CN115917083A - Water-resistant fiber material and its production method - Google Patents
Water-resistant fiber material and its production method Download PDFInfo
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- CN115917083A CN115917083A CN202180045495.8A CN202180045495A CN115917083A CN 115917083 A CN115917083 A CN 115917083A CN 202180045495 A CN202180045495 A CN 202180045495A CN 115917083 A CN115917083 A CN 115917083A
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- Prior art keywords
- foam
- fibrous layer
- water resistant
- formed fibrous
- layer
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- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 title claims abstract description 76
- 239000002657 fibrous material Substances 0.000 title claims abstract description 44
- 238000004519 manufacturing process Methods 0.000 title abstract description 10
- 239000000123 paper Substances 0.000 claims abstract description 111
- 239000011087 paperboard Substances 0.000 claims abstract description 105
- -1 fatty acid halide Chemical class 0.000 claims abstract description 74
- 235000014113 dietary fatty acids Nutrition 0.000 claims abstract description 70
- 239000000194 fatty acid Substances 0.000 claims abstract description 70
- 229930195729 fatty acid Natural products 0.000 claims abstract description 70
- 239000000463 material Substances 0.000 claims abstract description 31
- 239000000835 fiber Substances 0.000 claims abstract description 29
- 239000003795 chemical substances by application Substances 0.000 claims description 43
- 239000006260 foam Substances 0.000 claims description 35
- 238000004513 sizing Methods 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 24
- 239000004094 surface-active agent Substances 0.000 claims description 13
- 230000002209 hydrophobic effect Effects 0.000 claims description 11
- 239000007788 liquid Substances 0.000 claims description 11
- 239000011436 cob Substances 0.000 claims description 10
- JVTAAEKCZFNVCJ-UHFFFAOYSA-N lactic acid Chemical compound CC(O)C(O)=O JVTAAEKCZFNVCJ-UHFFFAOYSA-N 0.000 claims description 10
- 229920000877 Melamine resin Polymers 0.000 claims description 8
- 229920001807 Urea-formaldehyde Polymers 0.000 claims description 8
- 238000010521 absorption reaction Methods 0.000 claims description 8
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 claims description 8
- ODGAOXROABLFNM-UHFFFAOYSA-N polynoxylin Chemical compound O=C.NC(N)=O ODGAOXROABLFNM-UHFFFAOYSA-N 0.000 claims description 8
- 239000000725 suspension Substances 0.000 claims description 7
- 235000021588 free fatty acids Nutrition 0.000 claims description 6
- 239000002002 slurry Substances 0.000 claims description 6
- 239000004310 lactic acid Substances 0.000 claims description 5
- 235000014655 lactic acid Nutrition 0.000 claims description 5
- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 claims description 4
- KHPCPRHQVVSZAH-HUOMCSJISA-N Rosin Natural products O(C/C=C/c1ccccc1)[C@H]1[C@H](O)[C@@H](O)[C@@H](O)[C@@H](CO)O1 KHPCPRHQVVSZAH-HUOMCSJISA-N 0.000 claims description 4
- 239000004088 foaming agent Substances 0.000 claims description 4
- 229940014800 succinic anhydride Drugs 0.000 claims description 4
- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 claims description 4
- 239000000654 additive Substances 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 19
- 229920002451 polyvinyl alcohol Polymers 0.000 description 19
- 238000004806 packaging method and process Methods 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 7
- 229920002678 cellulose Polymers 0.000 description 7
- 239000001913 cellulose Substances 0.000 description 7
- 150000004665 fatty acids Chemical class 0.000 description 7
- 239000007789 gas Substances 0.000 description 7
- 230000008569 process Effects 0.000 description 7
- 239000000126 substance Substances 0.000 description 7
- 229920003043 Cellulose fiber Polymers 0.000 description 5
- 229920001131 Pulp (paper) Polymers 0.000 description 5
- 239000004566 building material Substances 0.000 description 5
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 229920002689 polyvinyl acetate Polymers 0.000 description 5
- 239000011118 polyvinyl acetate Substances 0.000 description 5
- 239000004604 Blowing Agent Substances 0.000 description 4
- 238000005452 bending Methods 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 238000005516 engineering process Methods 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 230000035515 penetration Effects 0.000 description 4
- 230000035699 permeability Effects 0.000 description 4
- 239000000047 product Substances 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- 241000196324 Embryophyta Species 0.000 description 3
- DBMJMQXJHONAFJ-UHFFFAOYSA-M Sodium laurylsulphate Chemical compound [Na+].CCCCCCCCCCCCOS([O-])(=O)=O DBMJMQXJHONAFJ-UHFFFAOYSA-M 0.000 description 3
- 235000013361 beverage Nutrition 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- ARBOVOVUTSQWSS-UHFFFAOYSA-N hexadecanoyl chloride Chemical compound CCCCCCCCCCCCCCCC(Cl)=O ARBOVOVUTSQWSS-UHFFFAOYSA-N 0.000 description 3
- 230000004048 modification Effects 0.000 description 3
- 238000012986 modification Methods 0.000 description 3
- WTBAHSZERDXKKZ-UHFFFAOYSA-N octadecanoyl chloride Chemical compound CCCCCCCCCCCCCCCCCC(Cl)=O WTBAHSZERDXKKZ-UHFFFAOYSA-N 0.000 description 3
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 239000011111 cardboard Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 235000013611 frozen food Nutrition 0.000 description 2
- 238000000769 gas chromatography-flame ionisation detection Methods 0.000 description 2
- 150000004676 glycans Chemical class 0.000 description 2
- 239000011121 hardwood Substances 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000002609 medium Substances 0.000 description 2
- 239000005022 packaging material Substances 0.000 description 2
- 229920003023 plastic Polymers 0.000 description 2
- 239000004033 plastic Substances 0.000 description 2
- 229920000642 polymer Polymers 0.000 description 2
- 229920001282 polysaccharide Polymers 0.000 description 2
- 239000005017 polysaccharide Substances 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000002444 silanisation Methods 0.000 description 2
- 150000003384 small molecules Chemical class 0.000 description 2
- 239000011122 softwood Substances 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 230000003313 weakening effect Effects 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- UNSAJINGUOTTRA-UHFFFAOYSA-N 3-(3-bromophenyl)prop-2-yn-1-ol Chemical compound OCC#CC1=CC=CC(Br)=C1 UNSAJINGUOTTRA-UHFFFAOYSA-N 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004890 Hydrophobing Agent Substances 0.000 description 1
- 229920000433 Lyocell Polymers 0.000 description 1
- 235000008331 Pinus X rigitaeda Nutrition 0.000 description 1
- 235000011613 Pinus brutia Nutrition 0.000 description 1
- 241000018646 Pinus brutia Species 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 229920002522 Wood fibre Polymers 0.000 description 1
- 229920006243 acrylic copolymer Polymers 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 125000001931 aliphatic group Chemical group 0.000 description 1
- 125000000217 alkyl group Chemical group 0.000 description 1
- 239000006265 aqueous foam Substances 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 229910052799 carbon Inorganic materials 0.000 description 1
- 125000004432 carbon atom Chemical group C* 0.000 description 1
- 238000004132 cross linking Methods 0.000 description 1
- NQGIJDNPUZEBRU-UHFFFAOYSA-N dodecanoyl chloride Chemical compound CCCCCCCCCCCC(Cl)=O NQGIJDNPUZEBRU-UHFFFAOYSA-N 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000000605 extraction Methods 0.000 description 1
- 238000005189 flocculation Methods 0.000 description 1
- 230000016615 flocculation Effects 0.000 description 1
- 238000005187 foaming Methods 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 229910052739 hydrogen Inorganic materials 0.000 description 1
- 239000001257 hydrogen Substances 0.000 description 1
- 125000001165 hydrophobic group Chemical group 0.000 description 1
- 238000009449 lightweight packaging Methods 0.000 description 1
- 230000007246 mechanism Effects 0.000 description 1
- 239000012528 membrane Substances 0.000 description 1
- 239000010813 municipal solid waste Substances 0.000 description 1
- REEZZSHJLXOIHL-UHFFFAOYSA-N octanoyl chloride Chemical compound CCCCCCCC(Cl)=O REEZZSHJLXOIHL-UHFFFAOYSA-N 0.000 description 1
- 239000003960 organic solvent Substances 0.000 description 1
- 239000002985 plastic film Substances 0.000 description 1
- 229920006255 plastic film Polymers 0.000 description 1
- 239000004626 polylactic acid Substances 0.000 description 1
- 239000011148 porous material Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 108090000623 proteins and genes Chemical class 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000013074 reference sample Substances 0.000 description 1
- 239000004627 regenerated cellulose Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 238000009877 rendering Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000004381 surface treatment Methods 0.000 description 1
- 239000013501 sustainable material Substances 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- 239000002025 wood fiber Substances 0.000 description 1
Classifications
-
- 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
- D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
- D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
- D21H11/20—Chemically or biochemically modified fibres
-
- 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
-
- 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
- D21F11/002—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines by using a foamed suspension
-
- 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
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/03—Non-macromolecular organic compounds
- D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
- D21H17/14—Carboxylic acids; Derivatives thereof
-
- 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
- D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
- D21H17/03—Non-macromolecular organic compounds
- D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
- D21H17/18—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only forming new compounds in situ, e.g. within the pulp or paper, by chemical reaction with itself, or other added substances, e.g. by grafting on the fibres
-
- 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
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
- D21H21/16—Sizing or water-repelling agents
-
- 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
- D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
- D21H21/50—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by form
- D21H21/56—Foam
-
- 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
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/10—Packing paper
-
- 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
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/30—Multi-ply
- D21H27/38—Multi-ply at least one of the sheets having a fibrous composition differing from that of other sheets
Abstract
The present invention relates to a water resistant fibrous material such as a flexible sheet, paper or paperboard comprising a foam-formed fibrous layer, wherein the foam-formed fibrous layer has been subjected to grafting with a fatty acid halide to render the foam-formed fibrous layer water resistant. The invention also relates to a method for producing a water-resistant fibre material.
Description
Technical Field
The present disclosure relates to water resistant fibrous materials for use in wet or humid environments. More particularly, the present disclosure relates to water resistant fibrous materials comprising foam-formed fibrous layers (foam-formed fiber plies).
Background
Foam-forming (foam-forming) technology enables the preparation of recyclable and sustainable materials for a variety of applications, including lightweight packaging materials, building materials, and boards. Foam forming enables the use of longer fibers than conventional papermaking forming processes, improved control of web structure, and the manufacture of paper and board having low density compared to conventionally formed paper and paper.
In the foam-forming technique, aqueous foam is used instead of water as a carrier medium in the manufacture of fiber-based products. The presence of gas bubbles in the aqueous medium fundamentally changes the properties of the medium. This technique enables higher headbox consistency and results in structures with excellent formation and high bulk. Other benefits include reduced water usage and energy savings.
Water and other liquids resistance is an important property in many paper, paperboard or containerboard applications. Some examples include packaging such as boxes, bags, corrugated board and other containers; packaging fresh and sterile liquid; boxes, bags, corrugated board, trays or cups for hot, cold, dry, wet and frozen foods and beverages; products for outdoor use, such as boxes, bags, signs and posters; pots, trays and covers for plants; packaging for building materials, and building materials.
Paper, paperboard or containerboard used in wet or humid environments is often treated with sizing agents to improve certain qualities; and above all, to increase the resistance of water and other liquids to penetrate into the paper or paperboard. There are two main types of sizing: internal sizing and surface sizing. For internal sizing, chemicals are added to the pulp (pulp ) at the wet end, such as Alkyl Ketene Dimer (AKD), alkenyl Succinic Anhydride (ASA), or rosin sizing agents. Common surface sizing agents include, for example, starch or acrylic copolymers.
Coating paper, paperboard or containerboard with plastic is commonly used to combine the mechanical properties of paperboard with the barrier and sealing properties of plastic films. Also in plastic coated board, the board is usually treated with a hydrophobic sizing agent to prevent so called edge pick up (edge wick), i.e. to absorb liquid at the cut edge (or so called raw edge) of the board. Edge absorption resistance is an important parameter in many applications.
One problem with internal sizing agents such as AKD is that they interfere with hydrogen bonding between cellulose fibres, produce a debinding effect and thus weaker materials (weaver materials). To compensate for the weaker material, grammage of paper and board is increased, resulting in a higher carbon footprint due to excessive use of wood fiber and higher shipping weight at all stages downstream of production.
To improve the wet strength of the material, internal sizing agents are often combined with wet strength agents. Wet strength agents improve the tensile properties of paper or board in the wet state by, for example, covalently bonding to the cellulose fibers and also by forming a crosslinked network between the fibers or between the fibers and other dry strength agents. Common wet strength agents include urea-formaldehyde (UF), melamine-formaldehyde (MF), and polyamide-epichlorohydrin (PAE). Other wet strength agents may provide wet strength through other mechanisms, and some of these wet strength agents may also have temporary wet strength functionality.
One problem with the addition of wet strength agents is that the repulpability of the board is severely reduced.
Furthermore, in foam forming technology, the addition of internal sizing agents and wet strength agents can have an unexpected effect on the foam structure, or even foam collapse. Surface treatment of foam-formed structures with hydrophobing agents is possible, but the conventional concept may not work, since high bulk means that surface size absorption will be higher and the risk of substrate collapse is greater.
Thus, there is still a need for improved solutions to make paper or board comprising a foam-formed fibrous layer water resistant without weakening the material or destroying the foam structure and without reducing the repulpability of the material.
Disclosure of Invention
It is an object of the present disclosure to provide a water resistant fibrous material such as flexible sheet, paper or paperboard comprising a foam-formed fibrous layer having high repulpability.
It is another object of the present disclosure to provide a water-resistant fibrous material comprising a foam-formed fibrous layer having improved wet strength and similar repulpability, such as paper or paperboard, as compared to corresponding non-water resistant fibrous materials.
It is another object of the present disclosure to provide a water resistant fibrous material, such as a flexible sheet, paper or paperboard, that is free of added hydrophobic sizing agents or has only a small amount of added hydrophobic sizing agents, such as Alkyl Ketene Dimer (AKD), alkenyl Succinic Anhydride (ASA) and/or rosin sizing agents.
It is another object of the present disclosure to provide a water resistant fibrous material, such as a flexible sheet, paper or paperboard, which is free of added wet strength agents or has only a small amount of added wet strength agents, in particular cross-linking forming wet strength agents, such as urea-formaldehyde (UF), melamine-formaldehyde (MF) and/or polyamide-epichlorohydrin (PAE).
It is another object of the present disclosure to provide a method for rendering a fibrous material, such as a flexible sheet, paper or paperboard, water resistant without weakening the material and without reducing the repulpability of the material.
The above objects, as well as other objects that will be apparent to persons skilled in the art in light of the present disclosure, are achieved by various aspects of the present disclosure.
According to a first aspect shown herein, there is provided a water resistant fibrous material comprising:
a fibrous layer formed by the formation of the foam,
wherein the foam-formed fibrous layer has been subjected to grafting with a fatty acid halide to render the foam-formed fibrous layer water resistant.
According to one aspect of the invention, the foam-formed fibrous layer is a flexible sheet, paper or paperboard, which itself is preferably a flat, continuous or discontinuous sheet of a sheet or web of material formed from wood pulp or other fibrous matter containing cellulosic fibers. That is, the term "fiber" is intended herein to mean a material derived from or based on natural fibers such as wood pulp, non-wood pulp plant material, or combinations thereof.
The flexible sheet, paper or paperboard may be used as such, or it may be provided with various coatings and/or as a layer in a multilayer laminate comprising one or more additional cellulose-based or non-cellulose-based layers.
As used herein, the term "fibrous material" is intended to include at least the flexible sheet, paper or paperboard referred to in this application.
In this context, flexible sheet material generally refers to a flat, continuous or discontinuous sheet of fibrous sheet or web material made of wood or other fibrous substances containing cellulosic fibers, which has flexibility, tensile and strength properties that make the material suitable for use as, for example, lightweight carrier bags and sacks, shopping bags, trash bags, and for packaging of goods.
The flexible sheet described in this disclosure can have a thickness of 2-500g/m 2 Preferably 10 to 500g/m 2 The grammage of (c), which can be adjusted according to the end use. The flexible sheet further comprises a stretch in the range of 5-45% measured according to method ISO 1924-2.
Paper generally refers to sheet or web material made from wood pulp or other fibrous substances containing cellulose fibers, for example, for writing, drawing or printing thereon, or for use as packaging material.
Paperboard generally refers to strong, thick paper or cardboard containing cellulosic fibers, such as used in boxes, bags, and other types of packaging. The paperboard may comprise one or more layers. The paperboard can be bleached or unbleached, coated or uncoated, and produced in various thicknesses, depending on the end use requirements.
The basis weight of the paper or paperboard useful in the present disclosure may generally range from 15 to 500g/m 2 Within the range of (1).
The flexible sheet, paper or cardboard may typically have a thickness of between 700kg/m due to the foam-formed fibre layer 3 The following densities. In some embodiments, the density of the fibrous material is at 600kg/m 3 Below, preferably 500kg/m 3 Below or in 400kg/m 3 The following. Although in thinner fibrous materials, the density may be higher as long as the basis weight is still not too high. In thinner flexible sheets or papers having a thickness of less than about 100 μm, the density may be, for example, in the range of 600-1400kg/m 3 In the range of or 700-1200 kg-m 3 Within the range of (1). Higher density and thickness results in higher basis weight, preventing grafting throughout the entire thickness of the foam-forming fibrous layer.
The thickness of the fibrous material can range from thin to very thick. In some embodiments, the thickness of the fibrous material is above 30 μm, preferably above 100 μm. In some embodiments, the thickness of the fibrous material is in the range of 30 μm to 10 mm. In some embodiments, the thickness of the fibrous material is in the range of 100 μm to 1 mm.
In some embodiments, the basis weight of the fibrous material is in the range of 15 to 500g/m 2 In the range of 100 to 400g/m, preferably 2 Within the range of (1).
In some embodiments, the air permeability of the fibrous material measured using the Bendtsen method (ISO 5636-3) is in the range of 10 to 100 μm/(Pa · s).
The water resistant flexible sheet, paper or paperboard of the present invention comprises a foam-formed fibrous layer. Foam forming technology enables the improvement of paper properties, and the manufacture of high porosity and lightweight products. It also offers the possibility of significantly reducing raw material and production costs compared to conventional paper forming processes.
Improvements to foam forming technology can be made to existing paper and board machines to produce high quality bulkier sheet structures with excellent formability while also reducing energy and chemical consumption.
In foam formation, a large amount of air is added to an aqueous slurry suspension in the presence of a surfactant. The bubbles formed prevent flocculation of the fibers, enhance dewatering, and enable the production of lightweight structures.
As used herein, the terms foam and foamed refer to a substance made by trapping air or gas bubbles within a solid or liquid. Typically, the volume of gas is much larger than the volume of liquid or solid, with a membrane separating the gas pockets. To form a foam, three requirements must be met. Mechanical work is required to increase the surface area. This can be achieved by stirring, dispersing a large amount of gas into the liquid or injecting a gas into the liquid. A second requirement is that a foam forming agent, typically an amphiphilic material, surfactant or surface active component, must be present to reduce surface tension. Finally, the foam must form faster than it decomposes.
In some embodiments, a foam generator is used to achieve the foaming required for foam formation. The slurry suspension may be pumped through the foam generator one or more times to achieve the desired gas content or foam density. In some embodiments, the slurry suspension is pumped through a high shear mixer or refiner that produces foam. The foam can be generated off-line or on-line on the paper machine.
In some embodiments, the air content of the foam is brought to 60 to 70 volume percent prior to being applied to the forming fabric. The consistency of the foamed pulp may typically be in the range of 0.1 to 2 wt.%, based on the amount of water.
The foam is formed and stabilized using surfactants present in the slurry suspension. The surfactant may be a small molecule surfactant or a polymeric surfactant or a mixture thereof. The amount of surfactant in the foam may typically be in the range of 0.005 to 30 wt%, but can be readily determined by the skilled person. An example of a small molecule surfactant that can be used for foam formation is Sodium Dodecyl Sulfate (SDS). The amount of SDS in the foam may typically be in the range of 0.005 to 10 wt.%, for example about 0.02 wt.%. Examples of polymeric surfactants that can be used in foam formation include polyvinyl alcohol (PVOH) and partially hydrolyzed polyvinyl acetate (PVOH/Ac) or other modifications of PVOH. The amount of polyvinyl alcohol (PVOH) or partially hydrolyzed polyvinyl acetate (PVOH/Ac) in the foam can typically be in the range of 0.01 to 30 wt.%, e.g., about 5 wt.%. Polyvinyl alcohol (PVOH) and partially hydrolyzed polyvinyl acetate (PVOH/Ac) are particularly important as surfactants in the foam-formed fibrous layers of the present invention because, in addition to acting as surfactants, the hydroxyl groups will also act as substrates for grafting with the fatty acid halide. Long chains of polymeric surfactants such as PVOH can contribute to mechanical properties and also may not be readily leached or migrated from the fiber layer of the finished foam, which may be valuable in certain applications. Thus, in some preferred embodiments, the blowing agent is a polymeric blowing agent. In some embodiments, the polymeric foaming agent is selected from the group consisting of optionally hydrophobically modified polysaccharides, proteins, polyvinyl alcohol (PVOH), partially hydrolyzed polyvinyl acetate (PVOH/Ac), and mixtures thereof. The optional hydrophobic modification typically includes one or more hydrophobic groups, such as alkyl groups, covalently attached to the blowing agent. In a preferred embodiment, the blowing agent is polyvinyl alcohol (PVOH) or partially hydrolyzed polyvinyl acetate (PVOH/Ac). The foaming agent may also comprise a polysaccharide or a polymer or a derivative thereof.
The pulp suspension and thus the foam-formed fibre layer can be made of wood pulp or other fibre substances containing cellulose fibres. The foam-forming fibrous layer may comprise softwood or hardwood pulp. The foam-forming fibrous layer may also comprise a mixture of softwood and hardwood pulps. The foam-formed fibrous layer may also contain recycled fibers, such as recycled used beverage cartons (carton).
The foam forming process also allows the addition of longer synthetic or natural fibers, such as reinforcing pulp, polylactic acid (PLA) fibers, polyvinyl alcohol (PVOH) fibers or man-made cellulose fibers, such as regenerated cellulose, e.g. viscose fibers or lyocell fibers. The long fibers may be present in an amount of 0 to 50 wt.%, preferably 1 to 20 wt.% or 3 to 20 wt.%, based on the total dry weight of the foam-formed fibrous layer.
Foam forming can be carried out on an industrial scale on a running forming fabric of a paper or board machine, wherein a foam web is applied to the forming fabric, the web is dewatered by suction through the web and the forming fabric and finally dried in a drying section of the paper or board machine.
In some embodiments, the flexible sheet, paper or paperboard is comprised of a foam-formed fibrous layer.
In some embodiments, the water resistant flexible sheet, paper or paperboard may further comprise one or more additional fibrous or non-cellulose based layers.
In some embodiments, the flexible sheet, paper, or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers.
The additional fibrous layers may be foam-formed or non-foam-formed.
An important characteristic of paperboard is bending stiffness. The bending stiffness of a paperboard is typically established by having outer layers with high tensile stiffness and one or more bulk plies (bulk plies) between the outer layers so that the outer layers are placed at a desired distance from each other. The bulk layer is often referred to as an intermediate layer or layers. In some embodiments, the foam-formed fibrous layer constitutes an intermediate layer between two or more additional fibrous layers, preferably the foam-formed fibrous layer constitutes an intermediate layer between two or more non-foam-formed fibrous layers.
In embodiments where the foam-formed fibrous layer constitutes an intermediate layer between two or more additional fibrous layers, the thickness, density and/or grammage of at least one of the additional layers should be sufficiently low to allow grafting of the foam-formed fibrous layer through the additional layer. This typically means that the thickness of the foam-formed fibrous layer is significantly greater than the thickness of the one or more additional fibrous layers.
In embodiments where the flexible sheet, paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers, the foam-formed fibrous layer preferably constitutes at least 50 wt%, more preferably at least 60 wt%, at least 70 wt%, at least 80 wt% or at least 90 wt% of the total thickness of the foam-formed fibrous layer.
In embodiments wherein the flexible sheet, paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers, the foam-formed fibrous layer preferably constitutes at least 10 wt. -%, more preferably at least 30 wt. -% or at least 50 wt. -% of the total basis weight of the paper or paperboard.
The flexible sheet, paper or paperboard of the present invention is preferably used in wet or humid environments. In some embodiments, flexible sheets, paper or paperboard are used for packaging, such as boxes, bags, corrugated board and other containers; packaging fresh sterile liquid; boxes, bags, corrugated board, trays or cups for hot, cold, dry, wet and frozen foods and beverages; products for outdoor use, such as boxes, bags, signs and posters; pots, trays and covers for plants; packaging for building materials, and building materials.
The present disclosure is based on the following inventive recognition: the flexible sheet, paper or paperboard comprising the foam-formed fibrous layer may conveniently be rendered water-resistant by subjecting the foam-formed fibrous layer or the paper or paperboard comprising the foam-formed fibrous layer to grafting with a fatty acid halide. It has been found that fatty acid halide grafting is very effective for hydrophobization of paper or board comprising a foam-formed fibrous layer, possibly due to the relatively high porosity of the foam-formed cellulose. The foam-formed fibrous layer comprises an inherently open structure, which results in a need for a larger contact angle with water to prevent water penetration than a less porous structure. Surprisingly, it has been demonstrated that fatty acid halide grafting provides such water resistance to these porous materials.
Furthermore, unlike internal hydrophobic sizing agents, fatty acid halide grafting maintains and may even improve the strength properties of paper or paperboard. Furthermore, unlike paper or paperboard containing internal hydrophobic sizing agents and wet strength agents, fatty acid halide grafted paper or paperboard can be effectively repulped and recycled or reused.
The use of grafting to make the foamed fibrous material water resistant results in process related advantages. Thanks to the present invention, no (or hardly any) addition of internal sizing agents and/or wet strength agents is needed in the preparation of foamed material. In contrast, water resistance is obtained on already foamed dry materials. Thus, the problem of additive chemicals causing foam collapse is avoided.
In embodiments where the flexible sheet, paper or paperboard consists of a foam-formed fibrous layer, the fatty acid halide may be applied directly to the foam-formed fibrous layer.
In embodiments where the flexible sheet, paper or paperboard further comprises one or more additional fibrous or non-cellulose based layers, the fatty acid halide may be applied to the paper or paperboard to render the paper or paperboard (including the foam-formed fibrous layer) water resistant. Thus, in some embodiments, the paper or paperboard has undergone a fibrous layer grafted with a fatty acid halide to render the foam-formed water resistant.
In order to make the entire flexible sheet, paper or paperboard water resistant, grafting is preferably carried out such that grafting of the fatty acid to the cellulosic material is achieved throughout the entire thickness of the foam-formed fibrous layer or the paper or paperboard comprising the foam-formed fibrous layer. Thus, in some embodiments, the foam-formed fibrous layer has undergone grafting with a fatty acid halide throughout the thickness of the foam-formed fibrous layer.
In some embodiments, it is sufficient to graft the fibrous material with a fatty acid halide to render only the surface of the material water resistant.
The flexible sheet, paper or paperboard of the present invention is water resistant. The term "water-resistant" as used herein generally refers to a flexible sheet, paper or paperboard having a grafted fatty acid halide that has a higher water absorption resistance than the same flexible sheet, paper or paperboard without a grafted fatty acid halide (e.g., cobb after 60 seconds as determined according to standard ISO535 60 Indicated by the value).
In some embodiments, the fatty acid halide grafted onto the flexible sheet, paper, or paperboard has an aliphatic chain length of 8 to 22 carbon atoms. Examples of fatty acid halides include octanoyl chloride (C8), lauroyl chloride (C12), myristoyl chloride (C14), palmitoyl chloride (C16), and stearoyl chloride (C18) and/or mixtures thereof. In some embodiments, the fatty acid halide grafted onto the flexible sheet, paper, or paperboard is a C16 or C18 fatty acid halide or a mixture thereof. In some preferred embodiments, the fatty acid halide grafted onto the flexible sheet, paper, or paperboard is palmitoyl chloride or stearoyl chloride.
When the fatty acid halide grafting is performed, the flexible sheet, paper or paperboard is preferably dry. The term "dry" as used herein means that the dry content of the paper or paperboard is above 80 wt. -%, preferably above 90 wt. -% and more preferably above 95 wt. -%.
Grafting of the fatty acid halide onto the flexible sheet, paper or paperboard having available hydroxyl groups can be accomplished by applying the fatty acid halide to the surface of the flexible sheet, paper or paperboard, followed by penetration of the agent under heat (which also promotes formation of covalent bonds between the fatty acid halide and the hydroxyl groups of the foam-forming fibrous layer). The reaction between the fatty acid halide, e.g., fatty acid chloride, and the hydroxyl groups of the cellulosic material results in ester linkages between the agent and the foam-forming fibrous layer. To some extent, ungrafted and therefore unbound fatty acids may also be present. Upon reaction with hydroxyl groups in the foam-formed fibrous layer and/or with water in the foam-formed fibrous layer and/or air, a hydrohalic acid, such as hydrochloric acid, is formed as a reaction by-product. Grafting may preferably be followed by removal of the hydrohalic acid formed and optionally removal of the ungrafted residues (residues). One example of a grafting process that can be used to make the water-resistant paper or paperboard of the present disclosure is described in detail in international patent application WO2012066015 A1. Another example of a grafting process that can be used to make water-resistant paper or paperboard in the present disclosure is described in detail in international patent application WO2017002005 A1.
The grafting process may preferably be repeated to increase the amount of grafted and free fatty acids in the paper or paperboard. To achieve fatty acid halide grafting throughout the entire thickness of the paper or paperboard, it has been found that it may be preferable to graft the paper or paperboard at least twice with a fatty acid halide. Thus, in some embodiments, the paper or paperboard has a front surface and a back surface, and the paper or paperboard has been subjected to grafting with a fatty acid halide on both the front and back surfaces, or to grafting with a fatty acid halide on the same surface at least twice.
In some embodiments, the total amount of grafted and free fatty acids in the flexible sheet, paper or paperboard is from 0.1 to 4g/m of the total dry weight of the paper or paperboard 2 Within the range of (1). In some embodiments, the total amount of grafted and free fatty acids in the paper or paperboard is from 0.1 to 1.5g/m of the total dry weight of the paper or paperboard 2 Within the range of (1). The method used to analyze the amount of free and grafted fatty acids in the treated substrate was based on the method used for AKD analysis. Free fatty acids were extracted from the plate samples with organic solvents and analyzed after silanization using GC-FID. The same plate samples were then subjected to alkalinityHydrolysis to break the ester bond with cellulose, then extraction of the released fatty acids and analysis by GC-FID after silanization. The sum of the free fatty acids and bound fatty acids analyzed constitutes the total amount of fatty acid halides.
In some embodiments, the surface of the flexible sheet, paper or paperboard that is subjected to grafting with a fatty acid halide has a water contact angle above 90 °, preferably above 100 °. The method of measuring the Contact Angle (CA) is based on the standard ISO TC 6/SC 2/WG 41.
Fatty acid halide grafting typically results in Cobb of flexible sheet, paper or paperboard 60 A value of 30g/m 2 The following. In some embodiments, the Cobb of the paper or paperboard surface that is subjected to grafting with a fatty acid halide 60 The value (as determined after 60 seconds according to standard ISO535 2 Below, preferably 20g/m 2 Below, more preferably 10g/m 2 The following.
In some embodiments, the edge absorption index (1% lactic acid solution at 23 ℃ and 50% relative humidity 1 h) of a flexible sheet, paper or paperboard subjected to grafting with a fatty acid halide is at 1kg/m 2 h is less than, preferably 0.7kg/m 2 h is less and more preferably 0.4kg/m 2 h is less than or equal to h.
The fatty acid halide grafting throughout the entire thickness of the foam-formed fibrous layer eliminates the need for hydrophobic sizing agents. Thus, in some embodiments, the paper or paperboard is free of added hydrophobic sizing agents, or has only a small amount (e.g., less than 30% of the amount typically used) of added hydrophobic sizing agents, such as Alkyl Ketene Dimer (AKD), alkenyl Succinic Anhydride (ASA), and/or rosin sizing agents. In a preferred embodiment, the paper or paperboard is free of added hydrophobic sizing agents.
The fatty acid halide grafting throughout the entire thickness of the foam-formed fibrous layer also eliminates the need for added wet strength agents to improve the wet strength of the foam-formed fibrous layer. Thus, in some embodiments, the paper or paperboard has no added wet strength agent or only a small amount (e.g., less than 30% of the amount typically used) of added wet strength agent, such as urea-formaldehyde (UF), melamine-formaldehyde (MF), and polyamide-epichlorohydrin (PAE). In a preferred embodiment, the paper or paperboard is free of added wet strength agents.
The use of fatty acid halide grafting may also reduce the need for water resistant polymer coatings on paper or paperboard, which would reduce the need for additional coating steps, promote processability, and save materials, time, and cost.
Unlike paper and paperboard containing internal sizing agents and wet strength agents, the fatty acid halide grafted flexible sheet, paper or paperboard can be effectively repulped and recycled. In some embodiments, the flexible sheet, paper or paperboard is repulpable, and is characterized by a reject rate (as determined by PTS RH021/97 test method) of less than 20%, preferably less than 10%, more preferably less than 5% and most preferably less than 1%.
According to a second aspect shown herein, there is provided a method for manufacturing a water resistant fibre material comprising:
a) Providing a flexible sheet, paper or paperboard comprising a foam-formed fibrous layer; and
b) Subjecting the foam-formed fibrous layer to grafting with a fatty acid halide to render the foam-formed fibrous layer water-resistant.
In some embodiments, step a) comprises providing a flexible sheet, paper or paperboard, wherein at least one layer is formed by:
i) Introducing an aqueous slurry suspension comprising cellulosic material, a foaming agent and optionally additives into a foam;
ii) forming a foamed web; and
iii) The web is dewatered and dried to obtain a foam-formed fibrous layer.
In some embodiments, the flexible sheet, paper or paperboard is comprised of a foam-formed fibrous layer.
In some embodiments, the water resistant paper or paperboard may further comprise one or more additional fibrous or non-fibrous layers.
In some embodiments, the flexible sheet, paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers.
The additional fibrous layers may be foam-formed or non-foam-formed.
An important characteristic of paperboard is bending stiffness. The bending stiffness of a board is usually established by having outer layers with a high tensile stiffness and one or more bulk layers between the outer layers so that the outer layers are placed at a desired distance from each other. The bulk layer is often referred to as an intermediate layer or layers. In some embodiments, the foam-formed fibrous layer constitutes an intermediate layer between two or more additional fibrous layers, preferably the foam-formed fibrous layer constitutes an intermediate layer between two or more non-foam-formed fibrous layers.
In embodiments wherein the flexible sheet, paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers, the foam-formed fibrous layer preferably constitutes at least 50 wt.%, more preferably at least 60 wt.%, at least 70 wt.%, at least 80 wt.% or at least 90 wt.% of the total thickness of the foam-formed fibrous layer.
In embodiments wherein the flexible sheet, paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers, the foam-formed fibrous layer preferably constitutes at least 10 wt.%, more preferably at least 30 wt.% or at least 50 wt.% of the total basis weight of the paper or paperboard.
In embodiments where the flexible sheet, paper or paperboard consists of a foam-formed fibrous layer, the fatty acid halide may be applied directly to the foam-formed fibrous layer.
In embodiments where the flexible sheet, paper or paperboard further comprises one or more additional fibrous or non-cellulose based layers, the fatty acid halide may be applied to the paper or paperboard to render the flexible sheet, paper or paperboard (including the foam-formed fibrous layer) water resistant. Thus, in some embodiments, the flexible sheet, paper or paperboard is grafted with a fatty acid halide to render the foam-formed fibrous layer water resistant.
In order to make the entire flexible sheet, paper or paperboard water resistant, grafting is preferably carried out such that grafting of the fatty acid halide to the cellulosic material is achieved throughout the entire thickness of the foam-formed fibrous layer or the paper or paperboard comprising the foam-formed fibrous layer. Thus, in some embodiments, the foam-formed fibrous layer is grafted with a fatty acid halide throughout the thickness of the foam-formed fibrous layer.
Grafting may be performed as described above with reference to the first aspect.
When the fatty acid halide grafting is performed, the flexible sheet, paper or paperboard is preferably dry. The term "dry" as used herein means that the dry content of the paper or paperboard is above 80 wt. -%, preferably above 90 wt. -% and more preferably above 95 wt. -%.
In some embodiments, grafting comprises contacting at least one surface of the flexible sheet, paper or paperboard with a fatty acid halide in a liquid, spray and/or vapor state.
The grafting of the fatty acid halide in step b) results in Cobb of the paper or paperboard 60 A value of 30g/m 2 The following. In some embodiments, cobb subjected to paper or paperboard grafted with fatty acid halide 60 A value of 20g/m 2 Below, preferably 15g/m 2 The following.
The use of paper or paperboard comprising a foam-formed fibrous layer having a higher permeability to fatty acid halides may facilitate grafting throughout the entire thickness of the foam-formed fibrous layer. Thus, in some embodiments, grafting is performed only once.
To achieve fatty acid halide grafting throughout the entire thickness of the foam-formed fibrous layer, it has been found that it should be preferred to graft the foam-formed fibrous layer with a fatty acid halide at least twice. In some embodiments, the paper or paperboard has a front surface and a back surface, and the substrate has undergone grafting with a fatty acid halide on both the front and back surfaces, or at least twice on the same surface.
According to a third aspect shown herein, there is provided a carton blank comprising water resistant paper or paperboard according to the first aspect.
According to a fourth aspect shown herein, there is provided a container comprising a water resistant paper or paperboard according to the first aspect.
While the invention has been described with reference to various exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Example treatment of foam-formed Panels with fatty acid chloride
The panels were grafted by subjecting both sides of a foam-formed 1-ply board made of 100% bleached pine wood to palmitoyl chloride (C16), followed by heat treatment at 190 ℃.
The gram weight of the foam-formed board is 150g/m 2 A thickness of 300 μ and a density of 500kg/m 3 . The air permeability of the foamed sheet was 45 μm/(Pa · s). The air permeability was measured using the Bendtsen method (ISO 5636-3).
As shown in table 1, the untreated reference sample showed very poor surface hydrophobicity, had a high Cobb 60 value, and an immeasurable contact angle. After grafting, the surface hydrophobicity was significantly improved, showing low Cobb 60 values and very high contact angles.
The untreated reference showed no protection against edge penetration, but reached a very low LA absorption value (wick value) after grafting.
Table 1 cobb 60, contact angle and edge absorption values
Cobb was performed by ISO535 60 And (6) analyzing.
The Contact Angle (CA) is measured according to the standard ISO TC 6/SC 2/WG 41.
The marginal absorption penetration test was performed using Lactic Acid (LA) solution (1%) at 23 ℃ and 50% RH for 1 h.
Claims (26)
1. A water resistant fibrous material comprising:
a fibrous layer formed by the foam, wherein,
wherein the foam-formed fibrous layer has been subjected to grafting with a fatty acid halide to render the foam-formed fibrous layer water-resistant.
2. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer has been subjected to grafting with a fatty acid halide throughout the entire thickness of the foam-formed fibrous layer.
3. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer consists of a flexible sheet comprising a stretch in the range of 5-45% measured according to method ISO 1924-2.
4. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer consists of paper or paperboard.
5. The water resistant fibrous material of claim 4, wherein the paper or paperboard comprises a foam-formed fibrous layer and one or more additional fibrous layers.
6. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer constitutes an intermediate layer between two or more additional fibrous layers.
7. The water resistant fibrous material of any of the preceding claims, wherein the flexible sheet, paper or paperboard has been subjected to a fibrous layer grafted with a fatty acid halide to render the foam-shaped water resistant.
8. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer has a front surface and a back surface, and the foam-formed fibrous layer has been subjected to grafting with a fatty acid halide on both the front and back surfaces, or to grafting with a fatty acid halide on the same surface at least twice.
9. The water resistant fibrous material of any preceding claim, wherein the foam-formed fibrous layer has a density of 700kg/m 3 Below, preferably 600kg/m 3 Below 500kg/m 3 Below or in 400kg/m 3 The following.
10. A water resistant fibre material as claimed in any one of the preceding claims, wherein the thickness of the foam-formed fibre layer is above 30 μm, preferably above 100 μm.
11. A water resistant fibre material as claimed in any one of the preceding claims, wherein the basis weight of the foam-formed fibre layer is in the range of 15-500g/m 2 In the range of 100 to 400g/m, preferably 2 Within the range of (1).
12. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer constitutes at least 50 wt.%, more preferably at least 60 wt.%, at least 70 wt.%, at least 80 wt.% or at least 90 wt.% of the total thickness of the foam-formed fibrous layer.
13. The water resistant fibrous material according to any one of the preceding claims, wherein the foam-formed fibrous layer constitutes at least 10 wt.%, more preferably at least 30 wt.% or at least 50 wt.% of the total basis weight of the foam-formed fibrous layer.
14. The water resistant fibrous material of any preceding claim, wherein the total amount of grafted and free fatty acids in the foam-formed fibrous layer is from 0.1 to 1.5g/m of the total dry weight of the foam-formed fibrous layer 2 In the presence of a surfactant.
15. A water resistant fibre material as claimed in any one of the preceding claims, wherein the surface of the foam-formed fibre layer which has undergone grafting with a fatty acid halide has a water contact angle above 90 °, preferably above 100 °.
16. The water resistant fibrous material of any preceding claim, wherein the Cobb of the surface of the foam-formed fibrous layer that is subjected to grafting with a fatty acid halide 60 The value (determined according to standard ISO535:2014 after 60 seconds) is 30g/m 2 Below, preferably 20g/m 2 The concentration is preferably 10g/m or less 2 The following.
17. The water resistant fibrous material of any of the preceding claims, wherein the edge absorption index (1% lactic acid solution at 23 ℃ and 50% relative humidity 1 h) of the foam-formed fibrous layer that has undergone grafting with a fatty acid halide is at 1kg/m 2 h is less than, preferably 0.7kg/m 2 h is less than and more preferably 0.4kg/m 2 h is less than or equal to h.
18. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer is free of added hydrophobic sizing agents, such as Alkyl Ketene Dimer (AKD), alkenyl Succinic Anhydride (ASA), and/or rosin sizing agents.
19. The water-resistant fibrous material according to any one of the preceding claims, wherein the foam-formed fibrous layer is free of added wet strength agents, such as urea-formaldehyde (UF), melamine-formaldehyde (MF) and polyamide-epichlorohydrin (PAE).
20. The water resistant fibrous material according to any one of the preceding claims, wherein the foam-formed fibrous layer has repulpability characterized by a reject rate (determined according to PTS RH021/97 test) of below 20%, preferably below 10%, more preferably below 5% and most preferably below 1%.
21. The water resistant fibrous material of any of the preceding claims, wherein the foam-formed fibrous layer is used in a wet or humid environment.
22. A method for making a water resistant fibrous material, the method comprising:
a) Providing a fibrous material comprising a foam-formed fibrous layer, and
b) Subjecting the foam-formed fibrous layer to grafting with a fatty acid halide to render the foam-formed fibrous layer water-resistant.
23. The method of claim 22, wherein step a) comprises providing the fibrous material in the form of a flexible sheet, paper or paperboard, wherein at least one layer is formed by:
i) Introducing an aqueous slurry suspension comprising cellulosic material, a foaming agent and optionally additives into the foam;
ii) forming a web of foam; and
iii) The web is dewatered and dried to obtain a foam-formed fibrous layer.
24. The method of any one of claims 22-23, wherein step a) comprises subjecting the foam-formed fibrous layer to grafting with a fatty acid halide to render the foam-formed fibrous layer water resistant.
25. The method of any one of claims 22-24, wherein grafting comprises contacting at least one surface of the foam-formed fibrous layer with a fatty acid halide in a liquid, spray, and/or vapor state.
26. The method of any one of claims 22-25, wherein grafting is performed only once.
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| PCT/IB2021/055590 WO2021260606A1 (en) | 2020-06-24 | 2021-06-24 | Water-resistant fibrous material and method for manufacturing it |
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| CN115748307A (en) * | 2022-11-24 | 2023-03-07 | 中国海诚工程科技股份有限公司 | Laminated foam sheet molding green packaging material and preparation method thereof |
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| US20150238650A1 (en) * | 2012-09-26 | 2015-08-27 | Kemira Oyj | Absorbent materials, products including absorbent materials, compositions, and methods of making absorbent materials |
| CN107709666A (en) * | 2015-06-29 | 2018-02-16 | 斯道拉恩索公司 | Method for making cellulose base bottom hydrophobization |
| CN109891025A (en) * | 2016-09-01 | 2019-06-14 | Hs制造集团有限责任公司 | The method of the biology base derivatization on cellulosic surface |
Also Published As
| Publication number | Publication date |
|---|---|
| SE2050753A1 (en) | 2021-12-25 |
| EP4172412A1 (en) | 2023-05-03 |
| KR20230026353A (en) | 2023-02-24 |
| US20230243105A1 (en) | 2023-08-03 |
| SE544175C2 (en) | 2022-02-22 |
| CA3186605A1 (en) | 2021-12-30 |
| WO2021260606A1 (en) | 2021-12-30 |
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