Recycling of latex-containing broke
First Claim
1. A method comprising mechanically treating broke generated from scrap material accumulated during the production of paper products containing cellulosic fibers and a latex polymer to form fiber aggregates, wherein said latex polymer is present in said broke from about 1% to about 60% by weight, wherein said latex polymer is an adhesive latex, wherein said fiber aggregates have an average size of from about 0.5 to about 6 millimeters, wherein a first portion of said fiber aggregates are coated with said latex polymer and a second portion of said fiber aggregates remain relatively free from said latex polymer, wherein said mechanical treatment comprises pulping said broke in a pulper;
- andforming a paper product that contains said fiber aggregates, wherein said paper product comprises a multi-layered paper web.
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Accused Products
Abstract
Methods for recycling latex-containing broke are generally provided. Specifically, mechanical treatment may be employed to rework latex-containing broke for reuse in various products without the need for treatment with chemicals, such as hypochlorite, chlorine, or hypochlorous acid. As a result of mechanical treatment, fiber aggregates are formed that have a relatively small size. For instance, a large portion of the resulting fiber aggregates may be relatively free from the latex polymer. Specifically, the fiber aggregates can contain a “core” of latex from which extend short fibers and/or fragments that are uncoated with the latex. The result is fiber aggregates that are uniquely “partially coated” with a latex polymer. When recycled in paper products, these fiber aggregates may impart a variety of benefits, such as increased bulk retention and high water capacity without any loss in absorbency rate.
102 Citations
42 Claims
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1. A method comprising mechanically treating broke generated from scrap material accumulated during the production of paper products containing cellulosic fibers and a latex polymer to form fiber aggregates, wherein said latex polymer is present in said broke from about 1% to about 60% by weight, wherein said latex polymer is an adhesive latex, wherein said fiber aggregates have an average size of from about 0.5 to about 6 millimeters, wherein a first portion of said fiber aggregates are coated with said latex polymer and a second portion of said fiber aggregates remain relatively free from said latex polymer, wherein said mechanical treatment comprises pulping said broke in a pulper;
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forming a paper product that contains said fiber aggregates, wherein said paper product comprises a multi-layered paper web. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20)
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21. A method comprising:
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diluting broke to a solids consistency of from about 4% to about 10%, wherein the broke is generated from scrap material accumulated during the production of paper products and contains cellulosic fibers and a latex polymer selected from the group consisting of styrene butadiene, neoprene, polyvinyl chloride, vinyl copolymers, polyamides, ethylene vinyl terpolymers, acrylates, methacrylates, and combinations thereof, wherein said latex polymer is present in said broke from about 1% to about 60% by weight; pulping said diluted broke; thereafter refining said broke, wherein said pulping and said refining result in fiber aggregates having an average size of from about 0.5 to about 6 millimeters, and wherein a first portion of said fiber aggregates are coated with said latex polymer and a second portion of said fiber aggregates remain relatively free from said latex polymers, and forming a paper product that contains said fiber aggregates, wherein said paper product comprises a multi-layered paper web. - View Dependent Claims (22, 23, 24, 25, 26, 27)
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28. A method comprising mechanically treating broke generated from scrap material accumulated during the production of paper products containing cellulosic fibers and a latex polymer to form fiber aggregates, wherein said latex polymer is present in said broke from about 1% to about 60% by weight, wherein said latex polymer is an adhesive latex polymer, wherein said fiber aggregates have an average size of from about 0.2 to about 12 millimeters and a Canadian Standard Freeness value of from about 400 to about 800, and wherein a first portion of said fiber aggregates are coated with said latex polymer and a second portion of said fiber aggregates remain relatively free from said latex polymer, and
forming a paper product that contains said fiber aggregates, wherein said paper product comprises a multi-layered paper web.
Specification