EP0532445A1 - Procédé pour fabriquer des produits à base de papier ayant des revêtements à base de ciment - Google Patents

Procédé pour fabriquer des produits à base de papier ayant des revêtements à base de ciment Download PDF

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Publication number
EP0532445A1
EP0532445A1 EP92610001A EP92610001A EP0532445A1 EP 0532445 A1 EP0532445 A1 EP 0532445A1 EP 92610001 A EP92610001 A EP 92610001A EP 92610001 A EP92610001 A EP 92610001A EP 0532445 A1 EP0532445 A1 EP 0532445A1
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EP
European Patent Office
Prior art keywords
coating composition
paper
product
cement
process defined
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP92610001A
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German (de)
English (en)
Inventor
Gordon William Spratt
Brian Donald Birmingham
John Wong
Clarke Cunningham
Elizabeth Rimniceanu
David Zepka
Nicholas Bush
Norman Wolfe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
IMP- PAK PACKAGING Corp
Original Assignee
IMP- PAK PACKAGING Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by IMP- PAK PACKAGING Corp filed Critical IMP- PAK PACKAGING Corp
Publication of EP0532445A1 publication Critical patent/EP0532445A1/fr
Withdrawn legal-status Critical Current

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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
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • 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
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/64—Inorganic compounds

Definitions

  • This invention relates to coating compositions and process for using the coating compositions. More particularly, this invention relates to cement-containing coating compositions which can be applied to paper products and the processes for preparing and coating these products.
  • plastic containers such as styrofoam containers
  • plastic containers such as those used in grocery stores and fast food restaurants to package food
  • harmful compounds are released into the atmosphere which cause pollution or which damage the ozone layer.
  • styrofoam is usually foamed by using chlorofluorocarbon blowing agents such as Freon 11 and Freon 12, which can damage the ozone layer.
  • chlorofluorocarbons are usually released into the atmosphere.
  • paper containers are degradable, a drawback to using paper containers instead of plastic containers for food is that paper absorbs moisture and grease leading to premature degradation of the container. Thus, in order for paper containers to be adequate substitutes for plastic containers, it is necessary to treat the surface of the paper containers to render them substantially moisture-resistant.
  • United States patent No. 3,063,851 discloses a cement-based paint comprised primarily of Portland cement admixed with a non-aqueous vehicle made up of a small amount of resin dissolved in an organic solvent. The cement-based paint is used to waterproof masonry walls.
  • United States patent No. 2,600,081 discloses a Portland cement-based paint that can be used to coat porous fibre-board material. The Portland cement-based paint contains methyl cellulose.
  • a United States patent No. 4,434,257 discloses a cement composition which is comprised of a mixture of a conventional cement composition with an ethylene-vinyl acetate copolymer emulsion which contains a polyvinyl alcohol and a fatty acid ester of a polyvalent alcohol.
  • the cement composition can be applied to buildings to improve water resistance.
  • United States patent No. 4,441,944 discloses a cementitious composition
  • a cementitious composition comprising a Portland cement, a polymeric emulsion and flyash.
  • the composition can be foamed and applied to the surface of a sheet-like insulating board which can be made of fibrous cellulose.
  • United States patent No. 4,395,159 discloses a coating composition applied to a metal substrate to protect the substrate from deterioration.
  • the coating composition comprises a cementitious material, such as Portland cement, a filler, a polymeric material, such as vinyl acetate polymers and copolymers, and chopped fibres.
  • United States patent No. 4,844,964 discloses that Portland cement can be mixed with water and an aqueous emulsion of polymers, such as ethylene vinyl acetate copolymers, and then used to prepare a signboard.
  • United States patent No. 4,892,586 discloses various organic acids or salts thereof which may be used as retarders for the setting or solidification of cements.
  • United States patent No. 2,470,505 discloses that maleic acid can be added to a cement slurry to act as a retardant to lengthen the stiffening time.
  • United States patent No. 4,054,461 discloses that hydroxypolycarboxylic acid may be used as a retarder in a cement composition
  • United States patent No. 3,188,221 discloses that some organic acids may be used as retarding agents for retarding the setting time of cement.
  • Canadian patent No. 638,274 discloses a cement product containing Portland cement and fatty acids.
  • the present invention provides a process for preparing a moulded paper product, the process comprising the steps of:
  • the process generally comprises providing a pulped paper feedstock, moulding the feedstock to produced a shaped product; drying the shaped product; coating the dried, shaped product with a coating composition; curing the coating composition; and, optionally, hot pressing the cured coated product.
  • a coating composition suitable for use in the present process is not particularly restricted and is preferably degradable to some extent.
  • the coating composition is comprised of a cement, at least one of a clay and a sulphate and an aqueous emulsion polymer. More preferably, the coating composition further comprises at least one of an organic acid and a wax.
  • pulped paper feedstock for use in the present process is not particularly restricted nor is the manner by which it is obtained.
  • the pulped paper feedstock is repulped newsprint or other paper-based waste.
  • the following detailed description of an embodiment of the present invention is provided in the context of using a pulped paper feedstock including a repulped newsprint or other paper-based feedstock; however, it will be appreciated that the invention is not limited solely to such a feedstock.
  • waste newsprint is repulped, separated, moulded, dried, coated, cured and hot pressed to produce a moulded paper product.
  • the stock which is used for coating with the composition of the instant invention is preferably a moulded pulp stock which is derived from waste paper, more preferably from waste newsprint and corrugated liner. Of course, virgin pulp and pulp screenings may also be used.
  • the waste paper is received in bulk and manually sorted to remove glossy printed papers which are difficult to recycle. After sorting, the selected waste paper is transferred by conveyor into a batch repulper, where it is mixed with water, rosin (which is used to size the paper) and an emulsified wax to help reduce moisture absorption.
  • the waste paper is beaten into a uniform consistency with a measured quantity of recycled water to produce a pulped paper feedstock having a solids content in the range of about 2 to about 10 percent by weight, preferably from about 3 to about 5 percent by weight.
  • the amount of rosin used is in the range of from about 0.5 to about 2 percent by weight, preferably from about 1 to about 3 percent by weight.
  • the emulsified wax is added in the range of from about 0.5 to about 2 percent by weight, preferably from about 1 to about 3 percent by weight.
  • the preferred emulsified waxes are paraffin based, although any waxes which are compatible with the stock solution herein may be used.
  • the stock is maintained in the batch repulper at a temperature which is normally slightly above ambient conditions, generally in the range of from about 80°F to about 115°F, preferably from about 90°F to about 100°F for about 30 to about 45 minutes or until the fibre is broken down and is in the form of a pulp.
  • the repulped waste paper stock is then pumped into a raw stock tank where it is held for further processing. From there, the raw stock is pumped into a high density separator to remove debris and other contaminants. Next, the raw stock may or may not be passed over a screen where lumpy material is removed. The lumpy material may then be processed through a refiner and combined with the acceptable material from the screen which together are then pumped to a refined stock tank where they are held for further processing at a slightly lower solids content than the raw stock storage.
  • the refined material and the material from the high density separator which is not in need of refining are pumped into a tank where they are blended with recirculated water, aluminum sulphate in the range of up to about 1 percent by weight to improve the ability of the rosin to size the paper stock, a defoamer in the range of from about 1 to about 10 parts per million by weight, and other necessary ingredients, depending upon the end use.
  • other ingredients include fillers, additives such as clays, including kaolin, calcium carbonate, as well as polymer de-watering enhancers such as cationic starch.
  • the blended material produced in this step is then suitable for use as pulped paper feedstock in the present process.
  • the blended material in this instance the pulped paper feedstock for the present process, is then transferred to the moulding vat where additional water is added to reduce the solids content to from about 0.3 to about 2.0 percent by weight, preferably from about 0.5 to about 1.0 percent by weight.
  • the pulp stock is continuously recirculated as it is exposed to the vacuum moulder which is designed to form the product to be utilized.
  • the moulder will form large size assemblies containing multiple units of the item to be formed. For example, with food trays the overall size of the assembly is about 14 x 25 inches and contains about 3-9 food trays per assembly.
  • the moulding machine itself comprises, in addition to the moulding vat, the vacuum moulder and the transfer dye mechanism.
  • the vacuum moulder consists of a moulding drum, preferably having several faces containing dyes having the shape of the desired product. As the drum rotates, each face in succession is dipped into the pulp stock. A vacuum system attached to the rotating drum causes the fibres contained in the pump stock to be deposited onto the forming dyes on the face of the drum as the water in which the fibres are suspended is drawn through the dyes and drained out. During the moulding operation the fibres orient in a mechanically-interlocked layer to form the moulded product. The removed water is recycled for further use.
  • the wet moulded product is then transferred into a dryer where it is dried for a period of time and under temperature conditions which are adjusted depending upon the size, shape and end use of the particular product being moulded.
  • the product is dried at an oven temperature in the range of from about 375°F to about 500°F, preferably from about 400°F to about 450°F, for period of time in the range of from about 10 to about 30 minutes.
  • a surface temperature Preferably, as the product leaves the dryer, it will have achieved a surface temperature of from about 180°F to about 230°F.
  • the product may be coated with a coating composition using one of several coating application techniques as described above.
  • the preferred method involves spray coating.
  • the tray assembly is reheated immediately before coating in an oven at the same temperature described above so that the temperature of the assembly is again elevated to a value in the range of from about 190°F to about 230°F.
  • the assembly is then reheated to about 190°F and the second side is coated.
  • the back or rough side of the tray assembly will be coated to a 3 mil dry film thickness while the front or smooth side will be coated to about a 1.5 mil dry film thickness.
  • the coating processes which are employed, as pointed out above may vary, it is preferred to use a two-step spraying process employing an air-assisted, low pressure spray followed by an electrostatic spraying.
  • the assembly After the assembly is coated, it is preferably passed through a 350°F to 500°F curing oven where it is maintained for a period of from about 30 seconds to several minutes, all again depending upon the coating composition and the desired end use involved.
  • the assembly may then be hot-pressed using a standard press for a period of from about 0.2 to about 2 seconds, at temperatures ranging between about 250°F and about 400°F, and at a pressure of from about 50 to about 250 psi.
  • the purpose of hot-pressing is to smooth the coating and to add gloss.
  • the coated assembly leaves the hot press it is then, in the preferred instance, disassembled by cutting, stacked and stored for shipment.
  • the preferred coating composition suitable for use in the present process comprises a cement, more preferably white Portland cement.
  • the preferred coating composition also preferably comprises a clay.
  • the clay should be of extremely fine particle size and should consist of one or more clay minerals, including hydrosilicates of aluminum, iron or magnesium. Most preferred among the clays are the kaolin clays which include kaolinite dickite and halloysite-endellite. Clays are well known in the art and the appropriate clay for use in the preferred coating composition would be apparent to a person skilled in the art.
  • a sulphate preferably, an alkali or alkaline earth metal sulphate, and most preferably, calcium sulphate.
  • cement, clay and sulphate suitable for use in the preferred coating composition are readily available commercially.
  • the preferred coating composition also contains an aqueous emulsion polymer which, preferably, has FDA (or other appropriate governmental) approval, if the finished product is to be used in a food-type application.
  • aqueous emulsion polymer which will impart water resistance to a paper substrate may be employed as long as it will not be degraded or otherwise break down at a relatively high pH or in the presence of a cement.
  • the polymer is a carboxyl functional emulsion polymer, such as acrylic, polyester, epoxy, vinyl, vinyl acetate, ethylene-vinyl acetate, or epoxy ester polymer or copolymer.
  • the emulsion polymer is an ethylene-vinyl acetate aqueous emulsion copolymer.
  • the ethylene-vinyl acetate copolymers which are suitable can be prepared by copolymerizing a mixture of ethylene and vinyl acetate in the presence of a free-radical catalyst.
  • Suitable ethylene-vinyl acetate emulsion compositions are readily available commercially.
  • One example of a suitable emulsion copolymer is AirflexTM 100 HS latex, available from Air Products and Chemicals, Inc.
  • the preferred coating composition for use in the present process more preferably further comprises a wax, most preferably a wax emulsion, to aid in press release and to retard water and other moisture absorption.
  • the waxes which may be used herein may either be synthetic or naturally occurring. However, in order for the wax to carry out its intended function, it is important that the wax not degrade in the presence of other components in the coating composition.
  • the waxes which may be used are included naturally occurring waxes such as esters of long chain fatty alcohols and acids, petroleum and mineral waxes.
  • the common waxes which may be used are the vegetable waxes such as carnauba wax, candelilla wax, and hydrogenated candelilla wax.
  • Other waxes include the synthetic waxes such as polyethylene waxes and paraffin waxes, these latter waxes being preferred.
  • the preferred coating composition more preferably further comprises an organic acid, such as maleic, stearic, potassium hydrogen tartrate or oleic acid or any organic sugar such as corn syrup, which serves to retard the setting time of the coating compositions.
  • organic acid such as maleic, stearic, potassium hydrogen tartrate or oleic acid or any organic sugar such as corn syrup.
  • Difunctional acids are preferred.
  • the presence of an organic acid in the coating composition helps to prolong the pot life and to make it easier to spray the composition onto a degradable substrate such as a paper substrate.
  • the coating composition may contain conventional fillers, additives, thickeners, defoamers and pigments. Since the cement coating composition can be readily applied to paper substrates, such as vacuum moulded pulp food trays, and since pigments can be readily added to the coating composition, the coating composition provides a relatively easy means for colouring the surface of a paper substrate a particular colour.
  • the coating composition is prepared by first combining the clay, the sulphate, the acid and the aqueous emulsion polymer in water.
  • the cement should be added shortly before the coating composition is applied to a paper substrate because the coating composition has a pot life of up to 24 hours once the cement is added.
  • the preferred coating composition will contain from about 40 to about 90 percent by weight cement, preferably from about 50 to about 75 percent by weight; from 0 to about 20 percent by weight of a clay, preferably from about 2 to about 10 percent by weight; from 0 to about 20 percent by weight of sulphate, preferably from about 1 to about 15 percent by weight; and from about 6 to about 60 percent by solids weight of the aqueous emulsion polymer, preferably from about 10 to about 40 percent by weight; with the proviso that at least one of the clay and the sulphate are actually present in the composition. All weights are based upon the total solids weight of aqueous emulsion polymer, cement, sulphate, and clay in the coating composition.
  • an organic acid or sugar it should be added in an amount in the range of from about 1 to about 20 percent based on the above compositional weight.
  • a wax it should be added in an amount in the range of from about the 1 to about 25 percent by weight solids level based on the above compositional weight.
  • the coating composition In order for the paper substrate to disintegrate after it is discarded, it is necessary for the coating composition to break down and degrade so that the paper substrate can degrade.
  • the intact cement coating serves as a protective coating for the paper substrate thereby inhibiting premature disintegration of the paper substrate. Once the cement coating begins to break down and degrade, the paper substrate can also begin to degrade.
  • Disintegration of the coating composition, and thus of the paper substrate will occur when the degradable coating is placed on at least one side of the paper substrate. Faster disintegration, of course, will occur when both sides of the paper substrate are coated with the degradable coating. However, it is possible to coat one side with the degradable coating described herein and another side with a more conventional coating or a less degradable coating. In general, with food products a less degradable or non-degradable coating is placed on the side of the paper which will be exposed to the food product and the reverse side is coated with the composition described herein.
  • the partially degradable compositions which may be used in conjunction with the coating compositions described otherwise herein simply involve the use of higher percentages of the coating composition of the emulsions described herein and lesser amounts of the cement and other components. When the cement and other components are totally removed, of course, the coating composition becomes essentially non-degradable.
  • a particularly preferred coating composition which still maintains certain degradative properties but which exhibits heightened resistance to liquids, generally, and food liquid specifically, involves a coating composition comprising: from about 15 to about 60 percent by weight of a cement; from about 40 to about 75 percent by weight on a solids basis of aqueous emulsion polymer; from 0 to about 20 percent, preferably from about 1 to 20 percent of sulphate; and from 0 to about 10 percent, preferably from about 1 to 10 percent of a clay, all as described above.
  • the coating composition used in the present process may be applied by conventional spraying or airless spraying, with or without electrostatic assist.
  • electrostatic discs may be used to apply the coating compositions during the present process.
  • the sulphate e.g. calcium sulphate
  • the coating will readily degrade and decompose within a few years in a moisture, and preferably biologically, active environment such as a landfill, thereby allowing the paper substrate also to degrade.
  • the preferred coating composition for use in the present process is substantially non-toxic, it may be used to coat paper articles for food storage, such as vacuum moulded paper food trays used in the fast food industry.
  • the paper containers coated with the coating composition have a semi-lustrous finish and smooth surface texture and are resistant to food juices and moisture.
  • Components A and B were prepared as follows:
  • Components A and B were then mixed together and exhibited a pot life of two hours. Over this period of time the mixture could readily be applied to reconstituted paper or cardboard flats by spraying as well as by other conventional coating means.
  • a coating of the Component A and Component B mixture was sprayed to a thickness of 3 mils on reconstituted paper plates using, in one case, a standard spray gun and, in another case, an electrostatic disc.
  • the plates were dried in a 350°F oven.
  • the plates were then placed in a platen press and heated at a temperature of 100° C and under 100 psi for about 1 second.
  • a uniform, smooth coating resulted.
  • the coatings degraded when placed in a moisture active landfill, i.e., a landfill containing sufficient moisture to degrade the coating in question over time.
  • a two-component coating composition was prepared as follows:
  • Components A and B were blended and sprayed to a thickness of 5 mil on a reconstituted paper plate stock, dried and cured as in Example 1. The reverse side of the plate was sprayed, dried and cured with the blend described in Example 1.
  • the coated plates were then brought in contact with meat products.
  • the inside coating using the Example 2 composition showed excellent resistance to the meat product.
  • the coated plate is exposed to a moisture active landfill, it degraded.
  • Example 2 blend contains a much higher level of emulsion than does Example 1 so as to retard food liquid penetration of the cardboard stock.
  • the material prepared in Example 1 is much more readily degradable because of its high concentration of cement and its relatively low amount of emulsion polymer.

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  • Inorganic Chemistry (AREA)
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EP92610001A 1991-08-21 1992-01-07 Procédé pour fabriquer des produits à base de papier ayant des revêtements à base de ciment Withdrawn EP0532445A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US74803191A 1991-08-21 1991-08-21
US748031 1991-08-21

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EP0532445A1 true EP0532445A1 (fr) 1993-03-17

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003000556A3 (fr) * 2000-01-21 2003-08-14 Joseph A Nicholson Objet cassable creux a revetement cassable absorbant le colorant
WO2005028752A1 (fr) * 2003-09-22 2005-03-31 Tembec Industries Inc. Matiere composite en fibre de lignocellulose-resine
WO2021073672A1 (fr) * 2019-10-14 2021-04-22 Kiefel Gmbh Installation par moulage de fibres pour la production de pièces moulées en matière fibreuse dégradable de manière respectueuse de l'environnement

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6245388B1 (en) 1999-06-30 2001-06-12 The Chinet Company Technology Wave coating of articles
CN109629283A (zh) * 2018-12-05 2019-04-16 广东轻工职业技术学院 一种纸胚体及其制备方法与应用

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2236900A (en) * 1935-09-06 1941-04-01 Carey Philip Mfg Co Reconstituted felt and manufacture of same

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2236900A (en) * 1935-09-06 1941-04-01 Carey Philip Mfg Co Reconstituted felt and manufacture of same

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003000556A3 (fr) * 2000-01-21 2003-08-14 Joseph A Nicholson Objet cassable creux a revetement cassable absorbant le colorant
WO2005028752A1 (fr) * 2003-09-22 2005-03-31 Tembec Industries Inc. Matiere composite en fibre de lignocellulose-resine
US7396438B2 (en) 2003-09-22 2008-07-08 Tembec Industries Inc. Lignocellulose fiber-resin composite material
US7628889B2 (en) 2003-09-22 2009-12-08 Tembec Industries Inc. Lignocellulose fiber-resin composite material
CN1856623B (zh) * 2003-09-22 2010-11-24 泰姆贝克工业公司 木质纤维素纤维-树脂复合材料
US8202398B2 (en) 2003-09-22 2012-06-19 Tembec Industries Inc. Lignocellulose fiber-resin composite material
WO2021073672A1 (fr) * 2019-10-14 2021-04-22 Kiefel Gmbh Installation par moulage de fibres pour la production de pièces moulées en matière fibreuse dégradable de manière respectueuse de l'environnement

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Publication number Publication date
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