EP4038236A1 - Re-pulpable thermally insulated paper products and methods of making and using the same - Google Patents
Re-pulpable thermally insulated paper products and methods of making and using the sameInfo
- Publication number
- EP4038236A1 EP4038236A1 EP20790167.9A EP20790167A EP4038236A1 EP 4038236 A1 EP4038236 A1 EP 4038236A1 EP 20790167 A EP20790167 A EP 20790167A EP 4038236 A1 EP4038236 A1 EP 4038236A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- layer
- paper product
- insulated
- insulated paper
- paper
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/10—Packing paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
- B65D65/38—Packaging materials of special type or form
- B65D65/40—Applications of laminates for particular packaging purposes
- B65D65/403—Applications of laminates for particular packaging purposes with at least one corrugated layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
- B65D65/38—Packaging materials of special type or form
- B65D65/42—Applications of coated or impregnated materials
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H19/00—Coated paper; Coating material
- D21H19/36—Coatings with pigments
- D21H19/38—Coatings with pigments characterised by the pigments
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/52—Additives of definite length or shape
- D21H21/54—Additives of definite length or shape being spherical, e.g. microcapsules, beads
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/38—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents with thermal insulation
Definitions
- the present invention relates generally to insulated paper products.
- the present invention further relates to methods of making and using insulated paper products.
- Food sold in fast food restaurants is often wrapped in a low basis weight paper product.
- the wrapping paper is often treated with a coating to provide wet strength, such as a silicone, or a fluorocarbon, or a wax, and further is often laminated to a thin aluminum foil.
- the aluminum foil serves several purposes. First, aluminum has a low thermal emissivity, and so the foil layer provides thermal insulation. Second, the foil adds some resiliency to the paper when subjected to hot moisture and lipids, such as vegetable and animal fats, dairy products etc.
- Aluminum foil (1) is persistent in the environment as it does not decompose, contributing to long term landfills, (2) is frequently litter that is unsightly and may cause obstruction in the guts of smaller animals when ingested, (3) is not recyclable or repulpable, causing problems if accidentally introduced into a repulping mill, (4) does not burn if the material is incinerated and (5) has been linked to certain neurodegenerative diseases in humans when ingested.
- paper beverage cups are also difficult to recycle. They are coated with a low molecular weight polyethylene, which causes problems when introduced into the pulp.
- What is needed is a highly thermally insulating paper structure that provides one or more of the following benefits: (1) is non-toxic and safe for use with food, (2) is thin and can be supplied to restaurants in roll or sheet format, (3) insulates hot food from cooling, (4) is recyclable by municipal recycling services without separation or segregation from other papers in the waste stream, (5) is biodegradable or biodestructable and therefore ephemeral when released into the environment (6) is able to maintain integrity with condensation formation after wrapping hot food, and (7) is resistant to the penetration of oils and fats.
- the present invention is directed to insulated paper products that (1) insulate food positioned therein and/or surrounded thereby, (2) are biodegradable or biodestructable, recyclable, repulpable, and (3) can be printed and decorated, and (4) are food contact safe.
- the disclosed insulated paper products utilize a coating that acts in a similar manner to a laminated aluminum foil. Insulating materials included within the coating are coated onto a variety of paper products.
- the present invention is directed to paper products coated with a thermally insulating layer.
- the insulated paper product of the present invention comprises an insulated coated paper product comprising one or more paper layers and at least one insulating coating.
- the insulated paper product of the present invention comprises a low basis weight paper coated on one side with a thermally insulating coating and a repulpable moisture and/or lipid barrier on the other side, wherein at least one of the coatings has a low thermal conductivity and/or a low thermal emissivity.
- the insulated paper product of the present invention comprises a corrugated integral paper product comprising: a first linerboard layer comprising one or more first coated layers, a second linerboard layer comprising one or more second coated layers, and a fluted paper layer comprising one or more fluted paper layers or a honeycomb layer positioned between the first linerboard layer and the second linerboard layer, wherein (i) the first linerboard layer, (ii) the second linerboard layer, and (iii) the fluted paper layer or the honeycomb layer may each independently comprise insulating material therein or thereon.
- the insulated paper product comprises a fully recyclable, re pulpable, biodegradable, biodestructable, and thermally insulating food wrapping paper product.
- the insulated paper product comprises a fully recyclable, re-pulpable, biodegradable, biodestructable, and thermally insulated cardboard box.
- the present invention is further directed to methods of making insulated paper products.
- the method of making an insulating wrapping paper product comprises: forming a paper sheet comprising one or more layers on a fourdrinier wire, then coating the formed paper layer with a coating with a low thermal conductivity and/or a low thermal emissivity onto the paper layer.
- the method of making an insulating wrapping paper product further comprises coating the formed paper layer with a moisture barrier and/or a grease resistant layer at the size press, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity.
- the method of making an insulating wrapping paper product comprises: forming a paper sheet comprising one or more layers, then coating the formed paper layer with a moisture barrier and/or a grease resistant layer on one side, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity on the opposite side.
- the method of making an insulating wrapping paper product comprises: forming a paper sheet comprising one or more layers, then coating the formed paper layer with a moisture barrier and/or a grease resistant layer on one side, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity on the same side.
- the present invention is even further directed to methods of using insulated paper products.
- the method of using an insulated paper product comprises: insulating an object (e.g., food, medicine, pharmaceuticals, ice, flowers, etc.) via any one of the herein- described insulated paper products.
- an object e.g., food, medicine, pharmaceuticals, ice, flowers, etc.
- FIG. 1 depicts a perspective view of an exemplary paper product of the present invention
- FIGS. 2A-2C depict exemplary cross-sectional views of the exemplary paper product shown in FIG. 1 as viewed along line 2-2 shown in FIG. 1;
- FIG. 3 depicts a perspective view of another exemplary paper product of the present invention.
- FIGS. 4A-4C depict side views of exemplary paper products of the present invention.
- FIG. 5 depicts a perspective view of another exemplary paper product of the present invention (also referred to herein as “an integral paper product”);
- FIGS. 6A-6D depict exemplary cross-sectional views of the exemplary paper product shown in FIG. 5 as viewed along line 6-6 shown in FIG. 5;
- FIGS. 7A-7C depict an exemplary process flow in an exemplary papermaking process suitable for use in forming the exemplary paper products of the present invention
- FIG. 8 depicts a side view of another paper product forming process step suitable for forming an exemplary paper product of the present invention
- FIGS. 9A-9C depict exemplary storage containers comprising any one of the exemplary insulated paper products of the present invention
- FIG. 9D depicts an exemplary cross-sectional view of the wall structure of the exemplary hot beverage cup shown in FIG. 9C;
- FIGS. 10-13A depict additional exemplary storage containers comprising any one of the exemplary insulated paper products of the present invention.
- FIG. 13B depicts a close-up cross-sectional view of the wall structure of the exemplary shipping container shown in FIG. 13A;
- FIG. 14 depicts an exemplary cross-sectional view of a wall structure of an exemplary shipping container
- FIGS. 15-17 depict views of another apparatus that may be used to determine the relative emissivity of paper samples and/or insulating materials
- FIG. 18 depicts a view of another apparatus that may be used to determine the relative emissivity of paper samples and/or insulating materials
- FIG. 19A and 19B depict views of an apparatus that may be used to determine the rate of heat transfer of paper samples and/or insulating materials with FIG. 19A depicts a cut-away view of modifications to an expanded polystyrene cooler including dimensions, as well as positioning of the window through the cooler wall.
- FIG. 19B depicts a cross sectional view of the test apparatus;
- FIG. 20 depicts a corrugated structure of the present invention with one side coated
- FIG. 21 depicts single faced corrugate paper hot beverage cup sleeves including the net and cross section.
- each paper layer 10 comprises fibers 11 (e.g., wood pulp fibers 11) with or without other paper layer additives including, but not limited to, an insulating material 12.
- the term “paper” is used to identify a type of non-woven material in which fibers are randomly oriented in all directions. Fibers principally made from cellulose are poured as a slurry on a mesh screen. As the paper is formed, the fibers come into contact with each other, and physically bond with neighboring fibers via a variety of interactions, including hydrogen bonding. The fibers originally come from plants including trees, although synthetic and mineral fibers, or other types of fibers, may optionally be included. Often, the paper also contains recycled fiber. Wood may be sourced from direct harvesting of trees from forest land, or from lumber industry byproducts (such as sawdust).
- Paper fibers may include the fibrous portions from many parts, including softwoods (such as those plants with needles instead of leaves, for example, loblolly pine) and hardwoods.
- Other plants that yield useful paper fibers include but are not limited to bamboo, sugar cane, wheat straw, reed grass, mischanthus grass, coconut fiber, hemp fiber, cotton fiber, jute, palm, reeds, and papyrus.
- Cellulose fibers in many plants are bound together with lignin.
- Recycled paper may include fibers from corrugated, fiber board, writing paper, pressboard, card, newspaper, tissue paper, specialty papers, linerboard, containerboard, boxboard, PE-lined paperboard, carton material, cup stock, or foodboard.
- Pulping methods may include a) thermomechanical pulping, which involves the use of steam and sheer forces generated between a spinning and a stationary plate, b) chemical pulping, which uses strong chemicals to break down the pulp by dissolving the lignin, and/or c) the semi-chem process, which uses a combination of mechanical and chemical methods.
- thermomechanical pulping which involves the use of steam and sheer forces generated between a spinning and a stationary plate
- chemical pulping which uses strong chemicals to break down the pulp by dissolving the lignin
- the semi-chem process which uses a combination of mechanical and chemical methods.
- fluted medium board e.g., fluted medium board 23
- Other types of pulp include solid bleached sulfate pulp, chipboard, and kraft.
- Paper and paper layer 10
- Paper may broadly include any material that includes 15% or more cellulose fibers (discussed further below).
- Other additives including insulating material 12, other particles/additives/components that impart grease resistant and/or water resistant, as well as other particles/additives/components to impart strength.
- Non-paper (and non-paper layer 30) is anything containing less than 15% of cellulose fibers (discussed further below).
- insulating material such as insulating material 12
- insulating material 12 is used to described inorganic or organic materials that provide some degree of insulation.
- the term insulating material, as in insulating material 12, does not include air alone or any other gas alone, although air and/or another gas could be trapped within one or more inorganic or organic insulating material 12.
- Paper products 10/100760 comprising fibers 11 (e.g., wood pulp fibers 11) and insulating material 12, can either be made flat (e.g., insulated paper products 100/100’) using a screen to make flat materials, or alternatively be molded, vacuum formed, or thermoformed from a pulp suspension to form essentially three-dimensional (non-flat) objects (e.g., molded or otherwise formed containers 60 shown in FIGS. 9A-13B).
- Such three-dimensional paper products include certain packaging, for instance, egg crates and egg cartons, packaging that protects the corners of products shipped in the mail, biodegradable compost containers, biodegradable plant pots, disposable urinals and bed pans used in hospitals, disposable cat little boxes, and the like.
- Additives including insulating material 12, may be included within and/or on the paper products 10/100760 to impart thermal insulation properties, strength under moist or wet conditions, impart water repellency or water proofing, impart grease absorption resistance, increase strength, improve the color, improve printability, or other aesthetic aspects.
- Additives, including insulating material 12 may be added to the paper pulp prior to casting on the paper wire or otherwise molding the pulp with additives into a product 10/100760. Alternatively, additives, including insulating material 12, may be added at the size press, or after the steam can dryers. Additives, including insulating material 12, can also be added to a clay coating (e.g., coating 30) often applied to liner board (e.g., liner board 21/22) to make clay coated kraftback, or clay coated newsback.
- a clay coating e.g., coating 30
- liner board e.g., liner board 21/22
- Paper packaging (e.g., containers 60 shown in FIGS. 9A-13B), formed from the insulated paper products 100/1007100” of the present invention, may include a wide variety of formats, including: regular slotted container (RSC), overlap slotted container, full overlap slotted container, special center slotted container, Bag-in-Box, center special overlap slotted container, center special full-overlap slotted container, snap- or 1 2-3 -bottom box with tuck top, snap- or 1 2-3 -bottom box with RSC top, Full Bottom File Box, Hamper Style, Ft.
- RSC regular slotted container
- overlap slotted container full overlap slotted container
- special center slotted container Bag-in-Box
- center special overlap slotted container center special full-overlap slotted container
- snap- or 1 2-3 -bottom box with tuck top snap- or 1 2-3 -bottom box with RSC top
- Full Bottom File Box Hamper Style
- Medium board used in the insulated paper products 100/1007100” of the present invention may be fluted with flutes of different dimensions. See, for example, exemplary fluted medium board 23 shown in FIGS. 6A-6D).
- the Fiber Box Handbook defines flutes and flute dimensions as: A, B, C, E, F, G, K, N, as well as R/S/T/D.
- the liner and medium papers may also be tested and rated by different burst grade: 125-350 SW, 23-55 ECT, 200-600 DW, 42-82 ECT DW, 700-1300 TW, 67 112 ECT TW.
- the carton or box (e.g., box 61) may then be folded into the following industry known styles: reverse tuck, snap lock, automatic bottom, straight tuck, tuck top snaplock bottom, tuck top automatic bottom, seal end, beers, mailing envelopes, folder, and simplex.
- the insulated paper products of the present invention may comprise a single paper layer with insulating material dispersed therein or coated thereon, or may comprise two or more paper layers in combination with insulating material, wherein the insulating material is within one or more of the paper layers of the insulated paper product and/or is present as a component within the insulated paper product (e.g., as a separate layer from the paper layers and/or as a filler within a layer or component of the insulated paper product). See, for example, exemplary insulated paper products 100/1007100” in FIGS. 1-6D.
- the insulated paper products of the present invention may further comprise one or additional layers other than the one or more paper layers and possible layers of insulating material.
- Suitable additional layers may include, but are not limited to, a coating that provides reduced emissivity of the insulated paper product, a coating that provides a desired color and/or surface texture for the insulated paper product, and a coating that provide enhanced water-repellency (e.g., waterproofing properties) to the insulated paper product. See, for example, exemplary insulated paper products 100/1007100” in FIGS 6A-6D
- a corrugated cardboard structure 100/1007100” comprises two liner boards 21/22 bonded to a fluted medium board 23.
- One (or both) of the liner boards 21/22 may be coated (e.g., clay coated) with coating layer 30 for aesthetics.
- the fluted medium 23 may have a range of flute dimensions, which are classified by the industry as A-flute through F-Flute.
- Each liner board 21/22 may be made from one ply of paper 10/100’, or it may comprise two or more plies 10/100’.
- pressboard - pressed fiber board e.g., two liner boards 21/22 with a honeycomb spacer in between.
- a corrugated cardboard structure 100/1007100 comprises two liner boards 21/22 bonded to a fluted medium board 23, and demonstrates several opportunities for incorporation of insulating additives 12 into the structure of corrugated cardboard 100/1007100”.
- insulating additives 12 have been added to the furnish of the fluted medium 23.
- the flutes have been further isolated from heat transfer via conduction by incorporating insulating additives 12 into the starch adhesive 40 that bonds each flute (e.g., of fluted medium 23) to the liner boards 21/22.
- the liner board 21 is coated with insulating additives 12 via a coating 30.
- a low emissivity coating 30 is overcoated on the outside of the corrugated cardboard structure 100/1007100” (e.g., a box 61). Such a coating 30 will reflect vs. absorb radiative heat and infra-red radiation.
- another corrugated cardboard structure 100/1007100 comprises two liner boards 21/22 bonded to a fluted medium board 23, and again demonstrates several opportunities for incorporation of insulating additives 12 into the corrugated cardboard structure 100/1007100”.
- insulating additives 12 have been added to the furnish of the fluted medium board 23, however, in such a way that the insulating material 12 has preferentially segregated to one face (e.g., the upper face as shown) of the medium fluted board 23 over the other (e.g., the lower face as shown).
- the flutes (of the medium fluted board 23) have been further isolated from heat transfer via conduction by incorporating insulating additives 12 into the starch adhesive 40 that bonds each flute of the medium fluted board 23 to the liner boards 21/22.
- another coating 310 containing insulating additives 12 has been incorporated in the valleys 231 of the flutes.
- one of the liner boards 21/22 contains insulating additives 12 distributed in a non-uniform manner (e.g., such as in first liner board 21 as shown).
- a low emissivity coating 30 is overcoated on the outside faces of both liner boards 21/22. Such a coating 30 will reflect vs. absorb radiative heat and infra-red radiation. Emissivity relates to both a surface’ s ability to absorb and radiate heat. Thus, a low emissivity coating will also show reduced heat loss through radiative cooling.
- another corrugated cardboard structure 100/1007100 comprises two liner boards 21/22 bonded to a fluted medium board 23, and again demonstrates several opportunities for incorporation of insulating additives 12 into the insulated paper product 100/1007100”.
- insulating additives 12 have been added to the furnish of the fluted medium board 23 in such a way that the insulating materials 12 are distributed evenly throughout the thickness of the one or more paper layers 10/100’.
- the flutes of the fluted medium board 23 have been further isolated from heat transfer via conduction by incorporating insulating additives 12 into the starch adhesive 40 that bonds each flute of the fluted medium board 23 to the liner boards 21/22.
- a low emissivity coating 30 is overcoated on the outside faces of one of the liner boards 21. Such a coating 30 will reflect vs. absorb radiative heat and infra-red radiation. It will also show reduced heat loss through radiative cooling because emissivity relates to both a surfaces ability to absorb and radiate heat.
- any of the insulated paper products of the present invention described herein may be configured into a variety of shapes.
- the insulated paper product is in the form of an insulated cup or mug that may be used to house a hot beverage such as coffee.
- Such insulated paper products may be used instead of STYROFOAM ® cups, eliminating the disposal and environmental problems associated with STYROFOAM ® cups.
- the insulated paper product is in the form of insulated packaging for temporary storage and transport of items such as food, medicines, etc.
- Such insulated paper products may be in the form of an insulated box, corrugated or not corrugated, as well as many other packaging items discussed herein. See, for example, exemplary insulated paper products 100/1007100” in FIGS. 9A-13B. Regardless of configuration and/or shape, the insulated paper products 100/1007100” of the present invention provide a degree of insulation due to coating compositions that reduce heat transfer.
- the present invention is further directed to methods of making and using the herein disclosed and described coated insulated paper products.
- the insulated paper products may be made using papermaking equipment and techniques so as to produce one or more paper layers.
- the methods of making the insulated paper products of the present invention involve the strategic placement of one or more insulating materials within a given insulated paper product and/or the strategic placement of one or more optional coatings on the insulated paper product so as to provide superior insulating properties, as well as other properties to the insulated paper product. Exemplary method steps and procedures for forming insulated paper products of the present invention are shown/de scribed in FIGS. 7A-7C and FIG. 8.
- FIGS. 7A-7C depict an exemplary process of forming paper sheets 10.
- pulp furnish
- the fiber content of the furnish is approximately 1- 2 wt% at this stage.
- a gate 205 allows furnish to flow out onto the moving forming wire (a fine mesh conveyor.) 206.
- the forming wire 206 may be 75-100 feet long. Initially, water drains via gravity, however, further down, vacuum boxes 207 beneath the wire 206 assist water removal, increasing the fiber content to around 20-30 wt%.
- the material (-20-30 wt% fiber) is then fed through one or more felt presses 208, which “blot” the precursor paper (i.e., precursor to paper layer 10), removing more water, and increasing the fiber content to around 45-50 wt%.
- the precursor paper i.e., precursor to paper layer 10
- starch or another additive or coating is to be applied, then that may be done at the size press 209 prior to drying.
- Many different materials may be added at the size press 209 prior to the dryers, including starch, sizes, waxes, coatings to impart wet strength, materials to impart water resistance, and materials that impart grease proofing.
- drying may be affected in a number of ways, including running over steam cans 210, or entering a long hot air-drying tunnel (not shown). After passing through calendar rolls 211 and prior to winding, the paper 10 may be between 6 to 10% moisture content.
- FIG. 8 depicts details of an exemplary linerboard 100 suitable for use in forming an insulated paper product 100/1007100” of the present invention or a component (e.g., a layer or outer linerboard) of an insulated paper product 100/1007100” of the present invention.
- exemplary linerboard 100 comprises two sheets of paper 10 laminated to one another.
- Exemplary linerboard 100 further comprises a first clay coating 30 directly on an outer surface 13 of one of the paper layers 10, and an outermost second white clay coating 30 so as to provide a printable surface/layer 38 for exemplary linerboard 100.
- First clay coating 30 evens out the valleys and troughs of the rough paper 10, leaving a smooth surface for additional coatings and for high-quality printing.
- the methods of using the insulated paper products 10/100/1007100” of the present invention may comprise insulating food, medicines, etc. from hot or cold environments.
- the method may simply comprise placing an item (e.g., food, medicines, etc.) within an insulated paper product 10/100/1007100” of the present invention (e.g., putting hot coffee in a cup of the present invention).
- the method may comprise placing an item (e.g., food, medicines, etc.) within an insulated paper product 10/100/1007100” of the present invention (e.g., a bag or a box), and sealing the insulated paper product 10/100/1007100” for transport.
- methods of using the insulated paper products 10/100/1007100” of the present invention may involve insulating an item (e.g., food, medicines, etc.) from hot or cold environments, wherein the item (e.g., food, medicines, etc.) is placed or packaged within an insulated paper product 10/100/1007100” that has a conventional shape, such as a cup or box.
- the insulated paper products 10/100/1007100” of the present invention take the place or conventional items such as cups and boxes so as to provide one or more advantages as discussed above.
- the insulated paper products 10/100/1007100” of the present invention may have a variety of shapes and configurations similar to many conventional items such as cups and boxes.
- the insulated paper products 10/100/1007100”/60 of the present invention desirably provide/have one or more of the following features/properties in addition to providing insulating properties:
- the insulated paper products 10/100/1007100”/60 of the present invention can be placed into a freezer and then taken out and stacked at room temperature.
- Such a process usually leads to the insulated paper product 10/100/1007100”/60 (e.g., a box 61) “sweating” through condensation in the warm air condensing on the surface of the insulated paper product 10/100/1007100”/60 (e.g., a box 61).
- a box 61 Multiple different additives can be used to reduce the propensity of the insulated paper product 10/100/1007100”/60 (e.g., a box 61) to absorb moisture and weaken when moist.
- perlite 12 is more hydrophobic than paper fibers 11, so the incorporation of perlite 12 into and/or onto a paper layer 10 renders the paper layer 10 less absorbent.
- the adhesive 40 that bonds flutes to liner board can be made moisture resistant by adding a moisture resistant adhesive resin, such as Coragum SR available from Ingredion, Westchester IL.
- a hydrophobic treatment can be applied to the exterior of the insulated paper product 10/100/1007100”/60 (e.g., a box 61).
- a chemical cross-linking agent or reactive resin e.g. a methylol melamine
- paper fiber 11 may be treated with rosin, and then aluminum sulfate can be added to the furnish to impart hydrophobicity to the paper layer 10.
- a wax may be added to paper layer 10 to impart hydrophobicity.
- water-resistant coatings that may be applied onto paper layer 10 include, Epotal S440 (BASF) (i.e., a styrene acrylic based copolymer emulsion), Rhoplex P-376 (Dow) (i.e., a styrene acrylic copolymer emulsion binder), Diofan B204 (Solvay) (i.e., a poly(vinylidene chloride) (PVDC) latex), Barrier-Grip 9471 A (IGI) (i.e., a blend including a styrene acrylic copolymer emulsion, a poly(ethylene) wax and clay), Daran SL143 (Owensboro) (i.e., a poly(vinylidene chloride) (PVDC) latex).
- BASF Epotal S440
- Rhoplex P-376 i.e., a styrene acrylic copolymer emulsion binder
- moisture barriers that are repulpable, including Barrier-Grip 9471A, Aquaban, EC404 (a repulpable moisture barrier) from International Group Inc., (Toronto Canada.) or EcoShield Barrier Coating from Cortec Packaging.
- These proprietary commercial materials may include moisture and gas barrier additives and treatments such as low-molecular weight resins, waxes including paraffin wax and natural waxes such as beeswax, linear fatty acid esters of fatty alcohols, branched esters for example esters of 15- hydroxypalmitic acid, fatty alcohol ethers, hydrocarbons in the range of about Cis to Cso, hydrocarbon resins, particularly petroleum resins, styrene resins, cyclopentadiene resins, and terpene resins.
- moisture and gas barrier additives and treatments such as low-molecular weight resins, waxes including paraffin wax and natural waxes such as beeswax, linear fatty acid esters of fatty alcohols, branched esters for example esters of 15- hydroxypalmitic acid, fatty alcohol ethers, hydrocarbons in the range of about Cis to Cso, hydrocarbon resins, particularly petroleum resins, styrene resins, cyclopent
- a thin layer of low density polyethylene may also be coated onto paper layer 10, fiberboard 21/22/23, and card stock to impart oil and water resistance, as is common practice in the fast food and hot & cold beverage retail industry.
- the surface of the paper may be cross linked by applying reactive groups that react with hydroxyl groups present in cellulose.
- melamine formaldehyde resins for examples, melamine formaldehyde resins, urea formaldehyde resins, methylol melamine, epichlorohydrin, trichlorotriazine, dichlorotriazine, chlorotriazine coupled with diazabicylco-[2,2,2]-octane which acts as a catalyst, compounds that can undergo Michael 1,4 addition in the presence of base, and a wide range of other bifunctional reactive compounds.
- the paper industry has experienced increased pressure to seek alternatives to PE liners and linings for packaging, leading the chemical industry to innovate new coatings that impart grease and water resistance while being repulpable.
- a chelating agent in another layer of the packaging (e.g., box 61), or for instance in the adhesive, or in one of the coatings.
- a chelating agent would function to remove the aluminum during a pulping process.
- Chelating agents may include oxalic acid and oxalate salts, EDTA (ethylene diamine tetraacetic acid) and its various salts, salicylate, sodium hexametaphosphate and other materials. In this way, the aluminum could be removed.
- Soluble aluminum salts are already used in papermaking for instance as a flocculant for fines, as well as in combination with rosin soap to impart water resistance.
- a repulpable/Recvclable/Biodestructable thermally insulating coating comprising one or more inorganic pigments, which have been found to reduce the transfer of radiant heat energy when coated onto paper.
- silica nanoparticles may be modified by reaction with terminal aminoalkylthrimethoxysilanes and then with copper II ions to further enhance the odor capturing capabilities.
- Molecular sieves may also be included to sequester low molecular weight odor forming molecules such as hydrogen sulfide and zeolites to sequester ammonia and amine odors.
- Activated carbon was also found to impart thermal insulation, and would also be anticipated to absorb multiple odors. Activated carbon tends to be acidic in nature, and so may be especially good at taking up basic and weakly basic odors such as ammonia and amine odors.
- More complex odors also have an affinity for activated carbon, including mercaptan, thiol, and aromatic odors.
- Cyclodextrins such as b-cyclodextrin or g-cyclodextrin and their derivatives may also be incorporated for their odor absorbing properties.
- One or more of these materials/features could be incorporated into any of the here-in described paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60 to modify and/or minimize any odors present.
- Odor transmission from one package to another, or from one good to another may also be mitigated through the use of barrier materials.
- one object of the present invention is repulpability of packaging, aluminum foil, PE or PET film, and other synthetic materials would not be consistent with some embodiments of the present invention.
- some materials that provide thermal insulation have a microscopic flake morphology, such as mica and coated mica, and these materials may be useful for effectively blocking the transport of low and high MW malodor causing materials from ingress into packages (e.g., comprising or formed from insulated paper product 10/100/1007100”) of the present invention.
- Fiber Blend. Recycling and Strength Short length fibers tend to come from refined hardwood, while longer fibers come from softwood. A good ratio of 75% softwood 25% hardwood balances the properties of the two types of fiber, optimizing tensile strength.
- hemp fibers have come under increasing attention as a paper additive. Hemp fibers are far longer than other pulp fibers, help increase strength due to increasing contact points and bonding, and so may be subjected to multiple recycling steps - far more than regular wood fibers. Hemp fibers, being much longer than softwood may be recycled around 40 times vs. 6 for other types of fiber.
- One or more of these materials/features could be incorporated into any of the here-in described insulated paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60.
- the fibers may be subjected to an extreme high-shear environment, such as a colloid mill.
- the high sheer environment of two plate spinning in contact fibrillates cellulose fiber aggregates, increasing bonding, as well as the propensity to retain filler solids.
- Other ways to fibrillate the fiber can include prolonged beating in a mechanical Hollander pulp beater such as disclosed in the U.S. Patent No. 1,883,051 or by high- sheer mixing, high-speed mixing, or media milling. Fibrillated cellulose may increase porosity of the paper and paper strength due to enhanced bonding area between fibers.
- Rosin is often used as part of a two-part system to impart moisture resistance in paper (e.g., paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60).
- the second part is post addition of aluminum salt solutions - e.g. aluminum chloride or aluminum sulfate.
- the aluminum reacts with the rosin soap to make a hydrophobic coating, which may impact repulpability yield.
- a chelating agent somewhere in another component of the paper product may remove the aluminum from the rosin, thereby increasing the repulpability yield.
- Other areas of the paper that could carry the chelating agent may include the starch adhesive, and internal layer - for instance, the fluted medium, or an inner layer of the composite.
- Vapor-Guard R5341B or Barrier Grip 9471A (The International Group Inc., Titusville PA) are also useful as barrier coatings that provide the paper with a degree of grease and water resistance, and are described along with other suitable materials in Georgia Pacific Patent Application Publication No. US2019/0077537.
- Binders are used in coatings to reduce pigment rub-off, ensure adhesion of the coating, and generally seal the coating or ink. Binders for water-based coatings may be solutions such as poly(vinyl alcohol) or ammonia neutralized poly(acrylic acid). Binders that are latex based are more common, as they have a lower viscosity and are easier to formulate with and handle. Latex binders in general are a stable emulsion or dispersion of polymer particles or droplets in water. For instance, natural rubber latex sourced from trees comprises non-crosslinked cis-poly(isoprene) in microscopic droplets dispersed in water, with protein acting as a surfactant to stabilize the latex emulsion.
- Man-made latex binders include polymers synthesized using emulsion polymerization such as poly(vinyl acetate), poly(acrylonitrile), poly(acrylates), poly(methacrylates), poly(butadiene), poly(styrene), poly(acrylic acid), and various copolymers of these and other polymers.
- emulsion polymerization such as poly(vinyl acetate), poly(acrylonitrile), poly(acrylates), poly(methacrylates), poly(butadiene), poly(styrene), poly(acrylic acid), and various copolymers of these and other polymers.
- Tg glass transition temperature
- Rovene VSR-50 is an acrylic latex binder with pH in the range of 8-9, and around 45% solids content.
- the polymer contained in Rovene VSR-50 has a Tg of around 12°C, and so a heat treatment is needed to coalesce the dried polymer particles to form a film.
- Rovene 4100 (Mallard Creek Polymers, NC) is a carboxylated styrene-butadiene copolymer emulsion with a polymer Tg around -5°C, so no post-dry heating is required to form a film.
- the product contains around 50% solids, and the emulsion has a pH of around 6.
- Rovene 6106 is a styrene-acrylic copolymer emulsion with a high Tg (>100°C), and so a post-heat treatment is required.
- Rovene 6090 is modified vinyl acetate copolymer emulsion with a polymer Tg of 39°C. This binder has release properties, allowing adhesive materials to be peeled from the coating surface.
- Tykote 6160 (Mallard Creek Polymers) is an approximately 50% solids pH 8.0-9.0 acrylic polymer emulsion, with a polymer Tg of 7°C. This binder is claimed to have flexibility combined with moisture
- any feature and/or component described herein may be present alone or in combination with any other feature and/or component or combination of features and/or components described herein to form the here-in described paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60 of the present invention.
- the numbered embodiments provided below describe many embodiments of the present invention, some claimed and some unclaimed. Even though some of the features in the numbered embodiments provided below may not be claimed, the unclaimed feature(s) in the numbered embodiments provided below do form part of the present invention, and may optionally be incorporated into any claimed product.
- An insulated paper product 100 comprising: one or more paper layers 10; and an insulating coating 30 on at least one outer surface 13/15 of said one or more paper layers 10, said insulating coating 30 comprising (i) one or more insulating materials 12 comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, sericite, powdered silicon, silver-coated glass bubbles, aluminum oxide, hollow polymeric microsphere pigments, or any mixture or combination thereof, and (ii) a binder.
- insulating materials 12 comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, sericite, powdered silicon, silver
- each paper layer 10 may further comprise one or more additives, the one or more additives including, but are not limited to, flocculants and retention aids such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers; additives to provide water resistance (e.g., wax, synthetic latexes and resins); or any combination thereof.
- the insulating coating 30 comprises one or more insulating materials 12 comprising bismuth oxychloride, mica, zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, sericite, or any mixture or combination thereof.
- the insulating coating 30 comprises one or more insulating materials 12 comprising bismuth oxychloride, mica, zinc oxide, or any mixture or combination thereof.
- insulating coating 30 comprises one or more insulating materials 12 comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof.
- the insulating coating 30 may comprise (i) any value between about 50.0 wt% and 99.9 wt%, in increments of 0.1 wt%, e.g., 95.7 wt%, or any range of values between about 50.0 wt% and 99.9 wt%, in increments of 0.1 wt%, e.g., from about 90.2 wt% to 98.1 wt%, of the one or more insulating materials 12, and (ii) any value between about 50.0 wt% and 0.1 wt%, in increments of 0.1 wt%, e.g., 2.4 wt%, or any range of values between about 50.0 wt% and 0.1 wt%, in increments of 0.1 wt%, e.g., from about 18.3 wt% to 0.2 wt%, of the binder.
- Suitable binders include, but are not limited to, one or more of the binders discussed on pages 14
- insulating coating 30 comprises from about 90.0 wt% to about 99.9 wt% of the one or more insulating materials 12 and from about 10.0 wt% to about 0.1 wt% of the binder.
- insulating coating 30 comprises from about 93.0 wt% to about 98.0 wt% of the one or more insulating materials 12 and from about 7.0 wt% to about 2.0 wt% of the binder.
- Suitable latex binders include, but are not limited to, latex binders comprising a polymer or co-polymer of one or more monomers selected from styrene, butadiene, acrylic acid, acrylate, methacrylate, and vinyl acetate.
- each insulating coating 30 independently comprises one or more coating layers 30 with each coating layer 30 comprising said insulating material 12 and said binder.
- insulating coating 30 comprises two or more coating layers 30 with each coating layer 30 comprising said insulating material 12 and said binder.
- said two or more coating layers 30 comprise (i) a first coating applied onto the one or more paper layers 10 and comprising zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof, and (ii) a second coating applied onto the first coating and comprising bismuth oxychloride, bismuth oxychloride-coated mica, or any mixture or combination thereof.
- BASF Epotal S440
- BASF Epotal S440
- a material other than paper e.g., a paper layer 10 containing hollow beads/particles (not shown)
- paper e.g., a paper layer 10 containing air pockets 19 therein, possibly formed via a molding process or a process in which a void-forming material is removed from the paper layer 10. See, FIGS. 5-6D.
- the insulated paper product 100 of any one of embodiments 1 to 26, wherein the integral paper product 100’ comprises (i) a first linerboard layer 21 comprising one or more first paper layers 10/100/100’, (ii) a second linerboard layer 22 comprising one or more second paper layers 10/100/100’, and (iii) (a) a fluted paper layer 23 comprising one or more fluted paper layers 10/100/100’ or (b) a honeycomb layer (not shown) positioned between the first linerboard layer 21 and the second linerboard layer 22, and (I) each of (i) said first linerboard layer 21, (ii) said second linerboard layer 22, and (iii) (a) said fluted paper layer 23 or (b) said honeycomb layer (not shown) may independently comprise insulating material 12 therein or thereon, and (II) said insulating coating 30 is present on (i) an outer surface of said first linerboard layer 21, (ii) an outer surface of said second linerboard layer 22, or (ii
- An insulated paper product 100 comprising a corrugated integral paper product 100”, said corrugated integral paper product 100” comprising: a first linerboard layer 21 comprising one or more first paper layers 10/100/100’, a second linerboard layer 22 comprising one or more second paper layers 10/100/100’, and (a) a fluted paper layer 23 comprising one or more fluted paper layers 10/100/100’ or (b) a honeycomb layer (not shown) positioned between the first linerboard layer 21 and the second linerboard layer 22, wherein one or more of (i) said first linerboard layer 21, (ii) said second linerboard layer 22, and (iii) (a) said fluted paper layer 23 or (b) said honeycomb layer (not shown) each independently comprise optional insulating material 12 therein or thereon; and an insulating coating 30 on (i) an outer surface of said first linerboard layer 21, (ii) an outer surface of said second linerboard layer 22, or (iii) both (i) and (ii)
- Suitable materials for adhesive 40 include, but are not limited to, starch adhesives, synthetic latex adhesives such as poly(vinyl acetate), natural rubber latex, modified starches, hydrocolloids such as hydroxypropylcellulose, carboxymethylcellulose, and other water-soluble polymers such as poly(vinyl alcohol).
- a cross-linking agent may also be added to the adhesive to avoid potential swelling of the adhesive and weakening of the bonds when wet.
- Flocculants and retention aids may also be included such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers.
- adhesive 40 is at least partially filled with one or more of the herein disclosed insulating materials 12.
- the insulated paper product 100 of any one of embodiments 27 to 34, wherein the integral paper product 100’ comprises said fluted paper layer 23.
- the insulated paper product 100 of any one of embodiments 27 to 34, wherein the integral paper product 100’ comprises said honeycomb layer (not shown).
- non-paper layer is used to describe a layer that contains less than 5.0 wt% paper pulp or cellulosic fiber, and typically contains 0 wt% to less than 4.0 wt% paper pulp or cellulosic fiber.
- paper layer (such as each paper layer 10) is used to describe a layer that contains 5.0 wt% or more paper pulp or cellulosic fiber, and typically contains greater than 6.0 wt% up to 100 wt% paper pulp or cellulosic fiber (or any value between 6.0 wt% and 100 wt%, in increments of 0.1 wt%, e.g., 50.0 wt%, or any range of values between 6.0 wt% and 100 wt%, in increments of 0.1 wt%, e.g., from 40.1 wt% to 70.2 wt%).
- the one or more additional non paper layers 20/30 comprise a gypsum layer, a clay-containing layer, a polymer coating, a pigment- containing layer, a fabric layer (e.g., a nonwoven, woven or knit fabric layer), a fiber-reinforcement layer (e.g., a layer of unidirectional fibers), a second layer of insulating material 12, a metal film layer, a foam layer, or any combination thereof.
- a gypsum layer e.g., a clay-containing layer, a polymer coating, a pigment- containing layer, a fabric layer (e.g., a nonwoven, woven or knit fabric layer), a fiber-reinforcement layer (e.g., a layer of unidirectional fibers), a second layer of insulating material 12, a metal film layer, a foam layer, or any combination thereof.
- One or more of the additional non-paper layers 20/30 may be added to the insulated paper product 100 in order to provide a desire property such as lower (or higher) emissivity, lower (or higher) thermal conductivity, enhanced water-repellency, an aesthetically pleasing color and/or texture, or any combination thereof.
- organic aerogels such as those disclosed in PCT WO 2019121242 to Henkel AG & Co. KGAA which comprise thiol-epoxy based aerogels, xerogels (i.e., collapsed aerogels), seagels (i.e., microfoams made from agar and alginates), foamed starch, foamed paper pulp, agar, foamed agar, alginates, foamed alginates, bismuth oxychloride, metalized ceramics, metalized fibers, cadmium yellow pigment (cadmium disulfide), or any combination thereof.
- thiol-epoxy based aerogels i.e., collapsed aerogels
- seagels i.e., microfoams made from agar and alginates
- foamed starch foamed paper pulp
- agar foamed agar
- alginates foamed alginates
- bismuth oxychloride
- Examples of commercially available insulating materials 12 include, but are not limited to, FOAMGLAS ® products commercially available from Owens Coming (Pittsburg PA); and Growstone products commercially available from Growstone, LLC, a subsidiary of Earthstone International Inc. (Santa Fe, NM).
- Recycled glass suitable for use as insulating materials 12 is typically crushed to a finely divided powder and mixed with a blowing agent, e.g., carbon or limestone. It is then passed into a furnace hot enough to begin to melt the glass. As the glass powder particles begin to fuse, the blowing agent gives off a gas or vapor, forming bubbles inside the glass. This generates a porous, mostly closed cell glass foam, with high thermal and sound insulation properties.
- a blowing agent e.g., carbon or limestone
- Vermiculite may also be used as a suitable insulating material 12.
- Vermiculite is a hydrous phyllosilicate mineral that undergoes significant expansion when heated. Exfoliation occurs when the mineral is heated sufficiently, and the effect is routinely produced in commercial furnaces. Vermiculite is formed by weathering or hydrothermal alteration of biotite or phlogopite.
- perlite e.g., in the paper 10, the adhesive 40, the coating 30, and/or the emissivity coating 30
- aerogel e.g., in the paper 10 and/or the adhesive 40
- glass bubbles e.g., in the adhesive 40 and/or the coating 30
- activated carbon e.g., in the paper 10, the adhesive 40, the coating 30, and/or the emissivity coating 30
- perlite particles typically have an average particle size ranging from about 5.0 to about 150 pm
- aerogel particles typically have an average particle size ranging from about 10 to about 800 pm
- glass bubble particles typically have an average particle size ranging from about 10.0 to about 50 pm.
- any paper layer 10 that contains insulating material 12 comprises from 4.0 weight percent (wt%) to 99.0 wt% fibers 11, and from about 96.0 wt% to about 1.0 wt% insulating material 12, based on a total weight of the paper layer 10.
- a given paper layer 10 that contains insulating material 12 can have (a) any weight percent of fibers 11 between 4.0 wt% and 99.0 wt% (i.e., in increments of 0.1 wt%, e.g., 55.5 wt%, or any range of values between 4.0 wt% and 99.0 wt%, in increments of 0.1 wt%, e.g., from 35.6 wt% to 74.1 wt%).
- any paper layer 10 that contains insulating material 12 comprises from 5.0 wt% to 75.0 wt% fibers 11, and from about 95.0 wt% to about 25.0 wt% insulating material 12, based on a total weight of the paper layer
- the insulating material 12 can have any material density less than 1.0 g/cm 3 such as from greater than 0.01 g/cm 3 to about 0.99 g/cm 3 (or any value between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., 0.48 g/cm 3 , or any range of values between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., from 0.10 g/cm 3 to 0.50 g/cm 3 ).
- the at least one layer 10 can have any layer density less than 1.0 g/cm 3 such as from greater than 0.01 g/cm 3 to about 0.99 g/cm 3 (or any value between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., 0.78 g/cm 3 , or any range of values between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., from 0.20 g/cm 3 to 0.60 g/cm 3 ).
- any number of layers 10 of said one or more paper layers 10 may have an independent layer density, each of which is less than 1.0 g/cm 3 (or any value between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., 0.88 g/cm 3 , or any range of values between 0.01 and 0.99, in increments of 0.01 g/cm 3 , e.g., from 0.15 g/cm 3 to 0.55 g/cm 3 ).
- a three-dimensional object e.g., a cup 62 or container 60.
- a storage container 60 comprising the insulated paper product 100 of any one of embodiments 1 to 51. See, FIGS. 9A-9C. 53.
- the one or more container walls 68 comprise a gypsum layer, a clay-containing layer, a polymer coating, a pigment- containing layer, a bismuth oxychloride-containing layer, a mica containing layer, an aerogel containing layer, a fabric layer (e.g., a nonwoven, woven or knit fabric layer), a fiber-reinforcement layer (e.g., a layer of unidirectional fibers), a layer of insulating material 12, a metal film layer, a foam layer, a layer of air, a coating that lowers an emissivity of the one or more container walls (e.g., such as mica, bismuth oxychloride, zinc oxide, zinc sulfide, kaolin clay, or cadmium sulfide), a coating that lowers a thermal conductivity of the one or more container walls, a coating that enhances a water-repellency of the
- the storage container 60 may be a hot beverage cup 62, which could replace both STYROFOAM ® cups, as well as lined paper cups along with the insulating paper ring currently provided to prevent burning fingers of the person holding the cup.
- a container may be made via molding pulp using a vacuum forming machine. See, for example, FIG. 10.
- exemplary shipping container 60 comprises (i) multiple thinner paper layers 10, each of which optionally includes insulating materials 12 incorporated therein, optionally with (ii) a non-uniform distribution of material particles 92 (which could be insulating material 12), optionally (iii) air 90 or an insulative filler material between the layers 10, and (iv) optionally additional coating(s) 30 on one or more of the paper layers 10.
- the closed cell foam 30’ may be a biodegradable foam 30’, for instance a foamed starch such as GreenCell® sold by KTM Industries Inc. Holt, MI, or a foamed alginate, or pectin, or gelatin, or agar material that has been foamed through one means or another, and optionally chemically cross-linked to a certain extent.
- the shipping container 60 may include paper layers 10 that may optionally include insulating material 12, and may also contain a thermal barrier coating 30.
- the coating 30 could be designed to reduce radiative heat transfer, or it could be designed to reduce conductive heat transfer, or it could be designed to reduce both.
- a low thermal emissivity refers to a thermal emissivity of less than 0.90, as measured using Thermal Emissivity Method #3 Recommended by Flir Systems Inc. (described in the “Example” section below).
- Suitable materials for use in a given “emissivity coating” include, but are not limited to, bismuth oxychloride, mica flakes, perlite, kaolin, and any combination thereof (e.g., mica flakes partially or completely coated with bismuth oxychloride).
- waterproofing it is meant that the outer surface 13/15 of the storage container 60 or the insulated paper product 100 can be in contact with water for 24 hours and maintain its structural integrity.
- treatment comprises adding one or more treatment additives to one or more of the one or more paper layers 10.
- the one or more treatment additives comprise a wax emulsion, a latex binder, Epotal S440 (BASF) (i.e., a styrene acrylic based dispersion), Rhoplex P-376 (Dow) (i.e., a styrene acrylic binder), Diofan B204 (Solvay) (i.e., a polyvinylidene chloride (PVDC) latex), Barrier-Grip 9471 A (IGI) (i.e., a styrene acrylic/PE wax/clay blend), Daran SL143 (Owensboro) (i.e., a polyvinylidene chloride (PVDC) latex), or any combination thereof.
- BASF Epotal S440
- Rhoplex P-376 i.e., a styrene acrylic binder
- Diofan B204 Solvay
- IGI i.e., a polyvinyliden
- the one or more treatment additives comprise a wax emulsion, a latex binder, Epotal S440 (BASF) (i.e., a styrene acrylic based copolymer emulsion), Rhoplex P-376 (Dow) (i.e., a styrene acrylic copolymer emulsion binder), Diofan B204 (Solvay) (i.e., a poly(vinylidene chloride) (PVDC) latex), Barrier-Grip 9471A (IGI) (i.e., a blend including a styrene acrylic copolymer emulsion, a po!y(ethylene) wax and clay), Daran SL143 (Owensboro) (i.e., a poly(vinylidene chloride) (PVDC) latex), or any combination thereof.
- BASF Epotal S440
- Rhoplex P-376 i.e., a st
- Suitable additives include, but are not limited to, one or more insulating materials 12, copper ions, waxes, synthetic (e.g., polymeric or glass) fibers, silica, surface modified silica, transition metal surface modified silica, cyclodextrin, sodium bicarbonate, silicones to impart grease and water resistance, metalized ceramic particles, metalized fibers, cationic starches, cationic polymers, such as cationic guar gum, poly(ethylene imine) (e.g., poly(ethylene imine marketed as Polymin P and available from Aldrich Chemical), fillers, sizes, binders, clays including bentonite clay, kaolin clay, and other minerals, calcium carbonate, calcium sulfate, and other materials that may be added to paper products for different reasons, and any combinations thereof.
- insulating materials 12 include, but are not limited to, one or more insulating materials 12, copper ions, waxes, synthetic (e.g., polymeric or glass) fibers, silica, surface
- the filler may make the paper more receptive to printing, for instance, or make the paper glossy.
- Many fillers have a density greater than 1.0 g/cm 3 .
- Flocculants and retention aids may also be included such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers. Sizes and binders may also be added to help provide strength to papers, and can include starches, hydrocolloids, artificial and natural polymer latexes, such as RHOPLEX ® acrylic resins from Dow Chemical and ROVENE ® binders from Mallard Creek Polymers (Charlotte NC). Water soluble polymers, such as poly(vinyl alcohol), and poly(acrylic acid) may also be added to the paper.
- Vapor-Guard R5341B or Barrier Grip 9471 A are useful as barrier coatings that provide a given paper layer 10 with a degree of grease and/or water resistance.
- the additional layer could be another layer 20 of insulating material 12, a coating 20/30 (e.g., a coating 30 that increases or decreases an emissivity of a paper layer 10/100” or an integrated product 100”), a non-paper layer 30, a layer of air 90, or any combination thereof. See, for example, FIGS. 6A-6D and 14.
- one method of making at least one paper layer 10 and a container 60 formed therefrom comprises forming a corrugated structure 100” with at least one outer ply/liner 21/22 that contains fiber 11 and insulating material 12, and a fluted median ply/liner 23 without insulating material 12, comprising: suspending cellulose fibers 11 in water to make paper pulp 11; forming a fibrous first layer 10 from the pulp 11; suspending cellulose fibers 11 in water, adding voided materials (e.g., hollow insulating material 12), optionally adding surface active agents, optionally adding a flocculent; forming this layer 10 on top of the first layer of pulp 10; suspending cellulose fibers 11 in water to make paper pulp 11; forming a fibrous top layer 10 on top of the second layer 10; pressing and
- Another method of making at least one paper layer 10 and a container 60 formed therefrom comprises forming a corrugated structure 100” with at least one outer ply/liner 21/22 that contains a paper layer 10 and an insulating material layer 20, and a fluted median ply/liner 23 without insulating material 12, comprising: suspending cellulose fibers 11 in water to make paper pulp 11, and optionally adding a flocculant; forming a fibrous first layer 10 from pulp 11; suspending voided materials (e.g., hollow insulating material 12) in water, optionally adding surface active agents, and optionally adding a flocculent and/or a binder; forming this layer 20 on top of the first layer 10 of pulp 11, through curtain coating, slot-die coating, rod coating, spray application, etc.; suspending cellulose fibers 11 in water to make paper pulp 11 optionally adding a flocculant; forming a fibrous top layer 10 on top of the second layer 20; pressing and drying the resultant insulated paper sheet 100’; optionally
- Yet another method of making at least one paper layer 10 and a container 60 formed therefrom comprises forming a corrugated structure 100” with at least one outer ply/liner 21/22 that contains fiber 11 and insulating material 12, and a fluted median ply/liner 23 that comprises insulating material 12, comprising: suspending cellulose fibers 11 in water to make paper pulp 11; forming a fibrous first layer 10 from the pulp 11; suspending cellulose fibers 11 in water, adding voided materials (e.g., hollow insulating material 12), optionally adding surface active agents, optionally adding a flocculent; forming this layer 10 on top of the first layer of pulp 10; suspending cellulose fibers 11 in water to make paper pulp 11; forming a fibrous top layer 10 on top of the second layer 10; pressing and drying the resultant three-ply insulated paper sheet 100’; optionally coating at least one of the surfaces of the three-ply insulated paper sheet 100’ with a coating 30 selected from comprising aluminum, silver, mica, sericite
- Yet another method of making at least one paper layer 10 and a container 60 formed therefrom comprises forming a corrugated structure 100” with at least one outer ply/liner 21/22 that contains a paper layer 10 and an insulating material layer 20, and a fluted median ply/liner 23 with an insulating layer 20, comprising: suspending cellulose fibers 11 in water to make paper pulp 11, and optionally adding a flocculant; forming a fibrous first layer 10 from pulp 11; suspending voided materials (e.g., hollow insulating material 12) in water, optionally adding surface active agents, and optionally adding a flocculent and/or a binder; forming this layer 20 on top of the first layer 10 of pulp 11, through curtain coating, slot-die coating, rod coating, spray application, etc.; suspending cellulose fibers 11 in water to make paper pulp 11 optionally adding a flocculant; forming a fibrous top layer 10 on top of the second layer 20; pressing and drying the resultant insulated paper sheet 100’;
- the molding step comprises a pressure molding step, a thermoforming step, a vacuum forming step, or any combination thereof.
- each paper layer 10 that contains insulating material 12 comprises from 15.0 wt% to 99.0 wt% fibers 11, and from about 85.0 wt% to about 1.0 wt% insulating material 12, based on a total weight of the paper layer 10.
- each paper layer 10 that contains insulating material 12 comprises from 15.0 wt% to 80.0 wt% fibers 11, and from about 85.0 wt% to about 20.0 wt% insulating material 12, based on a total weight of the paper layer 10.
- any number of layers 10 of the one or more paper layers 10 may have an independent layer density, each of which is less than 1.0 g/cm 3 (or any value between 0.01 g/cm 3 and 0.99 g/cm 3 , in increments of 0.01 g/cm 3 , e.g., 0.44 g/cm 3 , or any range of values between 0.01 g/cm 3 and 0.99 g/cm 3 , in increments of 0.01 g/cm 3 , e.g., from 0.18 g/cm 3 to 0.85 g/cm 3 ).
- the object is a food item, a medicine, or any other item that is desirably kept at a cool temperature (e.g., a temperature below room temperature or a refrigerating temperature) or at an elevated temperature (e.g., a temperature above room temperature or a hot-out-of-the-oven temperature).
- a cool temperature e.g., a temperature below room temperature or a refrigerating temperature
- an elevated temperature e.g., a temperature above room temperature or a hot-out-of-the-oven temperature
- insulated paper product 100 comprises an insulating wrapper for a food item.
- any one of embodiments 90 to 94 wherein the method uses the storage container 60 and the storage container 60 comprises a box 61, a container 62 for temporarily housing a liquid (not shown), a cup, a mug, a flask, or a thermos 62, a clam shell 60 for hot food 80 (See, for example, FIG. 10.), a salad container 60 for chilled food 80 (See, for example, FIG. 11.), a padded envelope 60 (See, for example, FIG. 12.), a shipping container 60 (See, for example, FIG. 13A), a shipping container 60 comprising shipping container walls 69 that comprise a closed cell foam 30’ (See, for example, FIG. 14), or any combination thereof.
- the method comprises a method of maintaining an object at a controlled temperature comprising: heating or chilling an object (e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens) to a pre-determined temperature T; packaging the object inside any herein- described storage container 60.
- an object e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens
- the method comprises a method of shipping an object at a controlled temperature comprising: chilling an object (e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens) to below a spoiling temperature of the object; packaging the chilled object inside any herein-described storage container 60, along with frozen water gel packs, dry ice, etc.; closing the container; placing the storage container 60 into a vehicle (e.g., car, train, bus, airplane, etc.); transporting the package to a pre-determined destination; removing the storage container 60 from the vehicle; and delivering the storage container 60 to either the front door of a residence, or to the loading dock of a distribution center, or the entrance of a restaurant, or the receiving department of a business, wherein the temperature inside the unopened storage container 60 remains below the food spoiling temperature for at least 24 hours
- an object e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens
- the above-described insulated paper products and methods are described as “comprising” one or more components or steps, the above- described insulated paper products and methods may “comprise,” “consists of,” or “consist essentially of’ the above-described components or steps of the insulated paper products and methods. Consequently, where the present invention, or a portion thereof, has been described with an open- ended term such as “comprising,” it should be readily understood that (unless otherwise stated) the description of the present invention, or the portion thereof, should also be interpreted to describe the present invention, or a portion thereof, using the terms “consisting essentially of’ or “consisting of’ or variations thereof as discussed below.
- the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains”, “containing,” “characterized by” or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components.
- an insulated paper product and/or method that “comprises” a list of elements is not necessarily limited to only those elements (or components or steps), but may include other elements (or components or steps) not expressly listed or inherent to the insulated paper product and/or method.
- the transitional phrases “consists of’ and “consisting of’ exclude any element, step, or component not specified.
- “consists of’ or “consisting of’ used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e., impurities within a given component).
- the phrase “consists of’ or “consisting of’ appears in a clause of the body of a claim, rather than immediately following the preamble, the phrase “consists of’ or “consisting of’ limits only the elements (or components or steps) set forth in that clause; other elements (or components) are not excluded from the claim as a whole.
- transitional phrases “consists essentially of’ and “consisting essentially of’ are used to define an insulated paper product and and/or a method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention.
- the term “consisting essentially of’ occupies a middle ground between “comprising” and “consisting of’.
- the herein-described insulated paper products and/or methods may comprise, consist essentially of, or consist of any of the herein-described components, layers and features, as shown in the figures with or without any feature(s) not shown in the figures.
- the insulated paper products of the present invention do not have any additional features other than those shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the insulated paper products.
- the insulated paper products of the present invention do have one or more additional features that are not shown in the figures.
- Insulated paper products similar to exemplary insulated paper products 100/1007100’760 shown and described in FIGS. 1-21 were prepared.
- a polystyrene disposable weigh boat was accurately weighed to 4 decimal places (tare mass). Approximately 1-2 gram of liquid was placed in the weigh boat, and promptly weighed to four decimal places (gross-wet mass.) Subtracting the tare from the gross-wet mass gives the net-wet mass. The weigh boat was carefully tilted and rocked from side to side, allowing the liquid to coat the bottom of the weigh boat evenly, then it was placed in a cupboard for 24-48 hours to evaporate at room temperature. The dry weigh boat was re-weighed to four decimal places (gross-dry mass).
- FIG. 15 shows the view from directly above the hotplate 70, viewing the sample 10 in visible light.
- FIG. 17 shows the thermal view using the Flir E40 thermal camera 74.
- Digital hot plate 70 that heats to at least 37°C (98.6°F) and with a heating surface 71 at least 13 mm in diameter
- Matte black spray paint (Rust-oleum High Performance Wheel, matte black)
- the portion of the sample painted black has a high emissivity (approx. 0.90), and thus shows up red and displays the correct temperature.
- the polished aluminum material has a low emissivity (approx. 0.03), and thus shows up blue and displays a lower temperature than the object actually is.
- FIG. 18 shows the test apparatus used to quickly visually compare the thermal emissivity of materials directly from the way that they absorb and then re-emit heat radiated from a hot-filament light bulb 83
- Samples were mounted onto a shiny metal plate 82 Half of the sample was sprayed with mat black paint, and half was left exposed. All paint and adhesives used were allowed to dry at room temperature for at least 40 minutes.
- the camera 74 was switched on, and the spotlight was shone onto the samples from a low angle, so that stray heat radiation reflected away from the thermal camera 74.
- black and high emissivity materials lit up in the thermal camera screen, as the absorbed heat and then re-emitted it back out in all directions - including towards the thermal camera 74. Materials with low emissivity were generally much darker in color, after illumination for a few seconds.
- Method # 3 is as follows:
- Step 1 Determine the reflected apparent temperature. This is needed to compensate for reflected ambient radiation sources, reflecting from your sample.
- Step 2 Measuring the thermal emissivity: vi) Adhere a strip of black electrical tape to the sample. vii) Warm the sample up to at least 20°C warmer than the ambient temperature.
- the Table Top Emissimetry apparatus measures total normal emissivity over a broad wavelength band. Thin, square samples, 0.5” on a side are mounted facing downward on an isothermal copper block heated by a resistance heater and surrounded by ceramic insulation. Five type-K thermocouples are mounted on the bottom face of the isothermal plate. Sample temperatures during emissivity measurements are inferred from the closest thermocouple. The samples are exposed to ambient air with convection losses minimized by the face-down orientation of the samples and the small gap to the detector head.
- the IR detector is a broadband thermopile with a 1 mm diameter sensitive area and flat spectral response from 1 - 40 micrometers wavelength.
- the detector and radiation shield are water cooled and view the sample through a 3.56 mm aperture 5 mm from the sample surface.
- the detector is sensitive to radiation from an approximately 4.57 mm diameter spot on the sample. Stray radiation on the detector is minimized by a flat optical black coating on the inner surface of the shield and both faces of the aperture plate and by cooling the shield and aperture plates.
- the shield temperature is monitored by two type-K thermocouples embedded in the shield walls. Thermocouple and detector voltages are fed to an analog to digital module and attached to a personal computer.
- the emissivity e is calculated by the equation: where: and V is the detector voltage, T is the temperature measured in Kelvin. The subscripts are as follows: Tshutter is the temperature of the shutter.
- T shield is the temperature of the infrared detector when the shutter is in place.
- Tsensor is the temperature of the infrared detector during measurements.
- Tbiackbody is the temperature of the standard blackbody used to calculate the unknown values.
- T sample is the temperature of the sample using the thermocouple nearest the sample.
- V shuter is the voltage from the infrared detector when the shutter is in place.
- Vbiackbody is the voltage from the two black body readings taken.
- This test was devised to measure the amount of heat flowing through a given sample, as if it were placed in direct sunlight on a hot day. While a steady-state test would be ideal, the inventors sought methods to make rapid assessments of thermal properties for further research. While not wishing to be limited by theory, this test combines both emissivity (absorption of radiative heat) and conduction to give a measure of the amount of heat passing through a given sample.
- Expanded polystyrene coolers were purchased from Uline (Pleasant Prairie WI) (part number S21529) Inside dimensions: 8” x 6” x7”, wall thickness 1.5”, and outside dimensions 11” x 9” x 10”.
- Uline Peasant Prairie WI
- a 100mm diameter acrylic circular template was used to draw a circle on one of the 11” x 9” faces of the cooler. The circle was positioned 60mm from the top of the cooler, and 88mm from either side, as shown in FIG. 43A-43B. The circle was carefully cut out using an electrically heated hot knife (e.g. RoMech Pro Hot Knife Kit 200W Styrofoam cutter, made in China).
- an electrically heated hot knife e.g. RoMech Pro Hot Knife Kit 200W Styrofoam cutter, made in China.
- the silicone resin for example, Diamond Driven Liquid Silicone Compound, available from Amazon.com, or Oomoo 30 Silicone Mold Making Rubber available from Amazon.com, or Smooth-On Ecoflex 00-35 fast platinum cure silicone rubber compound kit, available from Smooth-On through Amazon.com, or RTV Silicone Rubber for Mold Making available from Specialty Resin & Chemical LLC, Dowagiac MI, or similar
- excess silicone resin was cut from the exterior of the cooler in the vicinity of the cut circular hole, to ensure bondability between the expanded polystyrene and the sample.
- silicone resins were used, it was also found that epoxy resins could alternately be used to waterproof seal coolers without destroying the expanded polystyrene structure.
- Sample preparation Coatings were made onto 35 lb per 1000 sq ft (35 MSQ or 170 gsm) kraft board using meyer rods and dried.
- Example board is available from Juvo Plus Inc. (Irwindale CA) in the form of “200 pack kraft laser and ink jet printer post cards 2 up per page” SKU LJ- WACHG-03 1218-11-1. This paper was selected as it proved to be a more consistent source of kraft fiberboard than obtaining samples of 35 lb MSQ liner board from various corrugated board manufacturers.
- the kraft fiberboard was substituted with a sheet of paper containing fillers, or thermal insulation elements or other materials that the inventors wished to assess, such as metallized bubble wrap.
- Aluminum foil e.g. Glad® Heavy Duty Aluminum Foil, distributed by Phoenix Industries Inc Denver CO, and available in grocery stores
- matt black spray paint e.g. Rust-Oleum® Painter’s Touch 2X Ultracover Paint + Primer, Rust-Oleum Corporation, Vernon Hills IL
- the acrylic 100mm diameter template was then used to mark and cut circular samples of coated kraft board.
- the back (kraft paper) sides of these were then sprayed with an adhesive such as 3M® Super 77 TM Multipurpose Adhesive, made by 3M Company (Minneapolis MN) and sold in many craft, office, and hardware stores.
- the discs were carefully bonded to the shiny side of the painted foil, and placed between paper sheets under several books (about 1 kg pressure) until dry, to maintain flatness of the sample.
- the foil sheet was trimmed so that approximately 0.5” to 1” of shiny foil remained surrounded each sample.
- 3M® Marine Adhesive Sealant Fast Cure 4000 UV (part # 05280) was then used to carefully adhere the black surface of the foil-sample composite to the outside of the cooler, so that the sample was in line with the opening into the cooler.
- Other sealants could be used provided that they bond to both painted foil and expanded polystyrene, do not destroy expanded polystyrene by partially dissolving it, and that they form a waterproof seal. This was then allowed to cure overnight.
- the cooler with the sample window was placed on the test rig built and illustrated in FIGS. 19A-19B.
- the test rig allows the repeatable location of the test window in front of the 110V 250W tungsten filament heat lamp such as those used in restaurants to keep prepared food hot prior to serving (e.g. Intertek 5000707, white incandescent tungsten heat lamp).
- the test rig shown in FIGS. 19A-19B includes adjustment of angle of incidence and distance from the surface of the lamp to the center of the test material. 4,500 g of water that had been allowed to equilibrate to room temperature was weighed to the nearest gram (using a Philips® Essence kitchen electronic top pan scale lg increments to 5 kg capacity) and poured into the cooler.
- the stirrer blade was inserted through the lid, and a digital thermometer probe was also inserted through the lid. A strobe light was used to time the rotation of the stir blade to 600 rpm.
- the water was stirred for several minutes until the temperature stabilized, at which time it was recorded. A timer was set for 15 minutes. The heat lamp was switched on, and the timer started simultaneously. The temperature of the water in the cooler was recorded every 15 minutes for one hour.
- Positive control sample was a kraft disk that also had a layer of aluminum foil laminated to it before adhering it to the shiny side of black painted foil, and a negative control consisted of an uncoated kraft disk mounted onto a similar foil sheet.
- E (Joules) 4.2 * DT * 4500
- 4.2 is the specific heat capacity of water in J.K fg 1
- 4500 is the mass of the water present in the container. Rate of energy transfer into the water Watts (ER) through the window is calculated by dividing by the number of seconds in one hour, viz. :
- the energy flux Watts per square meter can also be calculated (W.m 2 )
- an infrared thermometer (Etekcity Lasergrip 1025D) was also used to measure the outside temperature of the disk, to give an approximation of the temperature difference over the thickness of the sample.
- Repulpability was tested by SGS Integrated Paper Services Inc., Appleton WI according to the “Voluntary Standard for Repulping and Recycling Corrugated Fiberboard treated to Improve its Performance in the Presence of Water and Water Vapor Protocol of 2013”, generated by the Fiber Box Association, headquartered in Elk Grove Village, IL, 60007.
- Repulpable means the test material that can undergo the operation of re-wetting and fiberizing for subsequent sheet formation, using the process defined in this standard. In the repulpability test, materials are weighed, pulped in a specific manner using laboratory equipment, run through a laboratory disintegrator, and then run through a screen. The amount of rejected material is compared to the material that could be reused as pulp to make board as a % by mass.
- the first is the acceptable recovery of the fiber based upon the mass of material first entered into the test, and the second is the percentage of the recovered fiber that is accepted, not rejected. These figures constitute the “% re-pulpability”, and the fiber box association has determined that a pass for both measures of repulpability is >85%. Other parameters recorded are: a) material fouling the equipment during pulping or forming b) material that does not disintegrate and has to be removed (becomes part of the rejects) Coating Method:
- a clip attached to a 3 ⁇ 4” thick glass plate is used to hold a stack of photocopy paper and the sheet of paper to be coated.
- a strip of masking tape was placed along the top of the sheet to be coated, and a paper towel was left hanging off the end.
- a transfer pipette was used to make a line of coating on the masking tape. This prevented the coating from prematurely soaking into the paper board to be coated.
- Meyer rods (available from RD Specialties Inc.) were used to draw the coating down over the sheet. The coating was then dried under ambient conditions.
- materials Before materials can be included in a coating or into the fibrous matrix of paper, materials first have to be wetted out and dispersed. Some materials such as glass have high enough surface free energy that the wet out spontaneously - whereas materials such as perlite and aerogel require surfactants to lower the surface free energy of the water enough to wet out the material.
- Surfactants may be non-ionic, cationic, or anionic. They may be high molecular weight polymers or copolymers, or they may be low molecular weight, and able to reach newly created interfaces rapidly. Surfactants for aqueous systems may be characterized by their HLB value. HLB stands for Hydrophilic-Lipophilic Balance, and is a measure of the capability of the particular surfactant to wet out various surfaces of differing surface free energy. Very hydrophobic materials have a low surface free energy, so a matching surfactant should also have a low HLB value. More hydrophilic surfaces - those with multiple polar groups perhaps, require surfactants with higher HLB values.
- Microspersion EZ manufactured by Micropowders Inc. of Tarrytown NJ is a non-ionic low molecular weight surfactant with a low HLB.
- Dawn® liquid dish soap, manufactured by the Procter & Gamble Co (Cincinnati OH) is an example of a low molecular weight anionic surfactant.
- E-Sperse 100 from Ethos, Greenville SC
- Triton BG-10 (Dow)
- Glucopon 215 UP are additional materials that can wet out certain hydrophobic materials.
- the Surfynol ® range available from Evonik are ethoxylated acetylenic diols of fairly low molecular weight. They are non-ionic, and low foaming due to the molecular interactions of the acetylenic moiety with the water surface.
- Surfynol 104, 440, 420 are representative examples.
- Polymers may be anionic, cationic, or non-ionic - or have a mixture of characteristics.
- Polymeric dispersants also known as “grid aids” are often co-polymeric in nature, for instance some of the Joncryl resins from BASF are believed to be methacrylic acid - styrene - butylmethacrylate copolymers, containing anionic ionizable groups.
- Zetasperse 3100, Zetasperse 3800, TegoDispers 752W, and TegoDispers 755W are also higher molecular weight dispersing agents with a net negative formal charge when ionized available from Evonik.
- Disperbyk 190 as well as other Disperbyk products available from BYK Chemie (Wallingford CT) are also polymeric / copolymeric materials that help stabilize dispersions through a) increasing particle surface negative charge (electrokinetic stabilization), and b) by allowing steric stabilization by dint of segments of polymer dissolving into the continuous medium.
- clay coating provides a smooth flat ink-receptive surface that allows high quality printing, it covers the brown color of unbleached pulp with white, and gives the packaging a higher quality feel.
- the coating is applied in two layers.
- the first layer is kaolin clay based, whitened by calcium carbonate. This layer helps smooth the surface by filling in low spots.
- the second layer also contains titanium dioxide and calcium carbonate.
- the formulations of clay coatings vary. Usually, they contain kaolin clay, along with a film forming binder, such as an acrylic latex, or sometimes a cornstarch.
- a polymeric dispersant is usually included to stabilize the clay coating, and a viscosity control agent is usually also included, such as carboxymethyl cellulose, or an hydrophobically associated alkali swellable polymer (HASE polymer.) Calcium carbonate is also usually included, along with titanium dioxide pigment for whitening.
- the clay coating offers another opportunity to incorporate insulative elements that reduce conduction and radiative heat transfer.
- Glass beads including high refractive index glass, and retroreflective hemi-spherically mirrored glass beads - Cole Safety Products,
- Bismuth oxychloride - Making Cosmetics Inc (Redmond WA). This is a pearlescent pigment, commonly used in cosmetics and packaging to impart a pearl effect.
- Other sources include BASF, as Biju Ultra UFC and Pearl Glo.
- Zinc Oxide - Brambleberry (Bellingham, WA), and Sky Organics Snowflake Sparkle Mica - Brambleberry (Bellingham, WA)
- Rhoplex VSR-50 is an acrylic low VOC film forming binder emulsion in water. Commonly used in architectural coatings. Originally sold by Rohm & Haas, now available from Dow Chemical.
- Sericite comprised sericite mica surface treated with magnesium myristate or Sericite White sparkle luxury mica colorant pigment powder by H&B Oils Center Co.
- R-6090 denotes Rovene 6090 (Mallard Creek Polymers, NC) is a modified vinylacetate copolymer emulsion with a polymer Tg of 39°C. This binder has release properties, allowing adhesive materials to be peeled from the coating surface.
- TH500 EF is RopaqueTM TH500EF from Dow Chemical hollow polymeric microsphere pigment of approximate size 0.4 micron diameter, and 30% solids.
- TH1000 is RopaqueTM TH1000 from Dow Chemical hollow polymeric microsphere pigment of approximate size 1 micron diameter, and 26.5% solids
- Silver (Ag) -coated glass bubbles available from CoSpheric LLC.
- Kaolin clay coating 127-01 was coated onto 170 gsm (35 lbs/1000 sq ft) kraft laser & inkjet printer post cards, available from Juvo Plus Inc Irwinsdale CA, using a # 5 Meyer rod and dried in a hot air oven at 250°F for 5 mins. Various coatings were selected and coated onto the board, drying the coatings between each application. A representative area was selected, and tested on the test rig illustrated in FIG. 19A-19B. The distance to the lamp was set to 4.5”, 4500 grams of water were weighed into the cooler, and the stirrer rotation was set to 600 rpm. The water temperature rise over 1 hour of lamp exposure was recorded.
- A1 foil Aluminum foil (Reynolds heavy duty kitchen foil) was mounted dull face down to Juvo kraft paper using 3M spray adhesive.
- Thermal Emissivity Test Method #4 Thermal Emissivity Test Method #4.
- Several coatings have been discovered by the inventors that apparently reduce the transfer of radiant heat energy from an incandescent light bulb (as a proxy to the full-sun illumination of a delivered package) through sheets of paper.
- the inventors were surprised to find that the emissivity results from the third-party laboratory did not correlate with the heat transfer through the materials measured by the cooler window tests.
- the inventors may have discovered several coatings with non-obvious and unexpected thermal properties.
- 35 lb liner board International Paper
- 35 lb liner board International Paper
- surfactants if necessary for wetting.
- a cationic polysaccharide such as cationic Guar Gum, available from Making Cosmetics Inc.
- a cationic starch sizing or a synthetic retention aid, such as Polymin P (BASF), also known as poly(ethylene imine), or a high molecular weight poly(acrylamide) available from various sources.
- BASF Polymin P
- BASF poly(ethylene imine)
- acrylamide high molecular weight poly(acrylamide) available from various sources.
- Hydrophobically associating polymers may also be incorporated, such as N-alkyl poly(acrylamides.)
- N-alkyl poly(acrylamides.) We wished to understand the amount of retained insulation in the paper following drying. The following formulations were made up and cast as paper, dried at room temperature and then sent for ash content and moisture content analysis:
- Paper sheets were made using the following formulations:
- a sheet of TL1 was hung from inside an inverted 5-gallon pail and held over a boiling tea kettle to steam the sheet.
- the cast iron hand-cranked corrugator was warmed with a hair dryer, and the warm steamed sheet was promptly rippled. This was promptly bonded between two non- corrugated sheets of TL1 to make a rudimentary corrugated structure.
- a sheet of EJ was hung from inside an inverted 5-gallon pail and held over a boiling tea kettle to steam the sheet.
- the cast iron hand-cranked corrugator was warmed with a hair dryer, and the warm steamed sheet was promptly fluted. This was promptly bonded between two non-corrugated sheets of EJ to make a rudimentary corrugated structure. This procedure was repeated using EK sheets for all three layers.
- a sheet of TL1, EJ, and EK were each coated with Kaolin clay formulation 127-01, then dried, and then coated with 137-02 (BiLite (BASF) - bismuth oxychloride coated mica flakes) and dried. More uncoated sheets were steamed and fluted, and similar corrugated structures were produced incorporating one of the coated sheets with the coating side facing out as depicted in FIG.
- 10 cm diameter disks were cut of each sample, and mounted into a cooler window for thermal testing. Prior to sealing with marine adhesive, the samples were gently pushed into the front of the cooler window so that the face of the composite was flush with the front of the cooler. 10cm discs of the following were also cut as controls: Aluminized bubble wrap, corrugated C-flute (351bs.MSQ kraft liners with 231b medium, Corrugated Supplies Inc.), corrugated B-flute (351bs.MSQ kraft liners with 231b medium, Corrugated Supplies Inc.), triple wall corrugated B-C flute (351bs.MSQ kraft liners with 231b medium, Corrugated Supplies Inc.)
- the paper had improved pigment rub-off compared to earlier formulations using similar materials, presumably, although without wishing to be bound by theory, because the binder concentration was increased and the surfactant package was changed. Interestingly, when the paper was folded or pleated, it made very little noise compared to the uncoated paper. Furthermore, the paper was found to be repulpable when tested.
- coated paper had a much smoother hand-feel than the uncoated paper. Haptic experiences can be difficult to describe, however, the paper felt more like handling a smooth fabric such as a microfiber polyester knit vs. kraft paper. The paper felt smoother, almost softer, and it made less noise when being handled compared to the uncoated paper. Furthermore, the paper was able to be folded without the coating flaking off. The paper was pleated to form pleats at approximately 1” intervals, with the intention for it to be used as insulating packaging.
Abstract
Description
Claims
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Application Number | Priority Date | Filing Date | Title |
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US16/590,224 US11247446B2 (en) | 2018-10-01 | 2019-10-01 | Re-pulpable insulated paper products and methods of making and using the same |
PCT/US2019/054121 WO2020072527A1 (en) | 2018-10-01 | 2019-10-01 | Re-pulpable insulated paper products and methods of making and using the same |
US16/837,129 US11377798B2 (en) | 2018-10-01 | 2020-04-01 | Re-pulpable thermally insulated paper products and methods of making and using the same |
PCT/US2020/053421 WO2021067367A1 (en) | 2019-10-01 | 2020-09-30 | Re-pulpable thermally insulated paper products and methods of making and using the same |
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CA (1) | CA3153211A1 (en) |
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US11731826B2 (en) | 2021-10-22 | 2023-08-22 | Packaging Technology Group, Llc | Recyclable, thermally insulated shipping container with packed, loose-fill organic insulation |
US11953262B2 (en) | 2013-05-10 | 2024-04-09 | Packaging Technology Group, Llc | Recyclable, thermally insulated shipping container with packed, loose-fill organic insulation and PCM bladder insert |
WO2022226253A1 (en) * | 2021-04-23 | 2022-10-27 | Sealed Air Corporation (Us) | Recyclable retention/suspension packaging assembly |
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US1883051A (en) | 1930-05-31 | 1932-10-18 | Riegel Paper Corp | Control for motor-driven apparatus |
SE9003600L (en) * | 1990-11-12 | 1992-05-13 | Casco Nobel Ab | EXPANDABLE THERMOPLASTIC MICROSPHERES AND PROCEDURES FOR PRODUCING THEREOF |
US6265040B1 (en) * | 1996-06-14 | 2001-07-24 | Insulation Dimension Corporation | Self-bonding syntactic foam insulated container sleeve |
US6740373B1 (en) * | 1997-02-26 | 2004-05-25 | Fort James Corporation | Coated paperboards and paperboard containers having improved tactile and bulk insulation properties |
US7976855B2 (en) | 2002-04-30 | 2011-07-12 | Kimberly-Clark Worldwide, Inc. | Metal ion modified high surface area materials for odor removal and control |
AU2003295725A1 (en) * | 2002-11-19 | 2004-06-15 | International Paper Company | Water vapor transmission rate resistant and repulpable corrugated paperboard |
US7438875B2 (en) | 2003-10-16 | 2008-10-21 | Kimberly-Clark Worldwide, Inc. | Method for reducing odor using metal-modified silica particles |
US9469739B2 (en) | 2005-04-07 | 2016-10-18 | Aspen Aerogels, Inc. | Microporous polyolefin-based aerogels |
US10562659B2 (en) | 2017-09-08 | 2020-02-18 | Georgia-Pacific Bleached Board LLC | Heat sealable barrier coatings for paperboard |
EP3682922B1 (en) | 2017-09-15 | 2024-02-28 | Shin Nippon Biomedical Laboratories, Ltd. | Medicine storage cartridge with nozzle, sprayer therefor, and powdered medicine dispensing device for nasal cavity |
CN111971117A (en) | 2017-12-19 | 2020-11-20 | 汉高股份有限及两合公司 | Thiol-epoxide based aerogels |
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2020
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