Container with high moisture barrier properties and a reclosable pour spout

Abstract

A paperboard substrate that can be used to provide a food packaging particle is provided having a water vapor barrier layer comprising HDPE in combination with a nucleating agent which is extruded on to a paperboard substrate. The resulting substrate has sufficiently good water vapor barrier when properties that dry foods such as cereals do not require a bag or inner liner as a separate moisture barrier.

What is claimed is: 
     
         1 . An extruded paperboard laminate comprising:
 a paperboard substrate having the first side and a second side;   a first extruded layer of LDPE, extruded on to a first side of the paperboard layer;   a layer of HDPE applied to the first layer, the HDPE layer further comprising a nucleating agent;   a second extruded layer of LDPE applied the HDPE layer.   
     
     
         2 . The laminate as defined in  claim 1 , wherein polymers are coated on the paperboard by co-extrusion coating process or extrusion coatings in tandem. 
     
     
         3 . The laminate as defined in  claim 1 , wherein the concentration of nucleation agent is between 500 ppm and 2500 ppm in the polymer resin after mixing in the extruder. 
     
     
         4 . The process as defined in  claim 2 , wherein a melt temperature at an extrusion die is above 550° F. and below 650° F. 
     
     
         5 . The extrusion process as defined in  claim 2 , wherein an additional layer of polymer is applied to the nucleated polymer by either coextrusion or extrusion in tandem. 
     
     
         6 . The laminate as defined in  claim 1 , wherein its WVTR is in the range of ˜0 to 8 gm/m 2 /day (˜0 to 0.5 gm/100 in 2 /day) at 100° F. and 90% RH measured with Mocon Permatran equipment for ASTM F1249-06. 
     
     
         7 . The laminate as defined in  claim 1 , wherein the paper board is carton board, kraft board, solid bleached board, solid unbleached board, white lined chipboard, or container board. 
     
     
         8 . The laminate as defined in  claim 1 , wherein the nucleation agent can be Group II metal salts of organic dibasic acids, calcium 1,2-cyclohexanedicarboxylate, organic pigments such as c-quinacridone and Cibantine Blue 2B, aromatic amide compounds such as N,N′-dicyclohexylterephthalamide and N,N′-dicyclohexyl-2,6-naphthalene dicarboxamide, and combinations thereof. 
     
     
         9 . A method for manufacturing a heat sealable packaging material comprising the steps of:
 providing a paperboard substrate;   applying a water vapor barrier layer containing HDPE and a nucleating agent as an extrusion layer on one side of the paperboard substrate; and   applying an outer heat sealing layer to the substrate wherein the HDPE and nucleating layer is positioned between the paperboard substrate and the heat sealed layer.   
     
     
         10 . A paperboard substrate comprising a plurality of extruded polymer layers wherein at least one of the polymer layers is a water vapor barrier layer comprising an extruded layer of HDPE containing a nucleating agent which promotes the crystallization of the HDPE extruded layer. 
     
     
         11 . A paperboard substrate comprising a plurality of extruded polymer layers wherein at least one of the polymer layers is a water vapor barrier layer consisting essentially of an extruded layer of HDPE containing a nucleating agent which promotes the crystallization of the HDPE extruded layer. 
     
     
         12 . The extruded paperboard laminate according to  claim 1  wherein the paperboard substrate as applied to a second side of the substrate in an extruded layer of polypropylene. 
     
     
         13 . The method according to  claim 9  comprising the additional step of applying an extruded layer of polypropylene to a paperboard substrate and on the side of the substrate opposite the HDPE layer wherein the resulting substrate is resistant to curling. 
     
     
         14 . A process of extrusion coating a moisture barrier layer onto a paperboard substrate using a nip roller on one side of the paperboard substrate and a chill roller on an opposite side of the substrate comprising the steps of:
 supplying a paperboard substrate;   supplying a melt curtain of at least two polymer layers to the paperboard substrate, at least one of the two polymer layers containing a moisture barrier layer of HDPE containing a nucleating agent, wherein the moisture barrier layer is separated from the chill roller by at least a second layer of the at least two polymer layers, wherein the nucleating agent present in the HDPE coating is quenched at a slower rate than if the moisture barrier layer was in direct contact with the chill roller.   
     
     
         15 . The process according to  claim 14  comprising the additional step of reheating the paperboard surface having an extruded barrier layer of HDPE containing a nucleating agent, thereby increasing the activity of the nucleating agent within the HDPE containing barrier layer. 
     
     
         16 . A carton with a fitment comprising:
 a carton having a top panel, a bottom panel, a first side panel, a second side panel, a front panel, a rear panel, the first side panel having a height less than the second side panel, thereby defining an angled portion between the top panel and the upper edge of the first side panel;   an opening defined within the angled portion;   a reclosable fitment positioned above opening, the fitment having a top portion reversibly engaging a base, the top portion and the base connected by a hinge along a rear wall of the base, the base further defining a front edge wall perpendicular to the base, the front edge wall having an inner surface engaging a portion of the first side panel, a first side wall perpendicular to the base, the first side wall having an inner surface engaging a portion of the first side panel, a second side wall perpendicular to the base, the second side wall having an inner surface engaging a portion of the second side panel; and   a rear edge wall of the fitment defining an angle greater than 90° relative to a claim of the base, the rear edge wall engaging an upper surface of a portion of a top panel in a substantially flush engagement.