US20140272352A1 - Repulpable and recyclable composite packaging articles and related methods - Google Patents

Repulpable and recyclable composite packaging articles and related methods Download PDF

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Publication number
US20140272352A1
US20140272352A1 US14/211,132 US201414211132A US2014272352A1 US 20140272352 A1 US20140272352 A1 US 20140272352A1 US 201414211132 A US201414211132 A US 201414211132A US 2014272352 A1 US2014272352 A1 US 2014272352A1
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United States
Prior art keywords
fiber
mineral
containing layer
packaging structure
composite packaging
Prior art date
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Abandoned
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US14/211,132
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English (en)
Inventor
Christopher R. Tilton
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SMART PLANET TECHNOLOGIES Inc
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SMART PLANET TECHNOLOGIES Inc
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Family has litigation
First worldwide family litigation filed litigation Critical https://patents.darts-ip.com/?family=51528244&utm_source=***_patent&utm_medium=platform_link&utm_campaign=public_patent_search&patent=US20140272352(A1) "Global patent litigation dataset” by Darts-ip is licensed under a Creative Commons Attribution 4.0 International License.
Application filed by SMART PLANET TECHNOLOGIES Inc filed Critical SMART PLANET TECHNOLOGIES Inc
Priority to US14/211,132 priority Critical patent/US20140272352A1/en
Assigned to SMART PLANET TECHNOLOGIES, INC. reassignment SMART PLANET TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TILTON, CHRISTOPHER R.
Publication of US20140272352A1 publication Critical patent/US20140272352A1/en
Assigned to SMART PLANET TECHNOLOGIES, INC. reassignment SMART PLANET TECHNOLOGIES, INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TILTON, CHRISTOPHER R
Priority to US15/877,136 priority patent/US10822468B2/en
Priority to US16/417,364 priority patent/US11466138B2/en
Priority to US17/819,768 priority patent/US20220403131A1/en
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J11/00—Recovery or working-up of waste materials
    • C08J11/04—Recovery or working-up of waste materials of polymers
    • C08J11/06—Recovery or working-up of waste materials of polymers without chemical reactions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/04—Manufacture of substantially flat articles, e.g. boards, from particles or fibres from fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27N—MANUFACTURE BY DRY PROCESSES OF ARTICLES, WITH OR WITHOUT ORGANIC BINDING AGENTS, MADE FROM PARTICLES OR FIBRES CONSISTING OF WOOD OR OTHER LIGNOCELLULOSIC OR LIKE ORGANIC MATERIAL
    • B27N3/00—Manufacture of substantially flat articles, e.g. boards, from particles or fibres
    • B27N3/08—Moulding or pressing
    • B27N3/28—Moulding or pressing characterised by using extrusion presses
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/02—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica the layer of fibres or particles being impregnated or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
    • C08J5/045—Reinforcing macromolecular compounds with loose or coherent fibrous material with vegetable or animal fibrous material
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/12—Making corrugated paper or board
    • 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
    • D21H5/00—Special paper or cardboard not otherwise provided for
    • D21H5/12—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/08—Impregnated or coated fibreboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/26—Processes for applying liquids or other fluent materials performed by applying the liquid or other fluent material from an outlet device in contact with, or almost in contact with, the surface
    • B05D1/265—Extrusion coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D2252/00—Sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/04—Disintegrating plastics, e.g. by milling
    • B29B17/0412—Disintegrating plastics, e.g. by milling to large particles, e.g. beads, granules, flakes, slices
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0217—Mechanical separating techniques; devices therefor
    • B29B2017/0224—Screens, sieves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B17/00—Recovery of plastics or other constituents of waste material containing plastics
    • B29B17/02—Separating plastics from other materials
    • B29B2017/0213—Specific separating techniques
    • B29B2017/0217—Mechanical separating techniques; devices therefor
    • B29B2017/0251—Hydropulping for converting the material under the influence of water into a slurry, e.g. for separating laminated plastic from paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2009/00—Layered products
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7162—Boxes, cartons, cases
    • B29L2031/7166—Cartons of the fruit juice or milk type, i.e. containers of polygonal cross sections formed by folding blanks into a tubular body with end-closing or contents-supporting elements, e.g. gable type containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/025—Particulate layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/702—Amorphous
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
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    • B32B2307/72—Density
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    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7246—Water vapor barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J2323/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
    • C08J2323/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
    • C08J2323/04—Homopolymers or copolymers of ethene
    • C08J2323/06—Polyethene
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K3/00—Use of inorganic substances as compounding ingredients
    • C08K3/18—Oxygen-containing compounds, e.g. metal carbonyls
    • C08K3/24—Acids; Salts thereof
    • C08K3/26—Carbonates; Bicarbonates
    • C08K2003/265—Calcium, strontium or barium carbonate
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/52—Mechanical processing of waste for the recovery of materials, e.g. crushing, shredding, separation or disassembly
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
    • Y10T428/2495—Thickness [relative or absolute]
    • Y10T428/24967—Absolute thicknesses specified
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/258—Alkali metal or alkaline earth metal or compound thereof
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
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    • Y10T428/25—Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
    • Y10T428/259—Silicic material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/26—Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/263—Coating layer not in excess of 5 mils thick or equivalent
    • Y10T428/264—Up to 3 mils

Definitions

  • the present embodiments relate generally to repulpable and recyclable composite packaging materials and/or finished packaging structures.
  • Packages and packaging materials for retail and shipping purposes are typically designed to be sufficiently durable to allow reliable use of the materials and protection of packaged goods.
  • pulping and recycling characteristics are critical considerations in the development of such packages and materials.
  • Other important considerations include barrier performance, heat seal during fabrication, surface energy, and efficiency in manufacturing.
  • Mineral particle densities within the polymer matrix of the mineral-containing layer may be from about 2.4 g/cm 3 to about 4.9 g/cm 3 .
  • Mineral particles within the polymer matrix of the mineral-containing layer may comprise the cube and block class.
  • Calcium carbonate particles within the polymer matrix of the mineral-containing layer may have about 18-80% particle diameters finer than 6 ⁇ m and about 33-96% particle diameters less than 10 ⁇ m.
  • a hardness of mineral particles within the polymer matrix of the mineral-containing layer may be from about 2.0 to 4.0 Mohs.
  • Mineral particles within the polymer matrix of the mineral-containing layer may have 0.05 to 0.5 maximum % on 325 mesh per ASTM D1199.
  • Mineral particles within the polymer matrix of the mineral-containing layer may have a pH from about 8.5 to about 10.5.
  • the polymer bonding agent(s) within the mineral-containing layer may have densities from about 0.908 g/cm 3 to about 1.60 g/cm 3 .
  • the polymer bonding agent(s) within the mineral-containing layer may have a physical melt flow index from about 4 g/m 2 /10 min to about 16 g/m 2 /10 min.
  • Minerals may be fully dispersed within the polymer bonding agent matrix.
  • the polymer bonding agent(s) within the mineral-containing layer may have a molecular weight (Mz) from about 150,000 to about 300,000.
  • the polymer content weight of the mineral-containing layer may be from about 3.5 lbs/3 msf to about 50 lbs/3 msf.
  • the mineral-containing layer may have a modulus from about 1.8 GPa to about 4.5 GPa.
  • About 40-60% of the mineral-containing layer may have a coefficient of thermal expansion from about 1 ⁇ 10 ⁇ 6 in/in to about 8 ⁇ 10 ⁇ 6 in/in.
  • the mineral-containing layer may be applied to the fiber-containing layer in coat weights from about 3 g/m 2 to about 20 g/m 2 .
  • Surfaces of the mineral-containing layer may have a coefficient of static friction from about 0.18 to about 0.59.
  • the mineral-containing layer may include a mixture of crystalline, semi-crystalline, and amorphous structures.
  • the polymer bonding agent(s) of the mineral-containing layer may have crystallinity from about 60% to about 85%.
  • the mineral-containing layer may contain coupling agents from about 0.05% to about 15% by weight.
  • the mineral-containing layer may contain from about 0.5% to about 10% plastomers and elastomers with densities from about 0.86 g/cm 3 to about 0.89 g/cm 3 per ASTM D 792.
  • the mineral-containing layer may have differential scanning calorimetry (DSC) melting peaks from about 59° C. to about 110° C.
  • DSC differential scanning calorimetry
  • the mineral-containing layer molecular weight ranges (Mw) may be from about 10,000 to about 100,000.
  • About 10% to about 70% of the mineral-containing layer may have a branching index (g′) of about 0.99 or less as measured at the Z-average molecular weight (Mz) of the bonding agent.
  • the polymer bonding agent(s) of the mineral-containing layer may have an isotactic run length from about 1 to about 40.
  • the polymer bonding agent(s) of the mineral-containing layer may have a physical shear rate from about 1 to about 10,000 at temperatures from about 180° C. to about 410° C.
  • the mineral-containing layer may have a basis weight from about 0.5 lbs/msf to about 175 lbs/msf.
  • the polymer bonding agent(s) of the mineral-containing layer may have from about 20% to about 60% amorphous structure and from about 20% to about 55% crystalline structure.
  • the polymer bonding agent(s) of the mineral-containing layer may comprise polyethylene having an amorphous fraction from about 40% to about 85%.
  • the mineral-containing layer may have a copolymer isotacticity index from about 20% to about 50% as measured by the DSC method.
  • Mineral particles within the polymer matrix of the mineral-containing layer may have an average surface area from about 1.0-1.3 m 2 /g to about 1.8-2.3 m 2 /g.
  • Mineral particles within the polymer matrix of the mineral-containing layer may have a Green Hunter reflectance range from about 91% to about 97%, and a Blue Hunter reflectance range from about 89% to about 96%.
  • the fiber-containing layer may contain inorganic mineral coatings and fillers, including without limitation, kaolin clay, mica, silica, TiO 2 , and other pigments.
  • the fiber-containing layer may contain vinyl and polymeric fillers.
  • a surface smoothness of the fiber-containing layer may be in the range of about 150 to about 200 Bekk seconds.
  • the fiber-containing layer may have an ash content from about 1% to about 40%.
  • Fiber Aspect Ratio Average
  • Average 5-100 Fiber Thickness (Softwood) 1.5-30 mm Fiber Thickness (Hardwood) 0.5-30 mm Filled Fiber Content 1% to 30% Fiber Density 0.3-0.7 g/cm 2 Fiber Diameter 16-42 microns Fiber Coarseness 16-42 mg/100 m Fiber Pulp Types Mechanical, Thermo-Mechanical, (Single- to Triple-Layered) Chemi-Thermo-Mechanical, and Chemical Permeability 0.1-110 m 2 ⁇ 10 15 Hydrogen Ion Concentration 4.5-10 Tear Strength (Tappi 496, 402) 56-250 Tear Resistance (Tappi 414) m49-250 Moisture Content 2%-18% by Weight
  • Burst Fiber Weight Tear Surface Strength (lbs/3 msf) g/m 2 Resistance (Mn) Roughness (kPa) 40-75 60-110 400-700 2.0-5.5 ⁇ m 140-300 75 110-130 650-750 2.0-3.5 ⁇ m 175-400 115 180-190 1400-1900 100-2500 mls/min 175-475 130 205-215 1600-2200 100-2500 mls/min 250-675 200 315-330 1900-3200 100-2500 mls/min 500-950 300 460-195 500-4000 100-2500 mls/min 700-1850
  • the mineral-containing layer may comprise a multilayer coextrusion, such as up to six layers, with each layer having from about 0% to about 70% by weight mineral content with a polymer bonding agent.
  • a weight of the overall composite may be from about 2.5 lbs/3 msf to about 150 lbs/3 msf.
  • the polymer bonding agent(s) of the mineral-containing layer may comprise linear, branched, and/or highly branched polymers.
  • the polymer bonding agent(s) of the mineral-containing layer may comprise polyolefin(s) having a number average molecular weight distributions (Mn) from about 5,500 to about 13,000, a weight average molecular weight (Mz) from about 170,000 to about 490,000, and/or a Z-average molecular weight (Mz) from about 170,000 to about 450,000.
  • Mn number average molecular weight distributions
  • Mz weight average molecular weight
  • Mz Z-average molecular weight
  • the mineral-containing layer may have a Mw/Mn ratio from about 6.50 to about 9.50.
  • the mineral particles within the polymer matrix of the mineral-containing layer may be surface treated at levels from about 1.6 to about 3.5 mg surface agent/m 2 of the particle.
  • the mineral particles within the polymer matrix of the mineral-containing layer may have a particle top cut from about d98 of 4-15 microns and a surface area from about 3.3 m 2 /g to about 10 m 2 /g.
  • the mineral particles within the polymer matrix of the mineral-containing layer may comprise CaCO 3 coated with fatty acids having from about 8 to about 24 carbon atoms, with a surface treatment level from about 0.6% to about 1.5% by weight of the treatment, or from about 90% to about 99% by weight of the CaCO 3 .
  • the mineral-containing layer may be from about 0.5 mil thick to about 5 mil thick.
  • non-fiber content in the fiber-containing layer examples include, but are not limited to, about 50-95% of #1 clay or #1 fine clay, about 3-20% by part calcined clay, about 3-40% by part TiO 2 , about 2-45% vinyl acrylic, and from about 1% to about 35% protein binders, co-binders, or tri-binders.
  • the mineral-containing layer may contain incremental quartz-silica content.
  • a process for recycling the present composite structure may have reject rates from about 10% to about 25% by weight of the starting composite, and screen plate efficiencies from about 60% to about 100%, with screen plates having the option of using hole, slotted, and contoured screens with one screen behind the other with an A plate having the smallest perforations, an intermediary B plate, and a C plate having the largest perforations, using processes including high density, forward, and through flow cleaners having a diameter from about 70 mm to about 400 mm and particle process out of fibers having reject rates of about 0.1% to about 30% and a particle removal efficiency from about 50% to 90% by mass, and particle sizes from about 150 microns to 0.05 microns.
  • a process for recycling the present composite structure may have feed-accept pressures in the range of about 2 kPa to about 12 kPa on smooth contoured and heavily contoured screens.
  • the present composite materials may have a pulper consistency from about 3% to about 30%, pulping temperatures from about 100° F. to about 200° F., pulping times from about 10 min. to about 60 min., with pulping pH from about 6 to about 9.5 ⁇ 0.5, and screen holes from about 0.050′′ to about 0.075′′ and slots from about 0.006′′ to about 0.020′′, drum pulping having an RPM from about 9 to about 20, having 4 mm to about 8 mm holes, with hole-type screens with holes from about 0.8 mm to about 1.5 mm in size, coarse to fine screen holes and slots from about 0.150 mm to about 2.8 mm, and screen rotor circumference speeds from about 10 m/s to about 30 m/s.
  • Certain of the present embodiments comprise a recyclable composite packaging structure.
  • the structure comprises a fiber-containing layer, and a barrier layer bonded to the fiber-containing layer.
  • the barrier layer includes mineral particles evenly dispersed in a matrix of a polyolefin bonding agent.
  • the barrier layer has a basis weight from about 4 lbs/3 msf to about 60 lbs/3 msf, a density from about 1.10 g/cm 3 to about 1.75 g/cm 3 , and a caliper from about 0.30 mil to about 3 mil.
  • the barrier layer may be extruded.
  • the fiber-containing layer may have a caliper from about 0.010′′ to about 0.030′′ and a basis weight from about 136 lbs/3 msf to about 286 lbs/3 msf.
  • the barrier layer may have a polyolefin content from about 30% to about 70% by weight.
  • the recyclable composite packaging structure may comprise about 1% to about 40% inorganic matter.
  • the recyclable composite packaging structure may comprise a total repulping recovery up to 98%.
  • the mineral particles may comprise diatomaceous earth with ultrafine nanoparticles having densities from about 2.4 g/cm 3 to about 4.9 g/cm 3 and particle sizes from about 100 nm to about 10 ⁇ m.
  • the polyolefin bonding agent may have molecular weights from about Mw 10,000 to about Mw 100,000 and a branching index (g′) from about 0.99 to about 0.65 as measured at the Z-average molecular weight (Mz) of the polymer.
  • the polyolefin bonding agent may have an isotactic run length from about 1 to about 40.
  • the polyolefin bonding agent may have a shear rate from about 1 to about 10,000 at temperatures from about 180° C. to about 410° C.
  • the mineral particles may be cube or block particles.
  • the mineral particles may have an average surface area from about 1-1.3 m 2 /g to about 1.8-2.3 m 2 /g.
  • the mineral particles may comprise calcium carbonate particles having from about 18%-80% particle diameters finer than 6 ⁇ m and from about 33%-96% particle diameters less than 10 ⁇ m and top cut from about d98 of 4-15 ⁇ m and a surface area from about 3.3 m 2 /g to about 10 m 2 /g, a surface treatment level from about 0.6% to about 1.5% by weight of treatment agent or about 99% by weight of the calcium carbonate.
  • the fiber-containing layer may comprise nano-cellulose having a crystalline content from about 40% to about 70%, including nano-fibrils, micro-fibrils, and non-fibril bundles having lateral dimensions from about 4 nm to about 30 nm and highly crystalline nano-whiskers from about 100 nm to about 1,000 nm, with fiber widths from about 3 nm to about 15 nm, having charge densities from about 0.5 meq/g to about 1.5 meq/g, and the nano-cellulose having a stiffness from about 140 GPa to about 220 GPa and a tensile strength from about 400 MPa to about 600 MPa.
  • Some of the mineral particles may contain fatty acid and stearate coatings having a Hunter reflectance (green) from about 91% to about 97%, a Hunter reflectance (blue) from about 89% to about 96%, a Mohs hardness from about 2.75 to about 4.0, a particle pH in water, 5% slurry, at 23° C., from about 8.5 to about 10.5, a particle resistance in water, at 23° C., from about 5,000 ohms to about 25,000 ohms, an ASTM D1199 maximum percentage on a 325 mesh from about 0.05 to about 0.5, a volume resistivity at 20° C. of 10 9 to about 10 11 ohms, a standard heat of formation from its elements at 25° C.
  • the fiber-containing layer may comprise vinyl and inorganic mineral coatings and fillers.
  • the fiber-containing layer may have a surface smoothness from about 1.50 to about 3.15, a smoothness from about 150 to about 200 Bekk-seconds, an ash content from about 1% to about 40% by weight, a static friction coefficient ⁇ s from about 0.02 to about 0.50, and a cellulose content having thermal conductivity from about 0.034 to about 0.05 W/mk.
  • Some virgin and recycled fiber types within the fiber-containing layer may include mechanical, thermo-mechanical, chemo-thermo-mechanical, and chemical having an average aspect ratio from about 5 to about 100, a softwood fiber thickness from about 1.5 mm to about 30 mm, a hardwood fiber thickness from about 0.5 mm to about 30 mm, a filled fiber content from about 1% to about 30%, a density from about 0.3 g/cm 3 to about 0.7 g/cm 3 , fiber diameters from about 16 ⁇ m to about 42 ⁇ m, a fiber coarseness from about 16 mg/100 m to about 42 mg/100 m, a permeability from about 0.1 ⁇ 10 15 m 2 to about 110 ⁇ 10 15 m 2 , a hydrogen ion concentration from about 4.5 to about 10, a Tappi 496, 402 tear strength from about 56 to about 250, a Tappi 414 tear resistance from about m49 to about m250, and a moisture content from about 2% to about 18% by weight.
  • the fiber-containing layer may comprise a combination of recycled fiber, virgin fiber, thermo-mechanical pulp “TMP,” virgin kraft fiber, clay coated craft fiber, clay coated unbleached kraft fiber, and solid bleached sulfate fiber.
  • the barrier layer may comprise Tappi T410 weights from about 5.5 g/m 2 to about 52.2 g/m 2 , Tappi T464 moisture barrier values from about 0.46 g/100 in 2 to about 37.7 g/100 in 2 , Tappi T441 Cobb 2-minute water absorption from about 0.00 to about 0.40, T441 30-minute water absorption from about 0.00 to about 0.45, and a Tappi T559 grease resistance of 12.0.
  • Certain of the present embodiments comprise a method of making a recyclable composite packaging structure including a fiber-containing layer and a mineral-containing layer.
  • the method comprises extrusion coating the mineral-containing layer onto the fiber-containing layer using a mineral-containing resin having mineral particles interspersed within a polyolefin bonding agent.
  • the extrusion process is carried out under the following conditions: the resin having a melt flow index from about 4 g/10 min. to about 16 g/10 min.; a melt temperature from about 440° F.
  • the mineral-containing resin may comprise between 20% and 70% mineral content by weight.
  • the mineral-containing resin may comprise pellets.
  • the mineral-containing layer may be applied to the fiber-containing layer in coat weights from about 4 lbs/3 msf to about 30 lbs/3 msf.
  • the recyclable composite packaging structure may not contain water-based dispersions, aqueous dispersions, aqueous coatings, emulsions, emulsion-containing coatings, water-containing dispersions, press-line applications, or off-line mixing processes.
  • the mineral-containing layer weighing from about 15 g/m 2 to about 50 g/m 2 , may be coextruded in line on an extrusion coating machine and bonded by extrusion to the fiber-containing layer.
  • the mineral-containing layer may have a density from about 1.22 g/cm 3 to about 1.41 g/cm 3 .
  • the mineral-containing layer may be from about 25% to about 75% amorphous and have a water vapor transmission rate (WVTR) under tropical conditions from about 5 gm/m 2 per day to about 22 g/m 2 per day.
  • WVTR water vapor transmission rate
  • FIG. 1 is a schematic side cross-sectional view of a multilayer repulpable packaging composite material according to the present embodiments
  • FIG. 1A is a detail view of the portion of FIG. 1 indicated by the circle 1 A- 1 A;
  • FIG. 2 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material according to the present embodiments
  • FIG. 3 is a schematic side cross-sectional view of a repulpable mineral-containing material according to the present embodiments
  • FIG. 4 is a schematic detail view of a pellet of a mineral-containing resin with mineral particles interspersed within a bonding agent according to the present embodiments;
  • FIG. 5 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material according to the present embodiments.
  • FIG. 6 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material according to the present embodiments.
  • FIG. 7 is a graph showing the stickies content of Sample 6# from Table 12;
  • FIG. 8 is a graph showing a total ion spectrum of DCM extract from a washout fraction of sample CLWR-2;
  • FIG. 9 is a container formed from a composite material according to the present embodiments.
  • FIG. 10 is a container liner formed from a composite material according to the present embodiments.
  • FIG. 11 is an envelope formed from a composite material according to the present embodiments.
  • FIG. 12 is a display tray formed from a composite material according to the present embodiments.
  • the present embodiments relate to methods and compositions providing repulpable and recyclable consumer packaging for containing, for example and without limitation, food products, dry goods, detergents, etc. More particularly, the present embodiments include using mineral-containing layer(s), minerals bonded by thermoplastic polymers and subsequently adhered to fiber-containing layer(s) using extrusion coating, extrusion lamination, or lamination adhering the mineral-containing layer continuously and substantially to the surface or surfaces of natural fiber-containing layers such that the finished package can be effectively repulped and recycled using both pre-consumer and post-consumer collection methods.
  • the present embodiments provide reusable pulp, thus offering reusability and reprocess ability into valuable recycled paper-containing packaging products.
  • the present packaging composites can be used to form one or more layers of all types of single-layer and multilayer packaging structures, e.g. folding cartons and the like, including single-wall or multi-wall corrugated structures using the composite packaging material as one or more inner or outer liner(s) and/or corrugated medium(s).
  • PE polyethylene
  • PP polypropylene
  • PVDC polyvinylidene chloride
  • various types of emulsion and aqueous coatings are applied to paper substrates for the same reason.
  • the present embodiments provide finished composite materials having high barrier performance, heat sealability, high performance adhesion to fiber, strength, repulpability, and low cost of manufacture.
  • barrier alternatives are considered by recycling (repulping) mills to be non-repulpable, mainly because they introduce quality problems in the fiber recovery process, either by upsetting the process, e.g. by plugging filter screens, or by contaminating the finished product.
  • Approximately 20% of known paperboards are laminated with the materials listed above, or similar materials, resulting in products that are incompatible within the recycling industry.
  • PET polyethylene terephthalate
  • PVDC barrier layers A major drawback to polyolefin and other polymer coatings, such as wax, acrylic, polyethylene terephthalate (PET) dispersions, and PVDC barrier layers, is that they are either difficult to reprocess or recycle and usually discarded, or they can only be processed at a recycling mill with specialized equipment, or, if processible, provide inferior barrier and heat seal performance for packaging articles such as cups or heat sealed folding cartons.
  • the disposal of moisture barrier packaging materials has become an important issue for paper mills and their customers. Repulping these materials poses special problems for
  • the packaging structure preferably provides a barrier for moisture, oxygen, oils, and fatty acids.
  • Other desirable characteristics include mechanical performance, aesthetics, cosmetics, resistance to chemicals, recyclability, heat sealability, surface energy, ink adhesion, ink wet-ability, film adhesion to fibers, improved surface for glue and adhesive application, and barrier performance (against oxygen, water, moisture, etc.). Therefore, extrusion coating fiber surfaces using polymers, (polyolefins being the most common) and bio-polymers is common practice.
  • the first method breaks up the source of wood fibers, such as packaging materials, by repulping, while other materials are filtered out.
  • the second method breaks up the packaging materials such that any non-fibrous material breaks up into tiny pieces (generally smaller than 1.6 mm), which then pass through the filter screen(s) with the wood fibers to constitute a pulp. This second method is frequently carried out with chemical additives and/or additional equipment, making it expensive and therefore undesirable.
  • mineralized layers when repulped break down into a preponderance of from about 35% to about 99% of much smaller and more dense fragments in sizes of from about 0.0005 mm 2 to about 2 mm 2 or larger, having densities from about 1.10 g/cm 3 to about 4.75 g/cm 3 .
  • These unique particles provide improved repulping and recycling processing benefits. Therefore, the mineral-containing layers can be applied successfully to fiber-containing layers with improved re-pulpability vs. polymer layers with mineral-containing layers applied in coat weights in the range of from about 4 lbs/msf (pounds per thousand square feet) to about 25 lbs/msf.
  • the processing of the mineralized layer composite material can be accomplished using industry standard repulping and recycling equipment, much of which is further described in this specification.
  • PVDC coating also has generally the same processing issues as PE. Further, other options such as emulsion and aqueous coating with vinyl content cannot provide comparable barrier performance or high performance heat sealability at low cost. Also, mixing at the point of manufacture is often required and single or multiple layers of vinyl plus separate layers for minerals, for example, may be required. Also, unlike polyolefins, barrier failure is quite common using these types of layers at points of package stress or fracture during converting or subsequent use. Finally, PVDC and related coatings provide major environmental toxic hazards and are therefore a poor option as a barrier layer.
  • non-fibrous barrier layers must be structurally brittle enough to break into small enough pieces to ensure the fibers efficiently release from the barrier layer and pass through the screen(s). Also, the pulped barrier layer fragments must not be too small to pass through the screen(s) and create process difficulties in the paper making machine. Finally, the pulped barrier layer pieces cannot be so large as to clog the screen(s) and foul the filtering process.
  • the mineral-containing polyolefin layer By introducing mineral content into a thermoplastic barrier layer using proper particle specifications and proper amounts of minerals added, the mineral-containing polyolefin layer obtains structural attributes providing for efficient, clean, and proper processing during the pulping process. Also, a 20%-70% mineralized layer easily releases fiber content through the screen(s), resulting in high fiber yields. Further, by using an extrusion coated thermoplastic, high speed, efficient production applying the barrier layer to the fiber can be enjoyed using common processes such as extrusion coating.
  • the thermoplastic content acts as a bonding agent for the particles, bonding the mineral particles together, fixing them in position in a compounded thermoplastic and mineral-containing resin pellet, heated at temperatures above 400° F., and extrusion coated in-line on a single piece of equipment and extrusion laminated on a single piece of equipment at high speeds from about 100 FPM (feet per minute) up to about 3,500 FPM on paper rolls up to and over from about 30′′ to about 140′′ wide.
  • the mineral-containing layer resin is extruded as a pre-mixed or master batch pellet, and as such the layer maintains its original integrity after extrusion. Therefore, unlike aqueous or emulsion coatings, no mixing is required prior to coating, and drying is not required during production at the point of printing and converting.
  • the mineralized polyolefin or polymer layer provides additional benefits, such as high speed heat sealing and improved barrier performance. Additional benefits may include an excellent surface for the application of room temperature and hot melt adhesives when forming a package and high levels of moisture, oil, and fatty acid barrier performance.
  • the fiber component of the repulpable composite may comprise softwood fibers, hardwood fibers, or a mixture thereof.
  • the paper substrate may comprise from about 5% to about 95% (such as from about 25% to about 90%) softwood fibers and from about 5% to about 95% (such as from about 25% to about 90%) hardwood fibers.
  • Paper substrates may also have, for example, a basis weight of from about 30 to about 200 lbs/3000 sq. ft and a caliper (thickness) of from about 0.006′′ to about 0.048′′.
  • the fibers are subjected to a cleansing and filtering process provided by one or more screens, thus removing unwanted materials from the re-pulped fiber.
  • Screen plates are commonly designed to be either hole, slotted, or contoured screens. The amount and type of rejected and removed material can have an impact on screen cleanliness. If the screens become clogged, they fail to function and must be cleaned, creating expensive downtime during processing.
  • the plates are normally found one behind another with an A plate having the smallest perforations, an intermediary B plate, and often a C plate having the largest perforations. Because of the size and conformation of plastic coating fragments generated during repulping, the plastic rejects clog and dirty the screening system, creating downtime and general inability to process efficiently.
  • the screen cleanliness efficiency achieved can be from about 60% to about 100%, including pressure screen devices.
  • the pressure drop expressed as Feed-Accept pressure, can range from about 2 kPa to about 12 kPa on smooth, contoured, or heavily contoured screens.
  • Post screen processing includes centrifugal cleaning of the screen accepts.
  • This pulp cleaning process uses fluid pressure to create rotational fluid motion in a tapered cylinder, causing denser particles to move outside faster than lighter particles.
  • Impurities such as dirt, metals, inks, sand, and any impurities are held in the downward current and removed from the bottom of the cleaner.
  • Mineral-containing layer impurities found in fiber accepts and rejects have a density of from about 1.01 g/cm 3 to about 4.25 g/cm 3 . Because the particles have large density differences from water, and size characteristics, the particles are effectively removed and cleaned from the accepts during cleaning.
  • the mineral-containing impurities process out of the fiber accepts efficiently in High Density, Forward, and Through Flow cleaners, the cleaners having a diameter of from about 70 mm to about 400 mm. Further, these particles process out of fibers having reject rates on or about 0.1-1% to about 5-30%. Additionally, because some particles are typically somewhat spherical in shape (CwAp) they separate more efficiently during centrifugal cleaning.
  • the particles are smaller in size and generally dense, they can often achieve a removal efficiency of from about 50% to about 95% by mass, particle sizes of from about 150 microns to about 0.05 microns using singularly or in combination, specific gravity activated centrifugal cleaners, flotation washers, and ultra-dispersion washing, the repulpable and recyclable composite material having a pulper consistency of from about 3% to about 30%, pulping temperatures of from about 100° F. to about 200° F., and pulping times of from about 10 minutes to about 60 minutes, with pulping pH from about 6 to about 9.5 ⁇ 0.5.
  • Process pressure screens can have holes from about 0.050′′ to about 0.075′′ with slots from about 0.006′′ to about 0.020′′.
  • Table 1 illustrates estimated repulpability ranges of a composite containing paper layer(s) combined with mineralized layer(s).
  • the chart is also applicable when using paper layer(s) fiber fine content from about 0.5% to 60% by weight of the paper.
  • This data is congruent using various pulping batch and continuous pulping methods including low consistency continuous, rotor de-trashing, drum pulping having 9-20 RPM, high consistency drum pulping, and drum pulping containing 4 mm to 8 mm holes, pulping consistency from about 3% to about 20%, also, using disk, pressure, and cylindrical screen types with hole type screen openings from about 0.8 mm to about 1.5 mm and slot and contoured type openings from about 0.1 mm to about 0.4 mm, further including coarse to fine screen holes and slots from about 0.150 mm to about 2.8 mm, and screen rotor circumference speeds from about 10 meters/second (m/s) to about 30 m/s.
  • diatomaceous earth mineral fillers and pigments are available for use within the repulpable mineral-containing layer within the composite structure including mica, silica, clay, kaolin, calcium carbonate, dolomite, and titanium dioxide to name a few.
  • the fillers offer improved performance for barrier, opacity, increased stiffness, thermal conductivity, and strength. Fillers are normally less expensive than polymers and are therefore a very economical component of the polymer layer.
  • the most commonly used mineral fillers have densities in the range of 2.4 g/cm 3 to 4.9 g/cm 3 .
  • Most polymers have densities in the range of 0.8 g/cm 3 to 1.85 g/cm 3 and many can be used as thermoplastic bonding agents.
  • Filler particles can vary in size and shape. Size can vary from 0.1 micron to 10.0 micron mean particle size.
  • An example of very fine mineral particles include nano-precipitated calcium carbonate which are less than 100 nanometers in size.
  • Ultrafine nanoparticles can range from 0.06 microns to 0.15 microns. These ultrafine particles are useful for controlling rheological properties such as viscosity, sag, and slump.
  • Mineral filler particles can have various shapes including e.g. spheres, rods, cubes, blocks, flakes, platelets, and irregular shapes of various proportions. The relationship between the particles' largest and smallest dimensions is known as aspect ratio. Together, aspect ratio and shape significantly impact the particles' effect in a composite polymer matrix.
  • particle hardness relates to coarseness, color to layer cosmetics and opacity.
  • Particle morphology suited for the present embodiments are primarily, but not limited to, the cube and block shapes of salt and calcite having the characteristics shown in Table 2, below. Examples of cubic structures include calcite and feldspar. Examples of block structures include calcite, feldspar, silica, barite, and nephelite.
  • Mineral particles also often have higher specific gravity than polymers. Therefore, the density increases cost through elevated weight. Many particles are surface treated with fatty acids or other organic materials, such as stearic acid and other materials to improve polymer dispersion during compounding. Surface treatments also affect dry flow properties, reduce surface absorption, and alter processing characteristics.
  • the specific gravity range potential of the minerals used in the present embodiments including pigments are from about 1.8 to about 4.85 g/cm 3 .
  • agglomerates act as flaws that can initiate crack formation and thus lower impact strength.
  • agglomerates are preferably less than about 30 microns to preferably less than about 10 microns in size.
  • Table 3 is a sample, but not limited to, extrusion coating production ranges for identified mineral-filled resins.
  • melt index measurements were stated under the guidelines of ASTM method D1238-04, and the density measured under the guidelines of ASTM standard method D1501-03.
  • Molecular chains in crystalline areas are arranged somewhat parallel to each other. In amorphous areas they are random. This mixture of crystalline and amorphous regions is essential to the extrusion of good extrusion coatings.
  • the crystals can act as a filler in the matrix, and so can mineralization, improving some mechanical properties.
  • a totally amorphous polyolefin would be grease-like and have poor physical properties.
  • a totally crystalline polymer would be very hard and brittle.
  • High-density polyethylene (HDPE) resins have molecular chains with comparatively few side chain branches. Therefore, the chains are packed closely together. Polyethylene, polypropylene, and polyesters are semi-crystalline. The result is crystallinity up to 95%.
  • Low-density polyethylene (LDPE) resins have, generally, a crystallinity ranging from 60% to 75%, and linear low-density polyethylene (LLDPE) resins have crystallinity from 60% to 85%.
  • Density ranges for extrusion coating resins include LDPE resins that range from 0.915 g/cm 3 to 0.925 g/cm 3 , LLDPE resins have densities ranging from 0.910 g/cm 3 to 0.940 g/cm 3 , and medium-density polyethylene (MDPE) resins have densities ranging from 0.926 g/cm 3 to 0.940 g/cm 3 .
  • HDPE resins range from 0.941 g/cm 3 to 0.955 g/cm 3 .
  • the density of PP resins range from 0.890 g/cm 3 to 0.915 g/cm 3 .
  • Addition of a mineral filler to the polymer results in a rise in viscosity.
  • the addition of filler may also change the amount of crystallinity in the polymer.
  • an increase in crystallinity also results in improved barrier properties, through increased tortuosity. This effect is expected to be prevalent for fillers that induce a high degree of transcrystallinity.
  • Some minerals can change the crystallization behavior of some thermoplastics and thus the properties of the polymer phase are not those of virgin material, providing novel characteristics during processing and in the performance of the finished composite structure. Thermoplastics crystallize in the cooling phase and solidify.
  • Solidification for semi-crystalline polymers is largely due to the formation of crystals, creating stiffer regions surrounding the amorphous area of the polymer matrix.
  • mineral fillers can act as nucleating agents, normally at higher temperatures. This process can provide mechanical properties in the polymer composite favorable to high barrier performance and adhesion to fiber surfaces without a detrimental effect on heat sealing characteristics.
  • Minerals can begin to significantly affect crystallinity when used from about 15% to about 70% by weight of the polymer composite.
  • Some of the factors influencing mechanical adhesion to paper include extrudate temperature, oxidation, and penetration into the fibers.
  • Mineral onset temperatures of the polymer extrudate influence cooling rate upon die exit to the nip roller, which can be adjusted by the extruder air gap setting. Other key factors include the mass of the polymers of the polymer interface layer. The crystalline onset temperatures vary, however, examples are shown in Table 4, below.
  • homogeneous blends of solid olefin polymers with varying densities and melt indexes can be mixed within the mineral composite layer, either interspersed or non-interspersed through coextrusion.
  • the mineral-containing composite layer can be applied and bonded substantially and continuously on at least a fiber-containing layer using extrusion or extrusion lamination, including blown film, cast, or extrusion coating methods.
  • Polymer content of the mineral-containing layer can be used as a tie layer for interspersed and non-interspersed constructions as well as particle bonding agents within each individual layer.
  • These bonding agents or tie layers can include individually, or in mixtures, polymers of monoolefins and diolefins, e.g.
  • ethylene/propylene copolymers linear low density polyethylene, and blends thereof with low density polyethylene, propylene but-1-ene, copolymers ethylene, propylene/isobutylene copolymers, ethylene/but-1-ene copolymers, ethylene/hexene copolymers, ethylene/octene copolymers, ethylene/methylepentene copolymers, ethylene/octene copolymers, ethylene/vinyelcyclohexane copolymers, ethylene/cycloolefin copolymers, COC, ethylene/1-olefin copolymers, the 1-olefin being produced in situ; propylene/butadiene copolymers, isobutylene/isoprene copolymers, ethylene/vinylcyclohexene copolymers, ethylene vinyl acetate copolymers, ethylene/alkyl methacrylate copolymers, ethylene/acrylic
  • epoxyacrylates, urethaneacrylates or polyesteracrylates and starch polymers and copolymers of such materials as poly lactic acids and its copolymers, cellulose, polyhdyroxy alcanoates, polycaprolactone, polybutylene succinate, polymers and copolymers of N-vinylpyrroolidone such as polyvinylpyrrrolidone, and crosslinked polyvinylpyrrolidone, ethyl vinyl alcohol.
  • thermoplastic polymers suitable for the mineral-containing composite include polypropylene, high density polyethylene combined with MS0825 Nanoreinforced FOSS polypropylene, thermoplastic elastomers, thermoplastic vulcinates, polyvinylchloride, polylactic acid, virgin and recycled polyesters, cellulosics, polyamides, polycarbonate, polybutylene tereaphthylate, polyester elastomers, thermoplastic polyurethane, cyclic olefin copolymer; biodegradable polymers such as Cereplast-Polylactic acid, Purac-Lactide PLA, Nec Corp PLA, Mitsubishi Chemical Corp GS PLS resins, Natureworks LLC PLA, Cereplast-Biopropropylene, Spartech PLA Rejuven 8, resins made from starch, cellulose, polyhydroxy alcanoates, polycaprolactone, polybutylene succinate or combinations thereof, such as Ecoflex FBX 7011 and Ecovio L Resins from BASF, polyvinylchloride and recycled
  • the mineral-containing layer can include coupling agents from about 0.05% to about 15% of the weight of the mineral-containing layer.
  • the agents aid in the mixing and the filling of the mineral into the polymer matrix.
  • Functional coupling groups include (Pyro-) phosphato, Benzene sulfonyl and ethylene diamino. These can be added to thermoplastics including polyethylene, polypropylene, polyester, and ethyl vinyl alcohol, aluminate, siloxane, silane, amino, malice anhydride, vinyl and methtacryl. The results of these combinations improve adhesion to fibers, heat seal strength, heat seal activation temperatures, surface energy, opacity, and cosmetics.
  • Mineral content can include, but is not limited to, wollanstonite, hydrated and non-hydrated, magnesium silicate, barium sulfate, barium ferrite, magnesium hydroxide, magnesium carbonate, aluminum trihydroxide, magnesium carbonate, aluminum trihydroxide, natural silica or sand, cristobalite, diaonite, novaculite, quartz tripoli clay calcined, muscovite, nepheliner-syenite, feldspar, calcium suphate-gypsum, terra alba, selenite, cristobalite, domite, silton mica, hydratized aluminum silicates, coke, montmorillonite (MMT), attapulgite (AT) carbon black, pecan nut flour, cellulose particles, wood flour, fly ash, starch, TiO2 and other pigments, barium carbonate, terra alba, selenite, nepheline-syenite, muscavite,
  • isotatic polybutylenes are relatively rigid at normal temperatures but flow readily when heated, and they most preferably, should show good flow when heated, expressed in melt flow.
  • Applicable isotatic polybutylenes should show a melt flow of from 0.1 to 500, preferably 0.2 to 300, more preferably from 0.4 to 40, most preferably 1 to 4.
  • Other polymers expressed within the contents of the present specification should also be considered within these parameters.
  • the layer of which can then be used to form a laminated structure of which the mineral-containing layer can be used as a peel coat onto a desired backing material.
  • the best peel seal for example, to the mineral-containing layer of the composite, may be selected from poly-4-methyl pentene, nylon, high-density polyethylene (HDPE), aluminum foil, polycarbonate polystyrene, polyurethane, polyvinyl chloride, polyester, polyacrylonitrile, polypropylene (PP), and paper.
  • An example extrusion process can be accomplished with a screw or pneumatic tube.
  • the mineralized polymers can be combined with such materials as plasticizers lubricants, stabilizers, and colorants by means of Banbury mixers.
  • the resulting mix is then extruded through rod shaped dies and chipped into pellets.
  • Pelletized mineralized polymer can then enhance the mineral and other content by “letting down” the resin pellet mix with inline or offline mixing capability before being fed into the end of a, for example, screw-type extruder, heated, and mixed into a viscous fluid or semi-fluid in the extruder barrel for further processing to the die.
  • the interaction between the mineral particles and the polymer content without covalent bonding results in improved van der Waals forces that provide attraction between the materials. This interaction results in some adhesion in the composite during extrusion, resulting in an absorbed polymer layer on the filler surface.
  • Molecular weight ranges of the polymer bonding agent component of the mineral-containing layer are from about Mw 10,000 to about Mw 100,000. Further, about 10%-70% of the polymer bonding agent may have a branching index (g′) of about 0.99 or less as measured at the Z-average molecular weight (Mz) of the polymer. Some, part, or all of the mineral-containing layer polymer bonding agent is preferred but not required to have an isotactic run length of from about 1 to about 40. Further, the polymer bonding agent of the mineral-containing layer has a shear rate range of from about 1 to about 10,000 at temperatures from about 180° C. to about 410° C.
  • nano-cellulose can be used in the mineral-containing composite layer having a crystalline content from about 40%-70%, including nano-fibrils, micro-fibrils, and nanofibril bundles, having lateral dimensions from about 0.4-30 nanometers (nm) to several microns, and highly crystalline nano-whiskers from about 100 to 1000 nanometers.
  • Nano-cellulose fiber widths are from about 3-5 nm and from about 5-15 nm, having charge densities from about 0.5 meq/g to about 1.5 meq/g, with the nano-cellulose having a stiffness from about an order of 140-220 GPa and tensile strength from about 400-600 MPa.
  • the mineral-containing interspersed or non-interspersed polymer composite layer can be substantially and continuously directly bonded to a fiber surface or to the fiber surface interface adhesive layer using extrusion coating or extrusion lamination.
  • the fiber-containing layer can contain inorganic mineral coatings and fillers, e.g. clay, kaolin, CaCO 3 , mica, silica, TiO 2 and other pigments, etc.
  • Other materials found in the fiber-containing layer include vinyl and polymeric fillers and surface treatments such as starch and latex.
  • Preferred characteristics of the fiber-containing layer bound to the mineral-containing layer include, but are not limited to, a smoothness range of about 150 to about 200 Bekk seconds, and an ash content from about 1% to about 40% by weight.
  • the fiber-containing layer coefficient of static friction, ⁇ is from about 0.02 to about 0.50.
  • Identified cellulose within the fiber-containing layer preferably has a thermal conductivity from about 0.034 to about 0.05 W/m ⁇ K.
  • the fiber content is preferably from about 40% to about 65% of the layer by weight.
  • Other preferred, but not limiting, characteristics of the fiber-containing layer are shown in Table 6, below.
  • Fiber Layer Characteristics Fiber Aspect Ratio Average
  • 5-100 Fiber Thickness Softwood
  • Fiber Thickness Hardwood
  • Fiber Thickness Hardwood
  • Fiber Thickness Hardwood
  • Fiber Diameter 16-42 microns
  • Fiber Coarseness 16-42 mg/100 m
  • Coextrusion methods provide the possibility for non-interspersed contact layers within the mineral-containing layer.
  • the finished composite structures can contain separate layers in the composite that can vary based on types of mineral and amount of mineral content per layer, degrees of amorphous and crystalline content per layer, and type of polymer resin and resin mixes per layer.
  • the more extruders feeding a common die assembly the more layered options become available to the non-interspersed mineral-containing layer.
  • the number of extruders depends on the number of different materials comprising the coextruded film.
  • a non-interspersed mineral-containing composite may comprise a three-layer to six-layer coextrusion including a barrier material core that could be, for example, a high density polyethylene and low density polyethylene mix having a 25% to 65% mineral content by weight in the first base layer, this layer making contact with the fiber surface.
  • a barrier material core that could be, for example, a high density polyethylene and low density polyethylene mix having a 25% to 65% mineral content by weight in the first base layer, this layer making contact with the fiber surface.
  • Subsequent layers may contain differing mineral contents, neat LDPE, or polypropylene.
  • Another example is a six-layer coextrusion including a bottom layer of LDPE, a tie-layer resin, a 20% to 65% mineral-containing polypropylene barrier resin, a tie-layer, and an EVA copolymer layer, and a final layer of polyester.
  • Any mineral-containing barrier layer according to the present embodiments may have a basis weight from about 4 lbs/3 msf to about 60 lbs/3 msf, a density from about 1.10 g/cm 3 to about 1.75 g/cm 3 , and/or a caliper from about 0.30 mil to about 3 mil.
  • Tie-layers often are used in the coextrusion coating of multiple layer constructions where mineral-containing polymers or other resins would not bond otherwise, and tie-layers are applied between layers of these materials to enable desired adhesion.
  • Another example multilayer film construction is 25%-65% mineral content LLDPE/tie-layer/EVOH barrier/tie-layer/EVA. Interspersed, e.g.
  • monolayer, and non-interspersed, e.g. multilayer, coextrusions can comprise from one to six layers of the mineral-containing layer substantially and continuously bonded across the surface of a fiber-containing layer.
  • Layers can be designed to improve hot tack, heat-sealability, seal activation temperature, and extrudate adhesion to fiber, mineral enhancement of barrier performance, surface energy, hot and cold glue adhesion improvements, etc.
  • Table 7, below, shows example layer constructions (not limited to) found in the mineral-containing resin and extrusion coated or laminate composite structure.
  • the preferred single layer ranges contain from about 0% to about 65% by weight mineral content, from 25%-80% amorphous to 25%-80% crystalline structure by weight, and 25%-65% cellulose, nano-cellulose, or nano-minerals by weight.
  • the mineral content of the mineral-containing layer(s) may comprise different fillers with different densities, size, and shape depending upon the desired outcome of the final composite structure.
  • Example 1 Example 2
  • Example 3 Example 4
  • Example 5 Example 6 Monolayer (1) LDPE HDPE LDPE-HDPE resin LDPE-MMW LLDPE-LDPE PLA- bio blend HDPE resin resin blend derived starch blend based resin blend Monolayer (2) Bio-derived, LDPE-bio LDPE-LLDPE-bio LDPE-HDPE- PP-bio derived ULDPE- starch derived starch derived starch blend LLDPE- blend starch based HDPE-bio polymer polymer blend polymer blend derived starch blend polymer blend 3-Layer HDPE- HDPE-PP HDPET LDPE-PP LLDPE-PET EVA-LDPE LDPE 4-Layer EVA- HDPE-EVA- Biaxially oriented Oriented EVA-PE- PVC-ABS- ethylene Ionomer resin- homopolypropylene- polypropylene- MMWHDPE- PC Nylon vinyl acetate Polyamide
  • the following resins are possible, but not limiting, bonding agents for these materials: carboxy-polymethyelene, polyacrylic acid polymers and copolymers, hydroxypropylcellulose, cellulose ethers, salts for poly(methyl vinyl ether-co-maleic anhydride), amorphous nylon, polyvinylchrloride, polymethylpentene, methyl methacrylate-acrylonitrile-butadiene-styrene, acrylonitrile-styrene, poly carbonate, polystyrene, poly methylcrylate, polyvynl pyrrolidone, ply (vinylpyrrolidone-co-vinyl acetate), polyesters, parylene, polyethylene napphatalate, ethylene vinyl alcohol, and polylactic acids containing from about 10% to about 65% mineral content.
  • Various mineral-containing layer polymer and mineral content can be determined based upon performance and content requirements considering the parameters shown in Table 7, above. Branched, highly branched, and linear polymer combinations are possible in all composite layer constructions. Examples are shown in Table 7 (not limited to combinations within the table) of the interspersed and non-interspersed mineral-containing layer constructions, not including tie layers. Layer combinations depend on coextrusion die design, flow properties, and processing temperature, allowing for coextrusion fusion layers and/or subsequently extrusion laminating or laminating the layers into the final mineral-containing composition, of which individual (non-interspersed) or total combination of layers have by weight mineral content of about 20%-65%.
  • Layers can be uniaxially or biaxially oriented (including stretching) from about 1.2 times to about 7 times in the machine direction (MD) and from about 5 times to about 10 times in the cross-machine (transverse) direction (CD), and stretched from about 10% to about 75% in both the MD and CD directions.
  • polyolefin mineral content bonding agents have number average molecular weight distributions (Mn) of from about 5,500 to about 13,000, weight average molecular weight (Mw) of from about 170,000 to about 490,000, and Z average molecular weight (Mz) of from about 170,000 to about 450,000.
  • a coextruded mineral-containing layer may differ in molecular weight, density, melt index, and/or polydispersity index within the finished layer structure.
  • the polydispersity index is the weight average molecular weight (Mw) divided by the number average molecular weight (Mn).
  • Mw weight average molecular weight
  • Mn number average molecular weight
  • the mineral-containing layer may have a Mw/Mn ratio of from about 6.50 to about 9.50.
  • wet or dry ground CaCO 3 as an example, it can be surface treated at levels from about 1.6 to about 3.5 mg surface agent/m 2 of CaCO 3 . The surface treatment can be applied before, during, or after grinding.
  • Mean particle sizes range from, without limitation, about 0.7 microns to about 2.5 microns, having a top cut from about d98 of 4-15 microns, and a surface area of from about 3.3 m 2 /g to about 10.0 m 2 /g.
  • the CaCO 3 mineral content can be coated with fatty acids from between, without limitation, about 8 to about 24 carbon atoms.
  • the preferred surface treatment range is about 0.6% to about 1.5% by weight of treatment agent or about 90%-99% by weight of CaCO 3 .
  • Polyolefin bonding agents having lower molecular weights and high melt index provide improved downstream moisture barrier characteristics.
  • Preferred mineral layer content could include finely divided wet ground marble with 65% solids in the presence of a sodium polyacrylate dispersant, dried, and surface treated, and also dispersant at 20% solids, dried, and surface treated.
  • MVTR/WVTR moisture vapor transmission rates and water vapor transmission rates
  • TAPPI Test Method T-464 orienting the barrier coating toward the higher humidity of the chamber atmosphere, when it is present on the surface.
  • TAPPI Test Method T-464 the standard short (2 minute) and long (20 minute) Cobb test is often used.
  • oil two tests are commonly used. The first is the 3M kit test per TAPPI T-559 standards, coating film weight as measured by TAPPI 410 standards. The second is red dyed canola oil and castor oil exposure to the coating surface using a 2-minute and a 20-minute Cobb ring.
  • Extruded mineral-containing interspersed and non-interspersed composite layers of the present embodiments demonstrate high barrier performance characteristics when substantially and continuously bonded to fiber-containing layers.
  • the fiber-containing layers may include in their composition or surface, but are not limited to, mineral and polymeric sizings, surface treatments, coatings, and mineral fillers.
  • Some advantages of the non-fiber content of the fiber-containing layer include improved fiber layer printability, ink hold out, dynamic water absorption, water resistance, sheet gloss, whiteness, delta gloss, pick strength, and surface smoothness.
  • mineral content contained within or upon one or more opposing surfaces of the fiber-containing layer can include, but is not limited to, clay, calcined clay, or combinations thereof.
  • the minerals are frequently applied to the surface of the fiber-containing layer through a blade or air coating process.
  • Common mineral binding methods include the use of protein systems such as a mixture of vinyl acrylic/protein co-binders.
  • Another non-limiting example is tri-binder systems, e.g. SB/Pvac/Protein.
  • pigments such as TiO 2 can be included to improve whiteness characteristics.
  • the nature of the fiber layer's mineral and binder content can impact the selection of the non-interspersed and interspersed mineral-containing layer characteristics when bonded substantially and continuously to one or more sides of the fiber-containing layer(s), which comprise part of the composite structure.
  • non-fiber content in the fiber-containing layer examples include, but are not limited to, 50%-95% of #1 clay or #1 fine clay, 3%-20% by part calcined clay, 3%-40% by part TiO 2 , 2%-45% vinyl acrylic, and from about 1% to about 35% protein binders, co-binders, or tri-binders.
  • the fiber-containing layer surfaces can have from about 55% to about 88% TAPPI 452 surface brightness.
  • Surface roughness values are based upon Parker Print Surf ( ⁇ m) and Bendtsen (mls/min) per TAPPI T-479 (moderate pressure), TAPPI T-538, and TAPPI 555 (print-surf method). Tear resistance per TAPPI T-414 standards are expressed in millinewtons (mN).
  • Surface brightness is expressed per TAPPI 452. Burst strength is expressed per TAPPI 403 standards.
  • Internal bond strength or interlayer strength of the fiber-containing layer is an important characteristic as represented by TAPPI T-403 and T-569.
  • Preferred fiber-containing layer internal strengths are, but are not limited to, from about 125 J/m 2 to about 1150 J/m 2 .
  • fiber-containing layer Z-direction tensile strength per TAPPI T-541 testing standard is from about 45-50 Nm/g to about 950 Nm/g.
  • preferred, but non-limiting, fiber-containing layer air resistance per TAPPI 547 is from about 0 to about 1500 mls/min, as represented by the Bendsten method.
  • Table 9 displays finished composite board barrier performance ranges, but is not limited to, that of a composite structure having from about 20% to about 70% mineral-containing layer bonded to at least one side of a fiber-containing layer.
  • the mineral-containing layer can be either a dispersed monolayer or non-interspersed coextrusion, for example.
  • Table 10 shows the barrier performance of a formed composite having a monolayer HDPE-PE mix with a density from about 0.925 gm/cm 3 to about 0.960 g/cm 3 and containing from about 36% to about 45% mineral content by weight.
  • Table 11 shows projected moisture barrier performance (MVTR, WVTR) for the present embodiments, comparing a coextruded mineral-containing layer bonded to a surface of a fiber-containing layer, the mineral-containing layer having both a monolayer and a multilayer (coextrusion) construction.
  • the fiber-containing layer in Table 11 lists Klabin virgin kraft fiber. However, the data is applicable to a range of both virgin and recycled fiber surfaces to include similar various weights and densities known in the art. Maximum MVTR via coextrusion is projected to be about the values in Table 11 in mineral-containing layers down to about 12 g/m 2 layer weight. The data illustrates two different MVTR values. The first value is coextrusion.
  • Coextrusion can provide superior results because of the flexibility to alter the type of polymers used per layer, density, branched or linear molecular nature, as well as crystallinity, among others. Also, because of stress fracturing found in more monolayer constructions as a result of bending, scoring, and processing, performance improvements using coextrusion are possible.
  • the base layer in the coextrusion can be more dense and crystalline, for example, than the outer layer, which is more amorphous and light density and more linear, thus not as vulnerable to stress fracture within the matrix, preventing percolation through the layer.
  • Other options for improving processing include additives to the mineral-containing blend, which include, but are not limited to, elastomers.
  • FIG. 1 is a schematic side cross-sectional view of a multilayer repulpable packaging composite material 20 according to the present embodiments.
  • the illustrated embodiment includes a mineral-containing layer 22 having an outer or heat-sealable surface 24 .
  • FIG. 1A is a detail view of the portion of FIG. 1 indicated by the circle 1 A- 1 A.
  • a plurality of mineral particles 26 are interspersed within a bonding agent 28 , which may be a thermoplastic.
  • the mineral-containing layer 22 may be substantially and continuously bonded to a first surface 30 of a fiber-containing layer 32 .
  • Another mineral-containing layer 22 may be substantially and continuously bonded to a second surface 34 of the fiber-containing layer 32 , the second surface 34 being opposite the first surface 30 .
  • the fiber-containing layer 32 includes a plurality of fiber particles 36 interspersed within a bonding agent 38 , which may be a thermoplastic.
  • the thermoplastic bonding agent of either or both of the mineral-containing layer 22 and the fiber-containing layer 32 may comprise, for example and without limitation, polyolefin, polyester, or any other thermoplastic or polymer-containing resins.
  • the mineral-containing layer(s) 22 may include about 30% to about 65% minerals, and the minerals may comprise any of the minerals described throughout this specification and combinations thereof.
  • the mineral-containing layer(s) 22 may be adhered to the fiber-containing layer 32 through coextrusion, extrusion-lamination, or any other suitable method or process. Extrusion-lamination may comprise a separately applied adhesive between the mineral- and fiber-containing layers.
  • the composite material 20 illustrated in FIG. 1 may advantageously be used as a single or multiple corrugate liner(s) or medium(s) within a single-layered or multilayered corrugated structure.
  • FIG. 2 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material 40 according to the present embodiments.
  • the illustrated embodiment includes a mineral-containing layer 22 substantially and continuously bonded to the first surface 30 of a fiber-containing layer 32 .
  • the second surface 34 of the fiber-containing layer 32 is not bonded to a mineral-containing layer 22 .
  • FIG. 3 is a schematic side cross-sectional view of a repulpable mineral-containing material according to the present embodiments.
  • the illustrated embodiment includes a mineral-containing layer 22 having both the first and second surfaces 30 , 34 uncovered by a mineral-containing layer 22 .
  • FIG. 4 is a schematic detail view of a pellet 42 of a mineral-containing resin with mineral particles interspersed within a bonding agent, according to the present embodiments. Pellets such as that illustrated in FIG. 4 may be used in an extrusion process to adhere the mineral-containing layer 22 and the fiber-containing layer 32 to one another. With reference to FIG. 4 , the mineral particles 26 are interspersed within the bonding agent 28 within the pellet 42 .
  • FIG. 5 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material according to the present embodiments.
  • the illustrated embodiment includes a first mineral-containing layer 22 substantially and continuously bonded to the first surface 30 of a fiber-containing layer 32 .
  • a second mineral-containing layer 44 is substantially and continuously bonded to the second surface 34 of the fiber-containing layer 32 .
  • the second mineral-containing layer 44 comprises three layers or plies of the first mineral-containing layer 22 .
  • the first and second mineral-containing layers 22 , 44 may be secured to the fiber-containing layer 32 through any of the processes described herein, such as coextrusion, extrusion-lamination, etc., or through any other process.
  • the plies 22 of the second mineral-containing layer 44 may be secured to one another through any of the processes described herein, such as coextrusion, extrusion-lamination, etc., or through any other process.
  • One or more of the plies 22 may comprise a mineral content and/or a bonding agent that is different from the mineral content and/or the bonding agent of another one or more of the plies 22 .
  • the illustrated embodiment in which the second mineral-containing layer 44 comprises three layers or plies 22 is only one example.
  • the second mineral-containing layer 44 may have any number of layers or plies 22 , such as two layers or plies, four layers or plies, five layers or plies, etc.
  • the fiber-containing layer 32 may have a multilayer mineral-containing layer 44 adhered to both the first and second surfaces 30 , 32 .
  • FIG. 6 is a schematic side cross-sectional view of another multilayer repulpable packaging composite material 46 according to the present embodiments.
  • the material 46 of FIG. 6 includes multiple layers of any of the material layers described herein, such as a first dual layer 48 and a second dual layer 50 with a corrugated layer 52 therebetween.
  • the composite materials illustrated in the foregoing figures and described above are well-suited for use as packaging materials, such as for packages for containing one or more products.
  • packages may comprise folding cartons and/or boxes.
  • the package material has high performance heat seal characteristics, elevated barrier performance, is repulpable, and provides excellent cosmetics and favorable economics.
  • the present composite materials can also be used as components, or layers, of multilayer packaging structures, such as corrugated boxes, and/or be used as a single-layer or multilayer corrugated liner or medium.
  • a 38.5% by weight mineralized HPDE-PE resin containing additives was compounded using wet ground and coated for dispersion finely ground within a range of about approximately 5-14 micron mean particle sized limestone-originating CaCO 3 particles with incremental crystalline silica content within a range of from about 0.2% to about 3.5%.
  • the specific heat of the ground CaCO 3 particles was from about 0.19 to about 0.31 kcal/kg ⁇ ° C.
  • the HDPE had a density within a range of about 0.939 to about 0.957 g/cm 3 and the PE had a density of from about 0.916 g/cm 3 to about 0.932 g/cm 3 .
  • the HDPE-PE bonding agent had a melt flow index of 14 g/10 minutes.
  • the finished and pelletized mineralized compound had an approximate density within a range of about of 0.125 to about 1.41 g/cm 3 .
  • the compound was coextruded using the mineralized HDPE-PE composite layer as a base layer applied at 22 g/m 2 coating thickness contacting the uncoated side of 320 g/m 2 weight Klabin virgin paper surface having a TAPPI T-441 Sheffield Smoothness of 74, a 7.5% moisture content, and a TAPPI T 556 MD-CD Taber Stiffness of 39.9 and 17.4, respectively.
  • the minor layer, or top facing, outer, polymer bonding agent mineral-containing layer of the coextrusion was about 8 g/m 2 weight having a mineral content from about 4% to about 65%, the base layer being predominately crystalline using the top layer to provide additional moisture barrier at box bend, scoring, and folding joints.
  • the extrusion processing condition melt temperature for the base layer was within a range of approximately 560° F. to 610° F. with barrel temperatures from zone one to zone six from about 405° F. to 600° F. Base layer die temperature zones were approximately 575° F. to 600° F.
  • the extruder die gap setting was within the range of 0.025′′-0.046′′. Unfilled Westlake® brand top neat PE mineral-containing layer processing was consistent with neat LDPE.
  • the extruder air gap was approximately 4′′-10′′, providing sufficient base layer oxidation and excellent adhesion use gas pre-heat, but without ozone or primer layers.
  • the extrusion line speeds were within the range of 150-600 meters per minute across a fiber web with within 50′′-118′′ range.
  • Post corona treatment was used.
  • Roll stock was in-process quality control checked for adhesion using “tape” testing and saturated for pin holing. Coat weight testing was done consistently using lab instrumentation. Finished and coated roll stock was rewound and sent for converting. Successful converting and packaging article forming, e.g. folding cartons/boxes, were done up to eight months post-extrusion coating.
  • the roll stock was run on high speed detergent box production lines at speeds from about 100 to 500 cartons per minute.
  • the enclosed detergent being sensitive to moisture exposure, was shipped in tropical moisture conditions.
  • Glue seams and small, medium, and large carton sizes were successfully formed having sufficient fiber tear, meeting standards with both room temperature and hot melt adhesives, including the manufacturer's seam.
  • Moisture barrier testing was completed for large size sampling sizes, which included full converted and formed case samples having MVTR performance of 13.91 g/m 2 /24 hours with a minimum of 13.03 g/m 2 /24 hours, with a standard deviation of 0.86.
  • a 43.5% by weight mineralized PE resin containing additives was compounded using wet ground and coated with fatty acid-containing materials for dispersion and finely ground approximately 4-12 micron mean particle sized limestone-originating CaCO 3 particles with incremental crystalline silica content of less than from about 0.2% to about 5%.
  • the resin blend also had 5% by weight titanium dioxide (TiO 2 ) for a total mineral content of from about 48.5% by weight.
  • the specific heat of the ground CaCO 3 particles was 0.21 kcal/kg ⁇ ° C.
  • the PE had a density of 0.919 g/cm 3 to about 93.1 g/cm 3 .
  • the PE bonding agent had a melt flow index of 16 g/10 minutes.
  • the finished and pelletized mineralized compound had an approximate density of 1.38 g/cm 3 .
  • the compound was then extruded using the mineralized PE and TiO 2 composite layer as a mono layer applied at 32 lbs/3 msf coating weight contacting the uncoated side of Rock Term AngelCote® approximately 100% recycled fiberboard with a nominal basis weight of 78 lbs/msf, with the paper surface having a TAPPI T-441 Sheffield Smoothness of approximately 68-72, a 5% to 7.5% moisture content, and a TAPPI T 556 MD-CD Taber Stiffness g-cm of 320 and 105, respectively.
  • the extrusion processing condition melt temperature was approximately 585° F. with barrel temperatures from zone one to zone six from about 400° F.
  • Moisture barrier testing was completed for large size sampling sizes, which included full converted and formed case samples having MVTR performance of 12 to 16 g/m 2 /24 hrs @ 100% humidity in tropical conditions with mineral composite layer coat weights from 12 lbs/3 msf to 16 lbs/3 msf.
  • Example 3 illustrates three different finished repulpable composites containing bleached virgin board SBS paper within a caliper range from about 0.014′′ to about 0.028′′ having a mineral-containing layer extrusion-coated to the fiber-containing layer. These composites were analyzed for ash content with Tappi standard T211, and for repulpability using an in-house procedure developed by the Georgia Institute of Technology. Results indicated that ash content varied from about 2.21% up to about 21.44%. Screen yield and overall recovery seem to depend at least in part on ash content of the starting paper.
  • the PE had a density from about 0.919 g/cm 3 to about 93.2 g/cm 3 .
  • the PE bonding agent had a melt flow index of 16 g/10 minutes.
  • the finished and pelletized mineralized compound had an approximate density from about 1.34 g/cm 3 to about 1.41 g/cm 3 .
  • the compound was then extruded as a mono layer substantially and continuously applied on the fiber-containing layer at from about 7.5 lbs/3 msf to about 16 lbs/3 msf layer weight contacting the uncoated side of International Paper Fortress SBS and Clearwater Paper Candesce SBS having approximately 89% to approximately 100% bleached virgin fiberboard with nominal basis weight from about 182 lbs to about 233 lbs, with the paper surface having a TAPPI T-441 Sheffield Smoothness of approximately 68-72, a 5% to 7.5% moisture content, and a TAPPI T 556 MD-CD Taber Stiffness g-cm above 375 and 105, respectively.
  • the extrusion processing condition melt temperature was from about 565° F.
  • the extruder die gap setting was within the range of about 0.020′′-0.040′′.
  • the extruder air gap was approximately 4′′-16′′, providing excellent extrudate to fiber adhesion without a gas pre-heat, ozone, or primer layers.
  • the extrusion line speeds were within the range of 150-1600 feet per minute across a 55′′-118′′ web width. Post corona treatment was used. Roll stock was in-process quality control checked for adhesion using “tape” testing and saturated for visual pin holing. Post production coat weight testing was done consistently using lab instrumentation.
  • Finished and coated roll stock was rewound and sent for converting. Successful converting and packaging forming was done up to three months post-extrusion coating. During converting, the roll stock was run for use in high barrier MVR requirement frozen seafood box production lines at speeds up to 250-500 boxes per minute, and cupstock as well as ice cream packaging material converted from about 150 to about 600 formed units per minute. The finished composite material was formed, bent, scored, and machined at standard production rates. The mineral-containing surface layer was efficiently offset printed using standard industry inks and aqueous press coatings. The mineral coating layer was highly opaque and maintained the fiber layer brightness of the base paper surface from about 80 to about 90 bright.
  • the mineral layer had a post corona treatment resident dyne level range of 42-56 as measured during post-production testing.
  • Moisture barrier testing was completed for large size sampling sizes, which included full converted and formed case samples having MVTR performance of about 8 g/m 2 /24 hrs to about 16 g/m 2 /24 hrs @ 100% humidity in tropical conditions with mineral composite layer coat weights from about 7.5 lbs/3 ms to about 16 lbs/3 msf.
  • Packages were closed and sealed using standard heat seal procedures found on cup forming and folding carton production lines.
  • Ash content was measured following Tappi standard T413. The time at maximum temperature was extended to eight hours to ensure complete ash.
  • the collected substances were plastics plus acid insoluble inorganics (ash), which was determined by the procedure stated under heading 1 above.
  • the fiber content was calculated from the weight difference of starting materials and substances after hydrolysis minus the acid soluble inorganics.
  • This portion of inorganics was determined from the ash content stated under heading 3 above, minus acid insoluble inorganics.
  • the plastics were the weight difference of acid insoluble substances minus acid insoluble inorganics.
  • Coated paper board and product are repulped and recovered in three fractions: accepts, rejects, and wash-out.
  • the oven dry weight of each fraction, along with the accepts yield and overall yield, are listed in Table 14, below.
  • compositions of the fractions are divided into three categories: fibers, plastics and inorganics which may come from the fillers in the base paper and the mineral coatings in the coating layers.
  • fibers, plastics and inorganics can be distinguished and quantified. This is based on the fact that fibers are composed of carbohydrates and they are readily hydrolyzed in sulfuric acid solution under elevated temperature. Plastics, however, are generally resistant toward such hydrolysis and will be recovered as insoluble substances. In the ashing process, both fibers and plastics will be burnt out. Inorganics survive this process and are recovered as ash.
  • Table 15 lists the experimental results indicating the percentage of each fraction in each sample.
  • Sample IP Mix, CLWR-2 and CLWR-8.1 have increasingly amounts of inorganics in the rejects. It is not known if these inorganics are closely packed inside the plastics or presented as separated particles. In the washout, the fibers are the major components, especially in sample CS-1 and IP MIX. Sample CLWR-2 and CLWR-8.1 have increasingly amounts of inorganics, probably presented as colloid particles in the washing liquor.
  • Impurities in the accepts are the major concern in the recycled pulp fibers.
  • composition analysis in section 2 provides information regarding these impurities, a visualized analysis can provide more subtle features of the impurities.
  • Stickies analysis (some of the particles could also be referred to as “dirties”) is thus performed to reveal the particle content and their size distribution.
  • Table 16 stickie count is represented as a number of stickies contained in the accepts sampling prior to any further processing. Therefore, the 3 gram hand sheets subsequently made from the accepts fibers contained 100% of the stickies and other miscellaneous particles in the accepts immediately after pulping but before further cleansing or processing such as cleaning, flotation, etc.
  • the hand sheets are pressed and dried at 350° F. and 500 psi on a Carver press for 5 minutes and tested for performance consistent with TAPPI T 537, TAPPI T277, TAPPI T 220, TAPPI 815, TAPPI T 826, TAPPI T 403, TAPPI T 831 and TAPPI T563. It is contemplated that the values shown in Table 16 above may vary by about ⁇ 50%.
  • Results shown in FIG. 7 indicate that contents of stickies in both CLWR-2 and CLWR-8.1 are comparable.
  • Particle size distribution plots indicate that all the stickies have a size less than 0.4 mm 2 . All particles having an area less than 0.05 mm 2 are dominant, with approximately 80% or more of the particles 0.0015 mm 2 or less. This result, however, is highly in line with what have been observed the accepts for each sampling. Since no further processing e.g.
  • the mineralized board testing samples CS-1, IP MIX, CLWR 8.1 CLW 2 and the handsheets would be considered fully recyclable fibers based on structural, cosmetic, and other considerations including processability within about pH 6 to 8 ⁇ 0.5 pH levels, fiber processing temperature levels from about 110° F. to about 135° F., pulper consistency from about 1.2 to 30%, pulping time from about 10 minutes to about 40 minutes, fiber on fiber yield from about 60% to about 95% and hand sheet drying temperatures in the range of about 240° F.
  • Rosin is a collective name given to a group of chemicals including abietic acid, pimaric acid, isopimirc acid, palustric acid, dehydroabietic acid, etc.
  • the rosin used in the paper making process can also be oxidized into different forms. Nonetheless, the acids are readily extracted by using DCM in acidic medium, and can be easily separated by using a neutral GC capillary column.
  • FIG. 7 Results of GC/MS analysis to the three fractions from sample CLWR-2 and CLWR-8.1 are shown in FIG. 7 .
  • FIG. 8 illustrates a typical total ion spectrum of the DCM extract.
  • the rosin acids are separated completely by GC. Judged from the peak area, the fibers fraction contains the highest amount of rosin, following by the washout and the rejects. It is contemplated that the values shown in FIG. 8 may vary by about ⁇ 50%.
  • Starch's whereabouts among the three fractions is determined by iodine detection. It is well known that starch will turn the iodine-contained solution into blue color. Based on this phenomenon, starch is found in both the fibers fraction and washout fraction, but not in the rejects fraction, as indicated in Table 3.
  • the majority of the stickies can be defined as “micro-stickies” as they particles sizes fell beneath 150 microns in size and above 0.001 micron in size. Because of the benign nature of the stickie composition, it is expected they will have little tendency to stick or adhere to equipment during processing. The data indicated that the rosin acids were found in almost all three fractions, but most of them associated with the accepts and the wash-out. An iodine detect technique found that the starch was in the accepts and the wash-out, and the rejects was practically starch-free.
  • FIG. 9 illustrates a container comprising a box 60 .
  • the box 60 may have many applications, such as, without limitation, retail and shipping.
  • the box 60 may be in the form of a cube or other parallelepiped that is sized to contain an item for retail sale and/or shipping.
  • the box 60 may be formed by preparing the composite structure in the form of a pliable sheet, for example by performing a milling step and/or other processing steps as described above, cutting the structure into a desired shape, and then folding and/or creasing the sheet, either manually or by machine, such as via an automated cartoning process, to form the final three-dimensional box shape.
  • Abutting surfaces of the box 60 may be secured to one another using the various heat seal processes described herein and/or other heat seal processes known in the art.
  • the composite structure forms the walls of the box 60 , including a bottom wall 62 , one or more side walls 64 , as well as a fold-over lid portion 66 .
  • the composite structures described herein may be formed into a container liner 70 for retail and/or shipping use, as shown in FIG. 10 .
  • the liner 70 may be used to line a shipping or retail container 72 to cushion and/or protect a product held in the container 72 , as well as to provide moisture resistance and deter infiltration of rodents and other pests.
  • the liner 70 formed of the composite structure may be sufficiently flexible and pliable such that it is capable of at least partially conforming to the shape of the container 72 .
  • the composite structures described herein may be formed into a shipping mailer 80 , such as an envelope, which may be used to ship documents and/or other items, as shown in FIG. 11 .
  • the composite structure may be used to form a part of or even all of the mailer structure 80 , and may be fabricated by using a series of folding, creasing, and/or adhesive/heat seal steps to prepare the desired mailer shape.
  • the composite structures described herein may be formed into a display tray 90 and/or other sales displays, as shown in FIG. 12 .
  • the composite structure may be cut, shaped, and/or folded into the shape of a display tray 90 capable of holding and displaying products for retail sale.
  • the composite structure can be molded by bending and/or folding, as well as via thermo- and/or vacuum-forming to form desired parts of the display 90 .

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  • Laminated Bodies (AREA)
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US14/211,132 2013-03-14 2014-03-14 Repulpable and recyclable composite packaging articles and related methods Abandoned US20140272352A1 (en)

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US16/417,364 US11466138B2 (en) 2013-03-14 2019-05-20 Repulpable and recyclable composite packaging articles and related methods
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US15/487,928 Active 2034-04-15 US10421848B2 (en) 2013-03-14 2017-04-14 Repulpable and recyclable composite packaging articles and related methods
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