Thermoformable dual ovenable recyclable coated cellulosic board, dual ovenable recyclable coated cellulosic board food vessels thermoformed therefrom, and methods for manufacturing and using thereof

Abstract

A method for manufacturing a thermoformable dual ovenable coated cellulosic board includes coating an aqueous-based polyester acrylate copolymer dispersion basecoat on a first major side of a cellulosic board substrate and coating an aqueous-based polyester acrylate copolymer dispersion barrier topcoat on the aqueous-based polyester acrylate copolymer dispersion basecoat.

1 . A method for manufacturing a thermoformable dual ovenable recyclable coated cellulosic board, the method comprising:
 coating an aqueous-based polyester acrylate copolymer dispersion basecoat on a first major side of a cellulosic board substrate; and   coating an aqueous-based polyester acrylate copolymer dispersion barrier topcoat on the aqueous-based polyester acrylate copolymer dispersion basecoat.   
     
     
         2 - 16 . (canceled) 
     
     
         17 . A coated cellulosic board comprising:
 a cellulosic board substrate having a first major side and a second major side;   a multilayer thermoformable dual ovenable coating comprising:   an aqueous-based polyester acrylate copolymer dispersion basecoat on the first major side of the cellulosic board substrate; and   an aqueous-based polyester acrylate copolymer dispersion barrier topcoat on the aqueous-based polyester acrylate copolymer dispersion basecoat.   
     
     
         18 . The coated cellulosic board of  claim 17  wherein the cellulosic board substrate has a caliper thickness in a range from about 7 point to about 30 point. 
     
     
         19 . (canceled) 
     
     
         20 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion basecoat has a basis weight of about 4 to about 20 dry grams per m 2 . 
     
     
         21 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion barrier topcoat has a basis weight of about 3 to about 20 dry grams per m 2 . 
     
     
         22 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion basecoat and the aqueous-based polyester acrylate copolymer dispersion barrier topcoat have a combined basis weight of about 7 to about 40 dry grams per m 2 . 
     
     
         23 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion basecoat comprises a pigment. 
     
     
         24 . (canceled) 
     
     
         25 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion basecoat comprises an aqueous-based polyester acrylate copolymer dispersion polymer that does not contain styrene butadiene. 
     
     
         26 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion barrier basecoat comprises an aqueous-based polyester acrylate copolymer dispersion polymer. 
     
     
         27 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion barrier basecoat has a surface tension in a range of 43 dyne/cm to 60+ dyne/cm. 
     
     
         28 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion barrier topcoat comprises an aqueous-based polyester acrylate copolymer dispersion polymer. 
     
     
         29 . The coated cellulosic board of  claim 17  wherein the aqueous-based polyester acrylate copolymer dispersion barrier topcoat is clear. 
     
     
         30 . The coated cellulosic board of  claim 17  wherein the multilayer thermoformable dual ovenable coating is capable of being tack bonded at about 250° F. or greater. 
     
     
         31 . The coated cellulosic board of  claim 17  wherein the multilayer thermoformable dual ovenable coating has chloroform-soluble extractives not exceeding about 0.5 mg/in 2  of food contact surface when exposed to a food simulating solvent at 150° F. for two hours. 
     
     
         32 . The coated cellulosic board of  claim 17  wherein the multilayer thermoformable dual ovenable coating is flexible enough to withstand conventional creasing in a cross direction with a 2 point male rule and a 0.062″ channel while sustaining a crack length of no greater than about 0.1 
     
     
         33 . The coated cellulosic board of  claim 17  wherein the multilayer thermoformable dual ovenable coating exhibits block resistance when stacked at ambient temperatures under a load of about 0.5 lbs/sq in. or greater. 
     
     
         34 . The coated cellulosic board of  claim 17  wherein the multilayer thermoformable dual ovenable coating is resilient enough for thermoforming at temperatures about 200 to about 425° F. without degradation or damage. 
     
     
         35 - 37 . (canceled) 
     
     
         38 . A method for manufacturing a thermoformed dual ovenable coated cellulosic board food vessel comprising thermoforming the coated cellulosic board of  claim 17  into the form of a thermoformed dual ovenable coated cellulosic board food vessel. 
     
     
         39 . (canceled) 
     
     
         40 . A dual ovenable coated cellulosic board food vessel comprising the coated cellulosic board of  claim 17  in the thermoformed condition. 
     
     
         41 - 42 . (canceled) 
     
     
         43 . A method for using a thermoformed dual ovenable coated cellulosic board food vessel of  claim 40 , the method comprising:
 placing a food product on the thermoformed dual ovenable coated cellulosic board food vessel; and   sealing the food product within the thermoformed dual ovenable coated cellulosic board food vessel.   
     
     
         44 . (canceled)