Cut resistant paper and paper articles and method for making same

• US 7,482,046 B2
• Filed: 10/15/2004
• Issued: 01/27/2009
• Est. Priority Date: 01/26/2000
• Status: Expired due to Term

• Current Assignee: International Paper Company
• Original Assignee: International Paper Company
• Inventors: Froass, Peter M, Williams, Richard C, Faber, Richard D, Boone, David A
• Primary Examiner(s): Miggins; Michael C
• Application Number:
  US10/967,074
• Publication Number:
  US 20050098286A1
• Time in Patent Office: 1,565 Days
• Field of Search: 428/34.2, 428/34.3, 428/35.6, 428/532, 428/537.1, 428/537.5, 428/213, 428/218, 428/219, 428/220, 428/340, 428/341, 428/342, 428/332, 428/402.21, 428/401, 162/158, 162/231, 229/67.1
• US Class Current: 428/34.2
• CPC Class Codes: D21H 19/20 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
• CPC Class Codes: D21H 19/22 Polyalkenes, e.g. polystyrene
• CPC Class Codes: D21H 19/28 Polyesters
• CPC Class Codes: D21H 21/54 being spherical, e.g. microcapsules, beads
• CPC Class Codes: D21H 27/10 Packing paper packaging materials of special type or form B65D65/38
• CPC Class Codes: Y10T 428/1303 Paper containing [e.g., paperboard, cardboard, fiberboard, etc.]
• CPC Class Codes: Y10T 428/1348 Cellular material derived from plant or animal source [e.g., wood, cotton, wool, leather, etc.]
• CPC Class Codes: Y10T 428/24215 Acute or reverse fold of exterior component
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/277 Cellulosic substrate
• CPC Class Codes: Y10T 428/2985 Solid-walled microcapsule from synthetic polymer

Abstract

The specification discloses a method for making a paper material having a reduced tendency to cut human skin. The method includes providing a papermaking furnish containing cellulosic fibers and from about 0.5 to about 5.0 wt % by weight dry basis expandable microspheres, forming a paperboard web from the papermaking furnish, drying the web, and calendaring the web to a caliper of from about 11.0 to about 18.0 mils and a density ranging from about 7.0 to about 12.0 lb/3000 ft²/mil. Papers formed according to the method and articles formed therefrom are also disclosed.

Claims

1. A paper substrate, comprising cellulosic fibers and from 0.5 to 5.0 wt % of microspheres based upon the total weight of the substrate on a dry basis, wherein said substrate has a density of from 7.0 to 12.0 lb/3000 ft²/mil and reverse die cut edges which exhibit improved resistance to inflicting cuts upon human skin.

2. The paper substrate according to claim 1, wherein the microspheres comprises synthetic polymeric microspheres.

3. The paper substrate according to claim 1, wherein the expanded microspheres are made from at least one material selected from the group consisting of methyl methacrylate, ortho-chlorostyrene, polyortho-chiorostyrene, polyvinylbenzyl chloride, acrylonitrile, vinylidene chloride, para-tert-butyl styrene, vinyl acetate, butyl acrylate, styrene, methacrylic acid, and vinylbeazyl chloride.

4. The paper substrate according to claim 1, wherein the fibers comprise at least 30 wt % softwood fibers by weight dry basis.

5. The paper substrate according to claim 1, wherein the fibers comprise not morc than 70 wt % hardwood fibers by weight dry basis.

6. The paper substrate according to claim 1, wherein said substrate has a Cutting Index of less than 40 when analyzed according to the Cutting Index 30 test.

7. The paper substrate according to claim 1, wherein said miorospheres are expanded, unexpanded, or mixtures thereof.

8. The paper substrate according to claim 1, wherein said microspheres comprise at least one volatile fluid.

9. The paper substrate according to claim 1, wherein said microspheres are dispersed within the cellulosic fibers.

10. The paper substrate according to claim 1, wherein the substrate is a folder or jacket.

11. The paper substrate according to claim 1, wherein the substrate is calendared.

12. The paper substrate aocordihg to claim 1, wherein said substrate has a caliper of from 11.0 to 18.0.

13. A method of making the paper substrate according to claim 1, comprising contacting said cellulosic fibers with said microspheres.

14. The method according to claim 13, comprising contacting said cellulosic fibers wit said microspheres at prior to a headbox of a papermaking machine.

15. The method according to claim 13, wherein the microspheres are expanded, unexpanded, or mixtures thereof.

16. The method according to claim 13, further comprising drying said substrate.

17. The method according to claim 13, further comprising calendaring said substrate.

18. A paper substrate, comprising cellulosic fibers and from 0.5 to 5.0 wt % of microspheres based upon the total weight of the substrate on a dry basis, wherein said substrate has a caliper of from 11.0 to 18.0 and reverse die cut edges which exhibit improved resistance to inflicting cuts upon human skin.

19. The paper substrate according to claim 18, wherein the microspheres comprises synthetic polymeric microspheres.

20. The paper substrate according to claim 18, wherein the expanded microspheres are made from at least one material selected from the group consisting of methyl methacrylate, ortho-chlorostyrene, polyortho-chiorostyrene, polyvinylbenzyl chloride, acrylonitrile, vinylidene chloride, para-tert-butyl styrene, vinyl acetate, butyl acrylate, styrene, methacrylic acid, and vinylbenzyl chloride.

21. The paper substrate according to claim 18, wherein the fibers comprise at least 30 wt % softwood fibers by weight dry basis.

22. The paper substrate according to claim 18, wherein the fibers comprise not more than 70 wt % hardwood fibers by weight dry basis.

23. The paper substrate according to claim 18, wherein said substrate has a Cutting Index of less than 40 when analyzed according to the Cutting Index 30 test

24. The paper substrate according to claim 18, wherein said microspheres are expanded, unexpanded, or mixtures thereof.

25. The paper substrate according to claim 18, wherein said microspheres comprise at least one volatile fluid.

26. The paper substrate according to claim 18, wherein said microspheres are dispersed within the cellulosic fibers.

27. The paper substrate according to claim 18, wherein the substrate is a folder or jacket.

28. The paper substrate according to claim 18, wherein the substrate is calendared.

29. The paper substrate according to claim 18, wherein the substrate has a density of from 7.0 to 12.0 lb/3000ft ² mil.

30. A method of making the paper substrate according to claim 18, comprising contacting said cellulosic fibers with said microspheres.

31. The method according to claim 30,comprising contacting said cellulosic fibers with said microspheres at prior to a headbox of a papermaking machine.

32. The method according to claim 30, wherein the microspheres are expanded, unexpanded, or mixtures thereof.

33. The method according to claim 30, further comprising drying said substrate.

34. The method according to claim 30, comprising calendaring said substrate.