Board Product and Method of Making the Same

Abstract

A method of forming a coated SBS board product is provided. An SBS board product is formed without being processed by a Yankee dryer or a wet-stack calendar, and further comprises a plurality of fiber plies, including outermost plies forming the top and back sides and comprised of bleached chemical pulp, and medial plies disposed between the outermost plies and comprised of pulp and/or broke. The SBS board is precalendered with a surface conditioning device and then the top side coated at least once such that the coated SBS board product has a density of between about 500 kg/m 3 and about 1000 kg/m 3 , and a basis weight of between about 150 g/m 2 and about 400 g/m 2 , and the top side has a PPS-s10 roughness of between about 0.5 μm and about 2.0 μm and a Hunter gloss of between about 40%o and about 80%.

1 . A method of forming a coated SBS board product, comprising:
 precalendering a SBS board product with a surface conditioning device comprising a heatable counter-roll disposed adjacent to a tubular flexible jacket extending around a fixed support element and having a load element disposed therebetween for biasing the flexible jacket against the counter-roll, the flexible jacket having opposed ends and being mounted to at least one end wall at each end, the flexible jacket and the at least one end wall at each end being rotatingly driven by a drive mechanism operably engaged therewith, the SBS board product being directed between the flexible jacket and the counter-roll so as to be precalendered thereby, the SBS board product having a top side, a back side, and being formed without being processed by either of a Yankee dryer and a wet-stack calender, the SBS board product further comprising a plurality of fiber plies, including outermost plies forming the top and back sides and comprised of bleached chemical pulp, and medial plies disposed between the outermost plies and comprised of at least one of pulp and broke; and   coating the top side of the SBS board product at least once, following precalendering thereof, such that the coated SBS board product has a density of between about 500 kg/m 3  and about 1000 kg/m 3 , and a basis weight of between about 150 g/m 2  and about 400 g/m 2 , and the top side of the coated SBS board product has a PPS-s10 roughness of between about 0.5 μm and about 2.0 μm and a Hunter gloss of between about 40% and about 80%.   
     
     
         2 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product without coating the back side thereof. 
     
     
         3 . A method according to  claim 1  further comprising coating the back side of the SBS board product at least once. 
     
     
         4 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product in a coating process such that the coated SBS board product has a basis weight of between about 180 g/m 2  and about 350 g/m 2 . 
     
     
         5 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product in a coating process such that the coated SBS board product has a basis weight of between about 180 g/m 2  and about 300 g/m 2 . 
     
     
         6 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product such that the top side thereof has a Bendtsen roughness of between about 0 ml/min and about 50 ml/min. 
     
     
         7 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product such that the top side thereof has a Bendtsen roughness of between about 0 ml/min and about 20 ml/min. 
     
     
         8 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product such that the top side thereof has a PPS-s10 roughness of between about 0.8 μm and about 1.5 μm. 
     
     
         9 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product such that the top side thereof has a Hunter gloss of between about 45% and about 65%. 
     
     
         10 . A method according to  claim 1 , wherein coating the top side of the SBS board product further comprises coating the top side of the SBS board product such that the coated SBS board product has a density of between about 750 kg/m 3  and about 1000 kg/m 3 . 
     
     
         11 . A method according to  claim 1  further comprising calendering the SBS board product with a calender following precalendering of the SBS board product, the calender being selected from the group consisting of at least one nip and a soft calender. 
     
     
         12 . A method according to  claim 1 , wherein precalendering the SBS board product further comprises moistening at least one of the top side and the back side of the SBS board product. 
     
     
         13 . A method according to  claim 1 , wherein precalendering the SBS board product further comprises precalendering the SBS board product without moistening either side thereof.