CN108473712A - 用于制造纸或纸板、纸板托盘的方法以及用于其中的用可发泡聚合物涂覆的纸浆颗粒 - Google Patents

用于制造纸或纸板、纸板托盘的方法以及用于其中的用可发泡聚合物涂覆的纸浆颗粒 Download PDF

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CN108473712A
CN108473712A CN201780007148.XA CN201780007148A CN108473712A CN 108473712 A CN108473712 A CN 108473712A CN 201780007148 A CN201780007148 A CN 201780007148A CN 108473712 A CN108473712 A CN 108473712A
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cardboard
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coating
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CN108473712B (zh
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J.拉萨宁
M.希尔图宁
A.哈林
H.科斯克拉
C.莱恩
L.克拉
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Stora Enso Oyj
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Abstract

本发明涉及制造纸或纸板的方法、由该方法获得的纸或纸板，以及由纸板生产托盘的方法。在用于造纸的纤维原料中并入一定量的聚合物涂覆的纤维颗粒，其中甚至含有发泡剂如水分。幅材在造纸机或纸板机的成形网上由纤维原料形成，随后压制并干燥成成品纸或纸板。当充分加热纸或纸板时，颗粒内的发泡剂蒸发，引起聚合物涂层的膨胀和起泡，这增加了纸板在被模制成成型制品如板托盘时的延展性。本发明甚至包括生产用于所述方法的双涂层纤维颗粒，内涂层为具有较高熔体流动速率的可发泡聚合物，而外涂层为较低熔体流动速率的不发泡聚合物。

Description

用于制造纸或纸板、纸板托盘的方法以及用于其中的用可发 泡聚合物涂覆的纸浆颗粒
背景技术
本发明涉及制造纸或纸板(board)的方法，以及可由此获得的纸或纸板。此外，本发明包括制造纸板制品(如盘子(plate)或托盘(tray))的方法，以及制备用于制造纸或纸板的聚合物涂覆的颗粒的方法。
纤维板制品例如盘子、托盘和类似容器的生产包括通过使用具有与制品形状相对应的凹部或空腔的模具的深拉或真空模制步骤。通常，该过程在矩形制品的角落处或当该制品具有圆弧形、通常为圆形或椭圆形的形状时沿着整个周边会产生皱褶或波纹。然而，已经开发了各种技术来减少或避免起皱以及改进用于制品的纸板的可模制性。
已知的用于避免起皱的方法包括如WO 2013/140034A1中所记载的生产托盘的阶梯式侧壁的多步模制技术，以及如WO 2015/063643A1中所记载的特别地设计成允许托盘侧壁的自由成形的模制工具。
一种不同的方法是提高用于模制制品如托盘的纸板的延展性。为此目的，存在具有夹在两个纤维板层之间的聚合物层的多层板。中间聚合物层的目的是通过在模制步骤使两个板层相互滑动来提高多层板的可模塑性。然而，这种可模制性相当有限，同时多层材料的制造成本很高。
WO 2014/080084提出了一种纤维幅材的泡沫成形，该纤维幅材用聚合物浸渍并且可以转变为模制制品。据说泡沫成形的聚合物浸渍材料具有改进的伸长率，特别是在热成形中。然而，使幅材进行随后的浸渍将使该过程不切实际地负担有额外的工作步骤。
在WO 2008/113887中记载了一种用于防止用一次性纸板杯享受的热饮烧烫使用者的手指的特定技术。教导了用聚合物如低密度聚乙烯(LDPE)掺杂用于制造纸板的基于纤维的原料，所述聚合物最终位于在纸板机中生产的干燥纸板中。当加热纸板时，聚合物熔化并且水蒸气气泡穿透它，使纸板变得多孔。产生孔的加热可以施加到纸板上或首先施加到由其制成的杯子上。充气孔起到了在手指和杯内的热液体之间的绝热的作用。
发明内容
以上述现有技术为背景，本发明解决的问题是开发一种用于模制盘子、托盘和类似容器的改进的技术，其基于纤维纸或纸板的新的构造。根据本发明，纸或纸板由包括以下步骤的方法来制造：
(i)用可发泡聚合物涂覆纸浆纤维和发泡剂，以制备聚合物涂覆的可发泡颗粒，
(ii)将一定量的所述颗粒并入到用于造纸的纤维原料中，
(iii)在造纸机或纸板机的成形网(forming fabric)上由所述纤维原料形成幅材，
(iv)将所述幅材压制并干燥成纸或纸板层，以及
(v)加热所述纸或纸板层以使颗粒中所含的发泡剂产生蒸气或气体，其使所述聚合物发泡。
本发明人发现，从内部使颗粒发泡产生其相当大的膨胀，并且优选使颗粒彼此接触，这大大增加了纤维层的可塑性和可模制性。在此方面，这种层与如上所讨论的已知的多层板的中间聚合物层非常相当的(comparable)。由于根据本发明的层可以通过普通造纸技术在造纸机或纸板机中生产，所以与现有技术的单独的聚合物层相比，生产更便宜，并且可以通过标准制造技术与常规(全纤维)纤维层结合至多层板中。
基于纤维的可发泡颗粒带来进一步的优点，即可生物再生纤维材料在可模制层和产品中的份额整体较高。颗粒可以是非常薄的聚合物涂覆的，即与纤维相比，颗粒中的聚合物的量可能较低，而当均匀分散在可模制层中时，颗粒仍具有大的膨胀和接合能力。
优选地，发泡剂为水，即纤维素纤维中所含有的水分，其蒸发并使聚合物发泡。其优点是纤维素纤维容纳或结合大量水以产生发泡的能力。
或者，发泡剂可以是其他挥发性液体或化学品，其在加热时分解并释放气体。例如，固体如碳酸氢钠或偶氮二甲酰胺(其在加热时释放气态二氧化碳)可以与湿润或干燥的纤维素纤维结合使用。
与WO 2008/113887相比，本发明的基本新颖性在于，在颗粒内的纤维和发泡剂的组合(优选湿润纤维)，使湿气蒸发并且使颗粒从其内部发泡并膨胀，这与参考文件中相反，其中掺杂聚合物颗粒的发泡依赖于来自外部的水分。由此颗粒的膨胀更广泛，并且不需要非发泡聚合物涂层来阻挡纸板表面以防止发泡所需的水分过早逸出。代替模制，WO 2008/113887记载了通过弯曲和密封由纸板坯制造饮料杯，而没有旨在或提及通过嵌入在纸板中的掺杂聚合物颗粒来改进可模制性。
为了确保在加热时的易发泡性，可发泡聚合物的熔体流动速率优选在190℃下为至少约15g/10分钟。用于本发明的合适的可发泡聚合物是低密度聚乙烯(LDPE)。
根据本发明的一个有利实施方案，在所述第一步骤(i)中，向颗粒提供双层涂层，其被特别地设计成使得内层的可发泡聚合物的熔体流动速率高于外层的聚合物的熔体流动速率，并且在所述最终步骤(v)中，内层的聚合物通过包封的发泡剂发泡，而外层的聚合物保持基本上不发泡。不发泡的薄外层能够根据发泡内层的膨胀而拉伸，同时阻挡产生和保持泡沫所需的蒸气或气体逸出。
包封在颗粒中的纤维的长度可以为1至50mm。所述颗粒中的聚合物的份额可以在5至65重量％的范围内变化。颗粒通常具有纵横比为约1:2至1:10的拉长的液滴的形状。然而，颗粒甚至可以是具有被聚合物彼此隔离的多根纤维的丝(yarn)。这样的颗粒可以通过纤维和聚合物的熔融共混物的挤出来制备。然后可以将所得的丝切割成适合于并入到用于造纸的纤维原料中的片段。
在另一个实施方案中，颗粒可以是充分湿润且用可发泡聚合物涂覆并且纵横比为最高达1:100或甚至最高达1:3000的完整纤维丝。这样的拉长的丝状颗粒的益处在于其在纸板被模制成制品时支撑纤维网络。
纸或纸板层中的可发泡和可膨胀颗粒的份额可以在5至25重量％的范围内变化。优选地，颗粒的量足以使至少部分颗粒在它们被发泡和膨胀时与邻近颗粒接触。
可以在造纸机或纸板机的流浆箱处将颗粒添加到纤维原料中，优选通过将颗粒与在该过程中循环的液体混合，以形成供应到成形网上的原料的干重的5至25％。市售的快速混合(Trumpjet)技术对于进行混合并将混合物供应到原料是有用的。
根据本发明的一个优选实施方案，将颗粒并入在多层板的中间层中。夹着这样的中间层的相邻层可以是通常的全纤维纸或纸板层，并且如果需要的话，可以存在常规的最外聚合物涂层用于阻挡和热封目的。
在所述步骤(v)中引起颗粒中的发泡的温度可以为约110至200℃，优选约115至125℃。后者更窄的范围适合于将水分蒸发以及使LDPE的内涂层熔化和发泡，同时留下具有较低熔体流动速率的不发泡的但根据内层的膨胀而拉伸的聚丙烯(PP)的外涂层。
通常优选的是，在加热(其在并入到原料中的颗粒中引起发泡)之前，向纸或纸板在其两侧提供挤出聚合物涂层。如果颗粒仅具有单层涂层，则用于涂覆纸或纸板的聚合物优选具有比颗粒的聚合物涂层更低的熔体流动速率。如果是双涂层颗粒，则该特征不太重要。常规的LDPE可用于挤出涂层以确保易热封性。
聚合物的发泡可以在新生产的纸或纸板卷起之前进行。或者，可以首先在纸板被模制成制品时进行发泡，或仅对预制模制制品进行发泡。
可通过使用根据本发明的方法获得的纸或纸板的特征在于其至少一个纤维层含有包封木浆纤维的发泡聚合物。
根据本发明的用于由如上所述生产的纸板制造纸板制品(如盘子或托盘)的方法包括以下步骤：
(i)将纸板放置在模具上，该模具具有与所生产的制品相一致的形状的凹部，
(ii)通过真空将纸板对着模具拉动，
(iii)在步骤(ii)期间，加热纸板以在并入到纸板中的聚合物涂覆的颗粒中引起发泡，以及
(iv)冷却新模制的制品以使纸板内的发泡的聚合物固化。
根据本发明的用于制备用于制造纸或纸板的聚合物涂覆的颗粒的方法包括以下步骤：
(i)将长度为1至50mm的纤维纤维素颗粒悬浮在含有可发泡的第一热塑性聚合物和第一溶剂的溶液中，
(ii)通过添加的水和相转化将所述第一热塑性聚合物沉淀到所述纤维颗粒上，以获得具有包封的湿度和第一聚合物涂层的纤维颗粒，
(iii)将在步骤(ii)中获得的聚合物涂覆的颗粒悬浮在含有第二热塑性聚合物和第二溶剂的溶液中，所述第二热塑性聚合物的熔体流动速率低于所述第一热塑性聚合物的熔体流动速率，以及
(iv)通过添加的水和相转化将所述第二热塑性聚合物沉淀到所述纤维颗粒上，以获得具有双层聚合物涂层的纤维颗粒，其中内部第一聚合物涂层是可发泡的，而外部第二聚合物涂层保持不发泡。
具体实施方式
聚合物涂覆的颗粒
为了制备聚合物涂覆的纤维颗粒，将长度为1至50mm、优选1至5mm的纤维素纤维或这样的纤维的束悬浮在含有可发泡热塑性聚合物和有机溶剂的溶液中。纤维可以是化学浆、化学热磨机械浆(CTMP)、热磨机械纸浆(TMP)等，其由桦树、松树、云杉、白杨、桉树等制备。用于该目的的优选的聚合物是在190℃或更高温度下的熔体流动速率为约15g/10分钟的LDPE，并且优选的溶剂是十氢化萘。然后将水添加到溶液中以引起相转化并将聚合物沉淀到纤维素纤维上。由此获得液滴状颗粒，其包含用聚合物层涂覆的湿润纤维素纤维。根据本发明的教导，这些颗粒可以用作用于造纸或纸板制造并随后用于制造模制盘子或托盘的纤维原料的添加剂。
任选地，纤维颗粒可以提供有两种不同聚合物的双层涂层。如上所述获得的涂层将用作与包封的湿润纤维接触的第一聚合物的可发泡内涂层。外层，优选第二聚合物的不可发泡的外涂层通过将所述单涂层颗粒悬浮在含有所述第二聚合物和有机溶剂的溶液中来制备。用于该目的的优选的聚合物是在190℃下的熔体流动速率小于15g/10分钟的LDPE，并且优选的溶剂是十氢化萘。然后将水添加到溶液中以引起相转化并将第二聚合物沉淀到单涂层颗粒上。结果是双涂层液滴状颗粒，双层聚合物涂层包封湿润纤维素纤维或这类纤维的束。对聚合物进行选择以使得在加热时，内涂层随着纤维中的水分的蒸发而熔化并发泡，而外部涂层保持未熔化和不发泡。根据本发明的教导，具有这种行为的双涂层颗粒是用于造纸或制造纸板以及随后制造模制盘子或托盘的优选的添加剂。
或者，可以通过纤维和聚合物的熔融共混物的挤出来制备用于本发明的单涂层纤维颗粒。如此制备的颗粒是细长的丝状的并且可以包含嵌入在连续聚合物相中的多根纤维或纤维束。然后可以将所制备的细长丝切割成较短的片段用于并入到纤维原料中。
制造纸或纸板
单层或多层纸或纸板可以通过使用普通造纸机或纸板机来生产。制备用于造纸的纤维原料，并且向其中添加一定量的单涂层或双涂层液滴状颗粒。将具有均匀分布的所述颗粒的原料从流浆箱供应到造纸机或纸板机的成形网，转变成纤维幅材，并且压制并干燥成成品纸或纸板产品。产品包括重量为40至130g/m2的单层或双层纸以及重量为130至500g/m2的多层板。重量为190g/m2或更大的纸板(其适合于转变为托盘)是优选的。产品的密度优选为约280g/dm3或更大。在多层板的情况下，即使在纸板产品的每层中均可能具有这样的颗粒，液滴状发泡颗粒也优选仅并入到内层中。
可以在成品纸或纸板幅材卷成卷运输之前进行通过加热使液滴状聚合物涂覆的颗粒发泡。然而，优选在该阶段使颗粒不发泡，并且在将纸或纸板模制成制品如盘子和托盘时首先使其发泡。
用于本发明的纤维原料可以具有普通的构造，即在含水介质中约0.2至1重量％的纤维。然而，为了实现液滴状颗粒的均匀分布，优选应用公知的泡沫成形技术，其中将纤维作为发泡分散体供应到造纸机或纸板机的成形网。将表面活性剂并入至原料中，并且吹入空气以产生空气含量为约60至70体积％或更多的泡沫。泡沫成形的基本技术记载于例如出版物GB 1 395757中，并且WO 2013/160553公开了包含在原料中的微原纤化纤维素(MFC)的进一步发展。在本发明的实践中，这类发泡原料在将其进料到成形网上之前将接受液滴状涂覆颗粒作为添加剂。使用MFC作为原料的组分在本发明的边界和范围内也是一种选择。
优选在造纸机或纸板机流浆箱之前通过快速混合技术将液滴状涂覆颗粒添加到纤维原料。商标为TrumpJet的用于快速混合的设备可从Wetend Technologies Ltd获得。
模制托盘
由如上所述获得的纸板来生产模制托盘使用了模具，该模具具有与所生产的托盘相一致的形状的空腔。可将纸板幅材被切割成坯件，其被设置为逐一面向模腔，然后是模制步骤，该步骤将其转变成托盘，或者可以连续地将幅材供给到模制工具，以使托盘在模制之后首先彼此分离。
模制操作优选通过借助真空将纸板对着模腔的底部拉动来进行。应用加热和润湿以有助于使纸板适应模腔的轮廓。此外，板的加热引起嵌入在纸板中的聚合物涂覆的液滴状颗粒的发泡。膨胀颗粒或多或少地彼此接触并且在模制操作期间增加了纸板的延展性，从而避免了起皱的趋势。如果颗粒是双涂层的，则在内部聚合物涂层中发生熔融和发泡，而外部聚合物涂层在发泡内层膨胀时被拉伸但保持固体且不发泡。最后，将新模制的托盘冷却，并且使纸板内的发泡聚合物在其膨胀状态下固化。
成品托盘特别地可用作各种食品的包装。避免托盘边缘(rimflange)上的皱褶可以为托盘提供热封盖，而不会有泄漏风险，从而增加了包装的保质期。
作为一次性餐具的盘子和本发明所覆盖的其他模制纸和纸板制品可以通过类似的技术仅通过根据需要改变模腔的形状来制造。

Claims (16)

1.制造纸或纸板的方法，包括以下步骤：
(i)用聚合物涂覆纸浆纤维和发泡剂，以制备聚合物涂覆的可发泡颗粒，
(ii)将一定量的所述颗粒并入到用于造纸的纤维原料中，
(iii)在造纸机或纸板机的成形网上由所述纤维原料形成幅材，
(iv)将所述幅材压制并干燥成纸或纸板层，以及
(v)加热所述纸或纸板层以使颗粒中所含有的发泡剂产生蒸气或气体，其使所述聚合物发泡。
2.权利要求1的方法，其特征在于发泡剂为水分，其蒸发并使聚合物发泡。
3.权利要求1或2的方法，其特征在于可发泡聚合物的熔体流动速率在190℃下为至少约15g/10分钟。
4.前述权利要求中任一项的方法，其特征在于可发泡聚合物包括低密度聚乙烯(LDPE)。
5.前述权利要求中任一项的方法，其特征在于
-在步骤(i)中，向所述颗粒提供双层涂层，其中内层的可发泡聚合物的熔体粘度高于外层的聚合物的熔体粘度，以及
-在步骤(v)中，内层的聚合物通过包封的发泡剂发泡，而外层的聚合物保持基本上不发泡。
6.前述权利要求中任一项的方法，其特征在于所述颗粒中的纤维的长度为1至50mm。
7.前述权利要求中任一项的方法，其特征在于所述颗粒中的聚合物的份额为5至65重量％。
8.前述权利要求中任一项的方法，其特征在于在造纸机或纸板机的流浆箱处将所述颗粒添加到纤维原料中，优选通过将颗粒与在该过程中循环的液体混合，以形成供应到成形网上的原料的干重的5至25％。
9.前述权利要求中任一项的方法，其特征在于将所述颗粒并入多层板的中间层中。
10.前述权利要求中任一项的方法，其特征在于在步骤(v)中使聚合物发泡的温度为约110至150℃，优选约115至125℃。
11.前述权利要求中任一项的方法，其特征在于，在并入到原料中的颗粒中引起发泡的加热之前，在纸或纸板的两侧向其提供聚合物涂层。
12.权利要求11的方法，其特征在于用于涂覆纸或纸板的聚合物具有比并入到原料中的颗粒的可发泡聚合物更低的熔体粘度。
13.权利要求11或12的方法，其特征在于聚合物的发泡在新生产的纸或纸板卷起之前进行。
14.通过使用前述权利要求中任一项的方法可获得的纸或纸板，其特征在于其至少一个纤维层含有包封木浆纤维的发泡的聚合物。
15.由根据权利要求1中的步骤(i)至(iv)生产的纸板制造纸板制品的方法，所述纸板制品例如为托盘或盘子，所述方法包括以下步骤：
(i)将在权利要求1中的步骤(iv)中生产的纸板放置在模具上，该模具具有与所生产的制品相一致的形状的凹部，
(ii)通过真空将纸板对着模具拉动，
(iii)在步骤(ii)期间，加热纸板以在并入到纸板中的聚合物涂覆的颗粒中引起发泡，以及
(iv)冷却新模制的制品以使纸板内的发泡的聚合物固化。
16.制备用于权利要求5的方法的聚合物涂覆的颗粒的方法，包括以下步骤：
(i)将长度为1至50mm的纤维纤维素颗粒悬浮在含有可发泡的第一热塑性聚合物和第一溶剂的溶液中，
(ii)通过添加的水和相转化将所述第一热塑性聚合物沉淀到所述纤维颗粒上，以获得具有包封的湿度和第一聚合物涂层的纤维颗粒，
(iii)将在步骤(ii)中获得的聚合物涂覆的颗粒悬浮在含有第二热塑性聚合物和第二溶剂的溶液中，所述第二热塑性聚合物的熔体粘度低于所述第一热塑性聚合物的熔体粘度，以及
(iv)通过添加的水和相转化将所述第二热塑性聚合物沉淀到所述纤维颗粒上，以获得具有双层聚合物涂层的纤维颗粒，其中内部第一聚合物涂层是可发泡的，而外部第二聚合物涂层保持不发泡。
CN201780007148.XA 2016-02-12 2017-02-06 用于制造纸或纸板、纸板托盘的方法以及用于其中的用可发泡聚合物涂覆的纸浆颗粒 Active CN108473712B (zh)

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WO2017137879A1 (en) 2017-08-17
EP3414282A4 (en) 2019-10-23
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EP3414282B1 (en) 2020-10-21
US20200308768A1 (en) 2020-10-01

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