EP4001504B1 - Base paper, its use and multilayer structure - Google Patents

Base paper, its use and multilayer structure Download PDF

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Publication number
EP4001504B1
EP4001504B1 EP20208279.8A EP20208279A EP4001504B1 EP 4001504 B1 EP4001504 B1 EP 4001504B1 EP 20208279 A EP20208279 A EP 20208279A EP 4001504 B1 EP4001504 B1 EP 4001504B1
Authority
EP
European Patent Office
Prior art keywords
base paper
laminates
range
weight
thermosetting resin
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.)
Active
Application number
EP20208279.8A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP4001504C0 (en
EP4001504A1 (en
Inventor
Jukka PIISPA
Teemu UKKOLA
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.)
Mm Kotkamills Absorbex Oy
Original Assignee
Mm Kotkamills Absorbex Oy
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 Mm Kotkamills Absorbex Oy filed Critical Mm Kotkamills Absorbex Oy
Priority to EP20208279.8A priority Critical patent/EP4001504B1/en
Priority to PL20208279.8T priority patent/PL4001504T3/pl
Priority to RS20231148A priority patent/RS64903B1/sr
Priority to HRP20231271TT priority patent/HRP20231271T1/hr
Priority to ES20208279T priority patent/ES2960957T3/es
Publication of EP4001504A1 publication Critical patent/EP4001504A1/en
Application granted granted Critical
Publication of EP4001504C0 publication Critical patent/EP4001504C0/en
Publication of EP4001504B1 publication Critical patent/EP4001504B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • 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
    • D21H17/20—Macromolecular organic compounds
    • D21H17/21—Macromolecular organic compounds of natural origin; Derivatives thereof
    • D21H17/23—Lignins
    • 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
    • D21H27/18—Paper- or board-based structures for surface covering
    • 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
    • D21H27/18—Paper- or board-based structures for surface covering
    • D21H27/22—Structures being applied on the surface by special manufacturing processes, e.g. in presses

Definitions

  • the present invention relates to a base paper, its use, and a multilayer structure comprising at least one layer made from said base paper, according to the preambles of the enclosed claims.
  • Atypical laminate structure may comprise a base or core, possibly a decorative paper layer(s) arranged on the base or core and finally an overlay layer.
  • the base or core may be a material board, such as a particle board, fibreboard or the like, or the base or core may be formed from a number of layers of core paper or base paper that have been permanently attached together during the manufacture of laminate structure, i.e. multilayer structure of multilayer product.
  • the laminate structure In case the base or core of the laminate structure comprises a material board, the laminate structure usually comprises one or several layers of base paper between the material board and the possible decorative layer(s) and the overlay layer.
  • Other multilayer products are, for example, evaporative cooling pads.
  • multilayered products, such as laminate structures usually thus comprise multiple layers of base paper, which usually is an absorbent kraft paper.
  • the layers may be attached together by a thermosetting resin which is cured during the manufacture of the multilayer product or structure.
  • the individual base or core paper layers and the decorative paper layers are impregnated with the thermosetting resin, the layers are stacked in the desired order, pressed together and the resin is cured, resulting the final multilayer product or structure, such as laminate structure.
  • the used core or base paper absorbs resin effectively and uniformly.
  • lignin-based resins could provide a sustainable alternative to petroleum-based polymers, as they are at least partly based on renewable sources and they can be manufactured by using raw-materials that otherwise might be considered as waste and incinerated.
  • lignin-based resins have not worked properly with the available base papers, and this have limited or prevented their use in these applications. Lignin-based resins have not been uniformly absorbed into the base paper, and a resin poor area has been formed in the middle of the base paper. As the consequence of the non-uniform resin absorption, the attachment of the layers during the manufacture of the multi-layered structures and products has been inadequate, which have resulted failed and/or non-usable structures or products.
  • An object of this invention is to minimise or possibly even eliminate the disadvantages existing in the prior art.
  • Another object of the present invention is to provide a base paper, which shows improved properties in a manufacture of multi-layered structures or products, especially a good ability to absorb resin uniformly.
  • Another object of the present invention is to provide a base paper, which is especially suitable for use with at least partly lignin-based thermosetting resins in manufacture of multilayer products.
  • a typical base paper according to the present invention for producing multilayer structure or multilayer product, such as laminate structure comprises cellulosic fibre material and has
  • a typical multilayer structure according to the present invention comprises at least one layer made from a base paper according to the invention impregnated with a thermosetting resin comprising lignin.
  • thermosetting resin especially a lignin-based thermosetting resin
  • a lignin-based thermosetting resin into the base paper
  • the base paper has a bulk density value ⁇ 590 kg/m 3 , a Bendtsen roughness value ⁇ 800 ml/min, and a Gurley porosity value ⁇ 15 s/100 ml, sometimes ⁇ 10 s/100 ml or ⁇ 5 s/100 ml.
  • Gurley porosity value ⁇ 15 s/100 ml, sometimes ⁇ 10 s/100 ml or ⁇ 5 s/100 ml.
  • thermosetting resins especially at least partly lignin-based thermosetting resins, throughout the base paper layer, while the absorbed resin amount is maintained at a proper level.
  • the present invention solves many of the problems that have this far limited or prevented the use of lignin-based thermosetting resins in manufacture of multi-layered products, such as laminates.
  • the present invention enables uniform absorption of thermosetting resin, especially at least partly lignin-based thermosetting resin, throughout the base paper. This means that a high resin content can be attained even in the middle region of the base paper, and a uniform or nearly uniform absorption profile for the thermosetting resin can be achieved throughout the base paper.
  • the base paper has a first large surface and a second large surface, which are parallel with each other. The distance between the first and the second surface defines the thickness of the base paper.
  • the base paper may comprise a first edge region, a second edge region and a middle region extending between the first edge region and the second edge region.
  • the first edge region extends from the first large surface of the base paper in the thickness direction towards the middle region of the base paper and the second edge region extends from the second large surface of the base paper in the thickness direction towards the middle region of the base paper.
  • the respective edge region usually comprises 15 % of the thickness of the base paper
  • the middle region usually comprises 70 % of the thickness of the base paper.
  • the base paper is impregnated with a thermosetting resin, preferably a thermosetting resin comprising lignin, i.e. at least partly lignin-based thermosetting resin.
  • concentration of the thermosetting resin in the first and second edge regions is essentially the same as in the middle region.
  • the difference in concentration of the thermosetting resin between the first and second edge regions and the middle region is at most 30 %, preferably at most 20 %, sometimes at most 10 %.
  • the difference in concentration of the thermosetting resin between the first and second edge regions and the middle region may be less than 15 % or even less than 5 %.
  • the multilayer structure or multilayer product preferably a laminate structure, which comprises at least one layer made from base paper according to the present invention, may comprise at least 10 weight-%, preferably at least 20 weight-%, of thermosetting resin, especially thermosetting resin comprising lignin, i.e. at least partly lignin-based resin.
  • the resin content in the multilayer structure or product in percentages is determined by calculating the weight difference between the impregnated base paper (structure/product) and unimpregnated base paper (structure/product), whereafter the weight difference is divided by the weight of the impregnated base paper (structure/product) and multiplied with 100. All weights are given as dry weights.
  • the base paper according to the present invention is especially suitable for impregnation or absorption with a thermosetting resin comprising lignin, i.e. at least partly lignin-based resin.
  • the thermosetting resin solution, which is used to impregnate the base paper may comprise at least 4 weight-%, preferably 8 weight-%, more preferably at least 12 weight%, of lignin, calculated from the total weight of the resin solution.
  • the term "base paper” denotes a paper made from cellulosic fibre material and intended for use as a layer in a multilayer structure or product, such as laminate structure.
  • the base paper comprises bleached and/or unbleached cellulosic fibre material, preferably unbleached cellulosic fibre material obtained by kraft pulping.
  • the cellulosic fibre material may comprise virgin cellulosic fibres and/or recycled cellulosic fibres.
  • the cellulosic fibre material may comprise cellulosic fibres obtained by mechanical pulping methods and/or cellulosic fibres originating from kraft pulping of sawdust.
  • the cellulosic fibre material comprises unbleached cellulosic fibres, recycled cellulosic fibres and/or cellulosic fibres originating from kraft pulping of sawdust.
  • the cellulosic fibre material may comprise 0 - 100 weight-%, preferably 10 - 90 weight-% or 25 - 75 weight-%, of unbleached cellulosic fibres, and/or 0 - 100 weight-%, preferably 10 - 90 weight-% or 25 - 75 weight-%, of recycled cellulosic fibres.
  • the base paper may have a bulk density value ⁇ 590 kg/m 3 or ⁇ 555 kg/m 3 , preferably ⁇ 550 kg/m 3 , more preferably ⁇ 540 kg/m 3 , sometimes even ⁇ 525 kg/m 3 .
  • the base paper may have a bulk density value in a range of 425 - 590 kg/m 3 or 440 - 555 kg/m 3 , preferably 450 - 550 kg/m 3 , more preferably 475 - 540 kg/m 3 . It has been observed that the bulk density of the base paper may be significantly lower compared to conventional base papers, where the bulk values are typically round 600 - 680 kg/m 3 .
  • the low bulk value of the base paper when combined with the selected porosity values, unexpectedly improves the absorption, i.e. impregnation of the thermosetting resin, especially at least partly lignin-based thermosetting resin, into the base paper. Improved resin impregnation enables smooth and effective operation of the manufacturing process for the multilayer structure or product, as well as enables the production of stronger and qualitatively more uniform and satisfactory structures or products.
  • the bulk values are measured by using standard ISO 534:2005.
  • the base paper may have a Bendtsen roughness value ⁇ 800 ml/min, preferably ⁇ 900 ml/min, more preferably ⁇ 950 ml/min.
  • the base paper may have the Bendtsen roughness value in the range of 800 - 1300 ml/min, preferably 900 - 1200 ml/min, more preferably 950 - 1150 ml/min.
  • Bendtsen roughness indicates the smoothness of the base paper surface. Conventionally, it has been assumed that the base paper should have a smooth surface, i.e. relatively low Bendtsen roughness value.
  • thermosetting resins having a large molecular size such as at least partly lignin-based thermosetting resins, are more easily absorbed when the Bendtsen roughness of the base paper is within the selected range.
  • the Bendtsen roughness values are measured by using standard ISO 8791-2:1990 part 2.
  • the base paper may have a Gurley porosity value ⁇ 15 s/100 ml, preferably in the range of 1 - 15 s/100 ml, more preferably 2 - 12.5 s/100 ml, even more preferably 4-8 s/100 ml.
  • the base paper may have a Gurley porosity value in the range of 3 - 9 s/100 ml, preferably 4 - 8 s/100 ml, more preferably 5 - 7 s/100 ml.
  • the base paper may have a Gurley porosity value even in the range of 7 - 13 s/100 ml, preferably 8 - 12 s/100 ml, more preferably 9-11 s/100 ml.
  • the base paper may have a Gurley porosity value ⁇ 5 s/100 ml, preferably ⁇ 4.5 s/100 ml, more preferably ⁇ 4 s/100 ml.
  • the Gurley porosity value may be in the range of 1 - 5 s/100 ml, preferably 1.5-4.5 s/100 ml, more preferably 2 -4 s/100 ml.
  • the Gurley porosity value describes the air permeability of the base paper.
  • the base paper is able to absorb increased amounts of thermosetting resin, especially lignin-based thermosetting resin.
  • the increased ability of the base paper to absorb resin ensures that the resin amount is sufficient during the pressing step in the manufacture of the multilayer product and the quality of the produced multilayer products is high.
  • the defined Gurley porosity for the base paper enables the absorption of proper amounts of thermosetting resin into the base paper, the overall efficiency of the process is improved.
  • the Gurley porosity values are measured by using standard ISO SCAN-P 19:78.
  • the base paper may have a moisture content of 4 - 10 weight-%, preferably 4-8 weight-%, sometimes 5-8 weight-%.
  • the moisture content is measured by using standard ISO 287:1985. It has been observed that the higher moisture content of the base paper further improves the absorption of the thermosetting resin into the base paper during the manufacture of multilayer products. At the same time, it is possible to achieve savings in energy consumption of the manufacturing process for the base paper as the drying need for the base paper in the process is reduced.
  • the base paper may have a basis weight in a range of 30 - 350 g/m 2 .
  • the base paper may preferably have a basis weight in a range of 30 - 120 g/m 2 , more preferably 40 - 100 g/m 2 .
  • the basis weight is measured by using standard ISO 536:1995. The base paper according to this embodiment is thus especially suitable for manufacture of overlays.
  • the base paper may have a basis weight in a range of 120 - 350 g/m 2 , preferably 150 - 300 g/m 2 .
  • the base paper according to this embodiment is thus especially suitable for manufacture of high-pressure laminates (HPL).
  • the base paper may preferably have a wet strength value at least 300 N/m, more preferably at least 350 N/m, even more preferably at least 400 N/m, sometimes even at least 450 N/m.
  • the wet strength value is measured by using test method ISO 3781.
  • Wet strength is an important property of the base paper, as it allows the effective absorption or impregnation of the base paper with the thermosetting resin.
  • the base paper may comprise one or more suitable wet strength resins, such as polyamidoamine epichlorohydrin resins or glyoxylated polyacrylamide, which can be added to the cellulosic fibre material during the manufacture of the base paper.
  • the base paper may comprise a wet strength resin in amount of at least 1 kg/ton paper (dry), preferably at least 2 kg/ton paper (dry), more preferably at least 4 kg/ton paper (dry).
  • the base paper according to the present invention is suitable for producing multilayer structures or multilayer products, such as laminate structures.
  • the base paper according to the present invention is especially suitable to be used for making a multilayer product selected from decorative high-pressure laminates, continuous pressed laminates, postform laminates, fire retardant laminates, compact laminates, drilling boards, electrotechnical laminates, and technical laminates.
  • the base paper according to the present invention is further especially suitable for use as cushion pads used in laminate impregnation, evaporative cooling pads, as plywood films, or as surface films.
  • the base paper according to the present invention can be manufactured as conventional in the art. By proper selection of process parameters at the press and drying sections as well as at the calandering, it is possible to produce base paper according to the present invention. The person skilled in the art is able to determine the required parameters with a few standard experiments. The present invention is not related to the manufacture of the base paper as such, but the specific combination of base paper properties providing unexpected advantages.
  • Base paper was made from unbleached chemical pulps.
  • the main raw material of base paper stock suspension was unbleached sawdust pulp.
  • Another raw material used for the base paper stock suspension was recycled fibre originating from old corrugated cartons (OCC).
  • Minimum virgin pulp quantity was 70 %.
  • wet strength resin was added to furnish. Wet strength resin quantity was 4 kg/ton to reach the required wet strength.
  • the headbox fed a very dilute stock suspension onto the wire.
  • On the wire section as much water as possible was removed from the stock suspension fed from the headbox. Water was removed by means of gravity and suction.
  • After the wire section paper web was pressed in a nip rolls and press felt, forcing water out of the paper to the felt.
  • the dryer section comprised steam-heated drying cylinders. The dryer section was followed by a machine calender which adjusted the thickness and density of the produced base paper.
  • Produced base paper had following properties:
  • thermosetting lignin-based resin When impregnated with thermosetting lignin-based resin, it was observed that the absorption of the resin throughout the base paper was uniform, and no significant difference in resin content could be observed between the edge regions and the middle region of the base paper.

Landscapes

  • Paper (AREA)
  • Laminated Bodies (AREA)
EP20208279.8A 2020-11-18 2020-11-18 Base paper, its use and multilayer structure Active EP4001504B1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP20208279.8A EP4001504B1 (en) 2020-11-18 2020-11-18 Base paper, its use and multilayer structure
PL20208279.8T PL4001504T3 (pl) 2020-11-18 2020-11-18 Papier bazowy, jego zastosowanie i struktura wielowarstwowa
RS20231148A RS64903B1 (sr) 2020-11-18 2020-11-18 Bazni papir, njegova upotreba i višeslojna struktura
HRP20231271TT HRP20231271T1 (hr) 2020-11-18 2020-11-18 Osnovni papir, njegova uporaba i višeslojna struktura
ES20208279T ES2960957T3 (es) 2020-11-18 2020-11-18 Papel base, su uso y estructura multicapa

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20208279.8A EP4001504B1 (en) 2020-11-18 2020-11-18 Base paper, its use and multilayer structure

Publications (3)

Publication Number Publication Date
EP4001504A1 EP4001504A1 (en) 2022-05-25
EP4001504C0 EP4001504C0 (en) 2023-09-27
EP4001504B1 true EP4001504B1 (en) 2023-09-27

Family

ID=73475942

Family Applications (1)

Application Number Title Priority Date Filing Date
EP20208279.8A Active EP4001504B1 (en) 2020-11-18 2020-11-18 Base paper, its use and multilayer structure

Country Status (5)

Country Link
EP (1) EP4001504B1 (sr)
ES (1) ES2960957T3 (sr)
HR (1) HRP20231271T1 (sr)
PL (1) PL4001504T3 (sr)
RS (1) RS64903B1 (sr)

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2860707B2 (ja) * 1992-11-24 1999-02-24 キャスコ ノーベル アクチェボラーグ フィルム複合材料
EP3211135B1 (en) * 2016-02-29 2018-08-29 BillerudKorsnäs AB High-stretch sackpaper
PL3385442T3 (pl) * 2017-04-06 2019-12-31 Billerudkorsnäs Ab Sposób wytwarzania papieru o dużej rozciągliwości
WO2018220130A1 (en) * 2017-05-31 2018-12-06 Tetra Laval Holdings & Finance S.A. Laminated packaging material, packaging containers manufactured therefrom and a method for manufacturing the laminate material

Also Published As

Publication number Publication date
EP4001504C0 (en) 2023-09-27
PL4001504T3 (pl) 2024-03-11
RS64903B1 (sr) 2023-12-29
EP4001504A1 (en) 2022-05-25
ES2960957T3 (es) 2024-03-07
HRP20231271T1 (hr) 2024-02-02

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