentioned:
In one preferred embodiment, the binder used is cationic starch. The cationic degree of this may be in the range of DS 0.005 to 0.05.
The proportion of starch in the barrier layer may be 40-85% by weight.
The surface-sizing starch used can be for example corn, potato, tapioca or pea starch.
In another preferred embodiment, that can be combined with the former, a thickening agent is used in the dispersion. The thickening agent used may be a synthetic thickening agent, the quantity of which may be even 10% by weight of the dry matter. The synthetic thickening agent may be, for example, PVA or polyacrylate. The thickening agent may also be, for example, carboxymethylcellulose or microfibrillated pulp or a mixture thereof.
In a third preferred embodiment that can be combined with the applications mentioned above, a hardener is used in the dispersion, in an amount of up to 1% by weight of the dry matter. The hardener used can be, for example, ammonium zirconium carbonate or potassium zirconium carbonate or the like.
In all of the above mentioned application cases, the dry matter may be within the range of 5-50%. The Brookfield viscosity can typically be within the range of 30-2000 mPas, for example 30-800 mPas.
After that, the coating layer is applied onto the barrier layer. Typically, it comprises binder and light-refracting pigment or a mixture of pigments. The barrier layer can be dried before application of the coating layer, but it is also possible to bring the coating layer on the top of a moist barrier layer.
More preferably, the coating layer comprises pigment that refracts light better than the slate-like mineral pigment of the barrier layer. The coating layer may be generated by using one fine mineral pigment, or a mixture of several fine pigments, as follows:
Water is added to the coating paste of this type in such a way that the dry matter content is typically 50-75%.
As examples of suitable pigments may be mentioned: precipitated calcium carbonate, ground calcium carbonate, calcium sulphate, calcium oxalate, aluminium silicate, kaolin (anhydrous aluminium silicate), aluminium hydroxide, magnesium silicate, talc (hydrous magnesium silicate), titanium dioxide and barium sulphate, and mixtures thereof. Synthetic pigments can also be used. Of the pigments mentioned above, the main pigments are kaolin, calcium carbonate, precipitated calcium carbonate and gypsum that in general constitute over 50% of the dry solids in the coating composition. Calcined kaolin, sodium dioxide, satin white, aluminium hydroxide, sodium aluminate and plastics pigments are additional pigments, and their amounts are in general less than 25% of the dry solids in the mix. Of the special pigments, special-quality kaolins and calcium carbonates, as well as barium sulphate and zinc oxide, should be mentioned.
In particular, the pigment of the coating layer is calcium carbonate, precipitated calcium carbonate, titanium dioxide, calcium sulphate, aluminium silicate, aluminium hydroxide, magnesium silicate or barium sulphate, or a mixture thereof.
In a refractive pigment-containing coating layer, it is possible to use any known binder that is commonly used as a binder in coating colours in the manufacturing of paper. Besides individual binders, it is possible to use mixtures of binders. Examples of typical binders include synthetic latexes made of polymers of ethylenically unsaturated compounds, for example butadiene-styrene type copolymers that possibly also comprise a comonomer that comprises a carboxyl group, such as acrylic acid, itaconic acid or maleic acid, and polyvinyl acetate having comonomers that comprise carboxyl groups. Together with the abovementioned agents, it is also possible to use as binders, for example, water-soluble polymers, starch, CMC, hydroxyethyl cellulose and polyvinyl alcohol.
In the coating composition, it is possible to use conventional additives and auxiliary agents (similarly as in the above barrier dispersion). Examples include dispersing agents, agents that affect the viscosity of the mixture, slip agents, hardeners, optical auxiliary agents, anti-foaming agents, pH controlling agents, and preservatives.
In one embodiment, the cardboard layer is coated only on one side, and there is a barrier layer only between this layer and the cardboard layer.
In another embodiment, on both sides of the cardboard layer there are coating layers, and preferably, barrier layers comprising binder and slate-like mineral pigment, are arranged between both coating layers and the corresponding cardboard surfaces.
The grammage of the coating layer can vary within wide limits, for example, according to the number of layers of the coating, and is typically approximately 0.5-50 g/m2/side, usually approximately 5-40 g/m2/side, for example approximately 5-30 g/m2/side. The amount of coating may be different in the surface and the back layers. For example, in the surface that forms the outer surface of the cardboard, the amount of coating is often approximately 10-35 g/m2, and in the back, i.e. inner surface, approximately 5-20 g/m2.
As described above, in laboratory, pilot and production scale experiments, the barrier according to the present invention was observed to have a good ability to prevent mineral oil migration and fat penetration.
Due to its network structure starch, which acts as the binder, slows down and prevents the penetration of unwanted substance molecules, in gas or liquid phase, through the barrier layer. The slate-like pigment creates in the barrier layer a complex structure that is filled with binder, in which case the path of the unwanted molecules is extended many times, compared to the binder layer only. The pigment also acts as a filler which reduces the production costs of the barrier.
When the barrier layers are located under the pigment coating, instead of the cardboard surfaces, the appearance, gluing, printing and other processing properties of the cardboard are maintained as unchanged as possible, compared to a standard product.
It should also be noted that there may be several coating layers in the cardboard. In one embodiment, the barrier layer is placed between the fibre layer which possibly is surface-sized and the coating layer. However, it is also possible to place the barrier layer between the layers of a multilayer coating.
The coating layers are primarily those that comprise light-refracting pigment and provide the product with the required optical characteristics, for example brightness and opacity. ISO brightness is, for example over 85, in particular over 87, most suitably over 90, and the opacity is better than 85, in particular better than 87%.
The following non-restricting examples illustrate the preferred embodiments.
The cardboards used in the examples are folding boxboards, in which case the middle layer of the multi-layer cardboard is formed of mechanical pulp, and its surface layers of chemical pulp, i.e. cellulose.
EXAMPLE 1 Barrier Coating of Cardboard A in the LaboratorySlate-like kaolin was elutriated in a laboratory mixer by first measuring the desired amount of water into a mixing vessel and then adding the dispersant while stirring. After that, dry kaolin powder was added gradually and the stirring was continued until the slurry became uniform. The stirring was continued for an additional hour. The dry matter content of the kaolin slurry was 67%.
A cooked surface sizing starch, which acts as the binder, was prepared in a production scale apparatus by first elutriating the starch in water in a suspender and then cooking it in a continuous digester, and diluting it to a desired dry matter content (14.5%).
The kaolin slurry and the cooked starch were mixed in such a way that the mixture ratio of their mass fractions was 20/80, in the order mentioned, and the dry matter content of the mixture was 17%.
The prepared mixture was used to coat cardboard A in the laboratory. The cardboard coating was carried out twice with a grooved bar number 2 (ERICHSEN GmbH & Co. KG K 101 Bar No. 2=12 μm (red)) at a rate of 4 m/min. The coating was dried after each application with an infrared dryer for a period of 1 minute.
The penetration rate of the organic solvent vapour was measured from the barrier coated cardboard. The measurement was carried out by weighing a constant amount of n-heptane in a vessel, on which was placed tightly the board to be examined, with a known surface area. Evaporation of the heptane through the cardboard was monitored by weighing, in which case the following penetration rates of n-heptane were achieved.
Example 1 shows the performance of a barrier layer, according to the present invention, in preventing penetration of the organic solvent vapours.
EXAMPLE 2 Barrier Coating of Cardboard B in the LaboratoryA kaolin-surface sizing starch mixture was prepared as in Example 1 in such a way that the mixture ratio of their mass fractions was 50/50, in the order mentioned, and the dry matter content was 18%. To the mixture was added a synthetic thickener in such a way that the Brookfield viscosity was 200 mPAs. Cardboard B was coated with this mixture twice with a laboratory coater as in Example 1. The penetration rate of the organic solvent vapour, which was measured as in Example 1, was 0.10 g/dm2/day.
Example 2 shows that with the addition of a thickener it is possible to further improve the barrier properties.
EXAMPLE 3Barrier Coating of Cardboard C with a Pilot Coating Machine
The back of a normal pigment coated cardboard was coated twice, with a mixture of kaolin-starch, according to Example 1, in such a way that the mixture ratio of their mass fractions was 50/50, in the order mentioned, and the dry matter content was 18%. A thickener and hardener were added into the barrier mixture until a good runnability was achieved at the coating station, and a uniform barrier layer, both of which were observed visually. The grammage of both of the barrier layers was 6 g/m2.
Indirect migration from the mineral oil containing outer packaging material was, without maximum potential. The indirect migration was determined by the method according to the following standard: EN 14338 Paper and board intended to come into contact with foodstuffs—Conditions for determination of migration from paper and board using modified polyphenylene oxide (MPPO) as a stimulant.
Example 3 shows that when there is an additional conventional pigment coating layer, the barrier properties are further improved.
EXAMPLE 4Manufacturing of Light Online Barrier Cardboard with a Pilot Coating Machine
The back of an uncoated base cardboard was surface sized and the surface side of the cardboard was coated with a film size press, with a mixture of kaolin and cooked starch, according to Example 1, the mixture ratio of the mass fractions of which was 50/50. After that, the surface side was coated for a second time by using a blade coater, with a mixture of kaolin and cold soluble starch, the mixture ratio of the mass fractions of which was 50/50. Finally, a pigment coating was applied onto the surface side, as well as onto the reference cardboard, which was otherwise prepared in the same way, but instead of the two barrier layers, there was only a surface sizing also on the surface side, under the pigment coating.
Permeation rates of organic vapours were as follows:
Indirect migration from the outer packaging material comprising mineral oil was 4.8% of the maximum potential.
Example 4 shows that it is possible to prepare the barrier layer under the pigment coating.
Claims
1. Coated food cardboard which comprises a cardboard layer and a coating layer on at least one side of it, further comprising a barrier layer between the coating layer and the cardboard containing binder and slate-like mineral pigment.
2. The cardboard according to claim 1, wherein the barrier layer is formed by dispersion coating.
3. The cardboard according to claim 1, wherein the barrier layer comprises non-hydrophobic binder.
4. The cardboard according claim 1, wherein the pigment and the binder together form a network structure, which is capable of slowing down the penetration of unwanted substance molecules through the barrier layer.
5. The cardboard according claim 1, wherein the barrier layer comprises of its dry matter 5-70% mineral pigment and 95-30% binder, in particular it comprises of its dry matter approximately 15-60% mineral pigment and 85-40% binder, possibly together with the additives of the dispersion.
6. The cardboard according to claim 1, wherein the binder of the barrier layer is starch, such as cooked or cold soluble surface sizing starch slurry, polyvinyl alcohol, ethylene vinyl alcohol or a mixture thereof.
7. The cardboard according to claim 1, wherein the slate-like mineral pigment of the barrier layer is kaolin, talc or a mixture thereof.
8. The cardboard according to claim 1, wherein the weight of the barrier layer is approximately 1-50 g/m2, in particular approximately 5-40 g/m2, most suitably approximately 10-30 g/m2, per cardboard side.
9. The cardboard according to claim 1, wherein the coating layer comprises binder and light-refracting pigment or mixture of pigments.
10. The cardboard according to claim 1, wherein the coating layer comprises pigment, which refracts light better than the slate-like mineral pigment of the barrier layer, in particular the pigment of the coating layer is calcium carbonate, titanium dioxide, calcium sulphate, aluminium silicate, aluminium hydroxide, magnesium silicate or barium sulphate or a mixture thereof.
11. The cardboard according to claim 1, wherein on both sides of the cardboard layer there are coating layers and preferably, barrier layers that comprise binder and slate-like mineral pigment are arranged between both coating layers and the corresponding cardboard surfaces.
12. The cardboard according claim 1, wherein there is a surface sizing agent layer between the cardboard surface and the barrier layer.
13. A method of producing coated cardboard, according to which method onto the cardboard is applied a coating mixture that comprises light-refracting pigment, in order to form a coating layer, wherein between the coating layer and the cardboard surface is formed, by dispersion coating, a barrier layer that is comprised of binder and slate-like pigments.
14. The method according to claim 13, wherein the barrier layer is formed of a dispersion that is prepared by dispersing slate-like pigment in water and mixing this into a non-hydrophobic binder.
15. The method according to claim 13, wherein the barrier layer is formed of a dispersion that is prepared by dispersing slate-like pigment in water, particularly in order to generate a pigment dispersion that has a solids content of over 50%, and this dispersion is combined with a binder by mixing, in which case the pigment share of the dry matter of the dispersion that is used to form the barrier layer, is approximately 5-70%, in particular approximately 15-60%.
16. The method according to claim 13, wherein the dispersion is applied at the cardboard machine, after any surface sizing and before any pigment coating, preferably the dispersion is applied directly at the cardboard machine after surface sizing and before pigment coating.
17. The method according to claim 13, wherein the dispersion is applied as at least two different layers.
18. The method according to claim 17, wherein the first dispersion layer is applied with a film size press, such that a barrier layer is achieved that follows the surface shapes and the roughness of the cardboard web.
19. The method according to claim 17, wherein the second dispersion layer is applied with a blade coating unit or a bar coating unit.
20. the method according to claim 17, wherein after the application of the second dispersion layer, the barrier layers are left unformulated or formulated by using a rotating or static, smooth or grooved bar, an air knife, or a metallic or ceramic blade.
21. The method according to claim 13, wherein the dispersion layer is applied from the pigment slurry, the dry matter content of which is 10-40% calculated by weight of the slurry.
22. The method according to claim 13, wherein a barrier layer is formed, the grammage of which is approximately 1-50 g/m2, in particular approximately 5-40 g/m2, most suitably approximately 10-30 g/m2, per cardboard side.
23. The method according to claim 13, wherein a non-hydrophobic binder, polyvinyl alcohol, ethylene vinyl alcohol or a mixture thereof, is used to form the dispersion.
24. The method according to claim 13, wherein the cardboard is surface sized before it is dispersion coated with a dispersion that forms the barrier layer.
25. The method according to claim 13, wherein the cardboard is coated, possibly after surface sizing, before it is dispersion coated with a dispersion that forms the barrier layer.
26. The method according to claim 13, wherein a coating layer is formed that comprises pigment that refracts light better than the late-like mineral pigment in the barrier layer, in particular the coating layer pigment is calcium carbonate, precipitated calcium carbonate, titanium dioxide, calcium sulphate, aluminium silicate, aluminium hydroxide, magnesium silicate or a mixture thereof.
27. The method according to claim 13, wherein on both sides of the cardboard layer, are brought coating layers that comprise slate-like mineral pigment, are arranged between both coating layers and the corresponding cardboard surfaces.
28. (canceled)
29. (canceled)
Type: Application
Filed: Apr 9, 2015
Publication Date: Feb 2, 2017
Applicant: Metsä Board Oyj (Metsä)
Inventors: Kai Hellstén (Äänekoski), Kari Juhela (Äänekoski), Pekka Suokas (Äänekoski)
Application Number: 15/303,027
