Lightweight Paper Board

• US 20190376234A1
• Filed: 02/13/2018
• Published: 12/12/2019
• Est. Priority Date: 02/15/2017
• Status: Active Grant

• Current Assignee: Flex R&D Inc.
• Original Assignee: Flex R&D Inc.
• Inventors: MALLYA, PRAKASH
• Granted Patent: US 10,640,925 B2
• Time in Patent Office: Days
• CPC Class Codes: D21F 11/002 by using a foamed suspension
• CPC Class Codes: D21H 11/10 Mixtures of chemical and mechanical pulp
• CPC Class Codes: D21H 11/18 Highly hydrated, swollen or fibrillatable fibres
• CPC Class Codes: D21H 11/20 Chemically or biochemically modified fibres
• CPC Class Codes: D21H 17/55 Polyamides; Polyaminoamides; Polyester-amides
• CPC Class Codes: D21H 21/18 Reinforcing agents
• CPC Class Codes: D21H 21/20 Wet strength agents
• CPC Class Codes: D21H 21/22 Agents rendering paper porous, absorbent or bulky
• CPC Class Codes: D21H 21/24 Surfactants
• CPC Class Codes: D21H 27/10 Packing paper packaging materials of special type or form B65D65/38
• CPC Class Codes: D21H 27/30 Multi-ply for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00

Abstract

A fibrous material, method for making the same, and articles comprising the same are shown and described. The fibrous material is a low density material that exhibits high strength properties. In embodiments, the fibrous material has a density of 0.15 g/cm³ or less and a tensile strength of 10 N/inch or greater. The fibrous material may be in the form of a paperboard and is suitable for use in a variety of applications including as a packaging material.

Claims

1-27. -27. (canceled)

28. A composition forming a foamed structure, comprising:

(a) a fibrous material selected from a group including a cellulosic fiber, or a combination of the cellulosic fiber and a synthetic fiber;

(b) a fibrillated cellulose selected from a group including a microfibrillated cellulose, a nanofibrillated cellulose, or a combination thereof;

(c) a wet strength cross-linker;

(d) a surfactant; and

(e) water.

29. The composition of claim 28, wherein the microfibrillated cellulose or the nanofibrillated cellulose or the combination of the microfibrillated cellulose and the nanofibrillated cellulose is present in an amount greater than 3.5 wt % based on the dry weight of the fibrous material.

30. The composition of claim 28, wherein the microfibrillated cellulose or the nanofibrillated cellulose or the combination of the microfibrillated cellulose and the nanofibrillated cellulose is present in an amount of from about 3.5 wt % to about 10 wt % based on the dry weight of the fibrous material.

31. The composition of claim 28, wherein the microfibrillated cellulose or the nanofibrillated cellulose or the combination of the microfibrillated cellulose and the nanofibrillated cellulose is present in an amount of from about 4 wt % to about 9 wt % based on the weight of dry fibrous material.

32. The composition of claim 28, wherein the microfibrillated cellulose or the nanofibrillated cellulose or the combination of the microfibrillated cellulose and the nanofibrillated cellulose is present in an amount of from about 5 wt % to about 7.5 wt % based on the weight of dry fibrous material.

33. The composition of claim 28, wherein the crosslinker is a cationic polyamide based epichlorohydrin.

34. The composition of claim 28, wherein the crosslinker is a cationic polyamide based Kemira Fennostrength 4063.

35. The composition of claim 33, wherein the polyaminoamide epichlorohydrin is present in an amount of from about 0.5 wt % to about 2.5 wt %, based on the dry weight of the fibrous material.

36. The composition of claim 33, wherein the polyaminoamide epichlorohydrin is present in an amount of from about 0.75 wt % to about 2 wt %, based on the dry weight of the fibrous material.

37. The composition of claim 33, wherein the polyaminoamide epichlorohydrin is present in an amount of from about 1 wt % to about 1.5 wt %, based on the dry weight of the fibrous material.

38. The composition of claim 35, wherein the fibrillated cellulose is present in an amount of from about 3.5 wt % to about 10 wt % based on the dry weight of the fibrous material, and the polyaminoamide epichlorohydrin is present in an amount of from about 0.5 wt % to about 2.5 wt %, based on the dry weight of the fibrous material.

39. The composition of claim 38, wherein the composition is in the form of a slurry and comprises from about 30% by volume to about 60% by volume of a gas entrained therein.

40. The composition of claim 39, wherein the gas is chosen from a group including air, nitrogen, oxygen, argon, carbon dioxide, or combination thereof.

41. A foamed paperboard formed from the composition of claim 40.

42. The foamed paperboard of claim 41, wherein the foamed paperboard has a density of about 0.15 g/cm³ or less.

43. The foamed paperboard of claim 42, wherein the foamed paperboard has a tensile strength of 10 N/inch or greater.

44. The foamed paperboard of claim 42, wherein the foamed paperboard has a tensile strength greater than an unfoamed paper made with a cellulosic material only.

45. An article comprising the foamed paperboard material of claim 43.

46. The article of claim 45 in the form of a container comprising three or more walls defining an opening between the walls, wherein at least one of the walls comprises the foamed paperboard material.

47. The article of claim 46, wherein the at least one of the walls comprising the foamed paperboard material is a multilayer structure, and at least one of the layers is formed from the foamed paperboard material.

48. The article of claim 46, wherein the at least one of the walls comprising the foamed paperboard material is a multilayer structure comprising (i) the foamed paperboard, and (ii) at least a second paperboard having a tensile strength of greater than 10 N/inch.

49. The article of article of claim 47, wherein the multilayer structure comprises (i) the foamed paperboard disposed between (ii) a first paperboard material having tensile strength greater than 10 N/inch and a second paperboard material having a tensile strength of greater than 10 N/inch.

50. The article of claim 47, wherein the multilayer structure comprises (i) a first foamed paperboard having tensile strength of greater than 10 N/inch having an upper surface and a lower surface, (ii) an upper layer disposed on the upper surface of the first foamed paperboard, and (iii) a lower layer disposed on the lower surface of the first foamed paperboard, wherein the upper and lower layers are formed from a second and a third low foamed paperboard.

51. The article of claim 47, wherein the multilayer structure comprises (i) a first foamed paperboard having tensile strength of greater than 10 N/inch having an upper surface and a lower surface, (ii) an upper layer disposed on the upper surface of the first foamed paperboard, and (iii) a lower layer disposed on the lower surface of the first foamed paperboard, wherein the upper and lower layers are formed from films selected from a group including a cellulose based film, a synthetic material film, a metallized film, wherein the upper and the lower layers comprise one or more properties selected from a group including barrier to gas, barrier to water, insulation and heat reflection.

52. The composition of claim 28, wherein the wet strength cross-linker comprises forming bridges between the cellulosic fiber and the microfibrillated cellulose, or between the cellulosic fiber and the nanofibrillated cellulose, or between the microfibrillated cellulose and the nanofibrillated cellulose.