Cellulosic structures for high barrier applications
A cellulosic substrate includes a first major side and a second major side opposed from the first major side, a single polyolefin aqueous polymer dispersion barrier layer on the first major side of the cellulosic substrate, and at least one non-polyolefin aqueous polymer dispersion barrier layer between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate.
1 . A cellulosic structure comprising:
a cellulosic substrate comprising a first major side and a second major side opposed from the first major side;
a single barrier layer on the first major side of the cellulosic substrate, the single barrier layer comprising a polyolefin aqueous polymer dispersion; and
at least one non-polyolefin aqueous polymer dispersion barrier layer between the single barrier layer and the first major side of the cellulosic substrate; and
at least one water soluble polymer barrier layer between the single barrier layer and the first major side of the cellulosic substrate, wherein the water soluble polymer barrier layer comprises a water soluble binder.
2 . The cellulosic structure of claim 1 wherein the cellulosic substrate comprises paperboard.
3 . The cellulosic structure of claim 1 wherein the single barrier layer comprises a polyolefin binder.
4 . The cellulosic structure of claim 3 wherein the single barrier layer comprises a pigment.
5 . The cellulosic structure of claim 4 wherein a ratio of the polyolefin binder to the pigment is at least 1 to 2.
6 . The cellulosic structure of claim 1 wherein the single barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 .
7 . The cellulosic structure of claim 1 wherein the non-polyolefin aqueous polymer dispersion barrier layer comprises a non-polyolefin binder.
8 . The cellulosic structure of claim 7 wherein the non-polyolefin binder comprises at least one of a styrene acrylic binder, a styrene-butadiene binder, a vinyl acrylic binder, and a polyester dispersion binder.
9 . The cellulosic structure of claim 7 wherein the non-polyolefin aqueous polymer dispersion barrier layer comprises a pigment.
10 . The cellulosic structure of claim 9 wherein a ratio of the non-polyolefin binder to the pigment is at least 1 to 2.
11 . The cellulosic structure of claim 1 wherein the non-polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 .
12 . The cellulosic structure of claim 1 wherein the water soluble binder comprises at least one of a polyvinyl alcohol binder, a carboxymethylcellulose binder, and an alginate binder.
13 . The cellulosic structure of claim 1 wherein the water soluble polymer barrier layer further comprises a pigment.
14 . The cellulosic structure of claim 13 wherein a ratio of the water soluble binder to the pigment is at least 1 to 1.
15 . The cellulosic structure of claim 1 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 .
16 . The cellulosic structure of claim 1 further comprising a barrier layer on the second major side of the cellulosic substrate.
17 . The cellulosic structure of claim 1 further comprising a non-barrier layer on the second major side of the cellulosic substrate.
18 . The cellulosic structure of claim 1 having a 30-minute-water-Cobb rating of at most about 20 g/m 2 .
19 . The cellulosic structure of claim 1 having a water vapor transmission rate of less than 1000 grams per square meter per day at 38° C./90% RH.
20 . The cellulosic structure of claim 1 having oxygen transmission rate of less than 500 cc per square meter per day at 23° C./0% RH/100% O2.
21 . The cellulosic structure of claim 1 having a 3M kit test value is at least 5.
22 . The cellulosic structure of claim 1 wherein the cellulosic structure has a blocking rating of 2.0 or less.
23 . The cellulosic structure of claim 1 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 50%.
24 . A container comprising the cellulosic structure of claim 1 .
25 . The cellulosic structure of claim 1 wherein the water soluble polymer barrier layer is between the at least one non-polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate.
26 . A method for manufacturing a cellulosic structure, the method comprising:
providing a cellulosic substrate comprising a first major side and a second major side opposed from the first major side;
forming at least one non-polyolefin aqueous polymer dispersion barrier layer on the first major side of the cellulosic substrate;
forming at least one water soluble polymer barrier layer on the first major side of the cellulosic substrate, wherein the water soluble polymer barrier layer comprises a water soluble binder; and
forming a single barrier layer on the first major side of the cellulosic substrate, the single barrier layer comprising a polyolefin aqueous polymer dispersion,
wherein the at least one non-polyolefin aqueous polymer dispersion barrier layer is between the single barrier layer and the first major side of the cellulosic substrate, and
wherein the at least one water soluble polymer barrier layer is between the single barrier layer and the first major side of the cellulosic substrate.