MXPA00002164A - Poly-coated paper composites - Google Patents

Abstract

Composites of poly-coated paper and a resin, and methods for forming the composites, are disclosed.

Description

MIXED PAPER MATERIALS POLY-COATED BACKGROUND OF THE INVENTION The invention relates to mixed materials of pol i-coated paper and a resin. Paper coated with a polymer (poly-coated paper) is used in a number of applications. For example, poly-coated paper is used to form a variety of food containers, including individual size juice cartons and food freezer boxes. Resins are also used in a variety of applications, for example, to pack food. Food containers made with poly-coated paper or resins are normally used once, then discarded. As a result, there is an increasing amount of poly-coated paper waste and resins. SUMMARY OF THE INVENTION In general, the invention relates to mixed materials of textured poly-coated paper and to a resin. The invention features a mixed material including at least about 2% by weight, more preferably, at least about 5% percent by weight, of textured poly-coated paper, and a resin, such as a thermoplastic resin. The mixed material also includes cellulosic or lignocellulosic fiber.

The invention also relates to mixed material including polyethylene and at least about 50% by weight of textured poly-coated paper. The invention further relates to mixed materials including poly-coated paper including a resin, having flexible resistances of at least about 210.9 kg / cm2, or tensile strengths of at least 210.9 kg / cm2. In addition, the invention relates to a process for the manufacture of a mixed material; The process includes cutting coated poly-coated paper to form textured poly-coated paper, thereby combining the textured poly-coated paper with a resin. A preferred method includes cutting the poly-coated paper with a rotating blade. The invention also relates to a process for the manufacture of a mixed material; the process includes cutting the poly-coated paper and the combination of the poly-coated paper with a resin. The term "textured poly-coated paper", as used herein, means that the paper has been cut to the extent that the internal fibers are substantially exposed. At least about 50%, more preferably at least 70%, of these fibers, as well as the external polymer fibers, have a length / diameter (L / D) ratio of at least 10, more preferably at least minus 25, or at least 50. An example of textured poly-coated paper is shown in Figure 1. ^^^^^^^^^^^^^^^^^^^^ gßSgsßsgg ^^^^^^^^^^^^^^^^^^^^^^^^^ g ^? B ^ áßtó ^^^^^^^^^^ i ^ The materials of the present invention are strong, lightweight and economical. The raw materials used to make the mixed materials are readily available. For example, they can include discarded containers composed of resins, and discarded containers composed of poly-coated paper. Poly-coated paper can be difficult to recycle because for many applications, paper and polymeric layers must be separated. In the present invention, both the paper and the polymer portions are used, so that it is not necessary to separate the two. The invention, therefore, helps to recycle the discarded containers after consumption, while at the same time useful materials are produced. Other aspects and advantages of the invention will be apparent from the description of the preferred embodiments thereof, and from the claims. BRIEF DESCRIPTION OF THE DRAWING Figure 1 is a photograph of a textured poly-coated paper pattern, magnified 50 times. Description of Preferred Modes A preferred mixed material includes textured poly-coated paper and a resin. Texturized poly-coated paper provides mixed material with resistance. The mixed material includes from approximately 30% to around 90%, more preferably from about 50% to about 70% by weight of the textured poly-coated paper. Examples of poly-coated paper include materials having polymer and paper layers, and materials having layers of polymer, paper and aluminum. A coated poly-coated paper is one that has layers of polymer and paper. Poly-coated paper is available in a variety of forms. For example, virgin poly-coated paper sheets can be purchased from International Paper, New York. Alternatively, small pieces of poly-coated paper can be obtained from International Paper or other manufacturers. The poly-coated paper used, in the form of discarded food and beverage containers, can be collected from various sources, including remelted waste. The used poly-coated paper can also be purchased from intermediaries of this material. If the poly-coated paper used is included in the mixed materials, it should be thoroughly washed before use. Polycoated paper is preferred in small pieces, since it is less expensive than full sheets. The resins encapsulate the textured poly-coated paper and help control the shape of the mixed material. The resins also transfer the external charges from the poly-coated paper and protect the poly-coated paper from the environment and structural damage. Preferred mixed materials include from about 20% to about 60%, more preferably from about 30% to about 50%, by weight of the resins. ^^^^ - g ^^^^ < ^^^ s ^? < ^^^^^^^^^ B ^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^^~ high density), polypropylene, polystyrene, polycarbonate, polybutylene, thermoplastic polyesters, polyethers, thermoplastic polyurethane, PVC, Nylon, and other resins. It is preferred that the resins have a low melt flow index. Preferred resins include polyethylene and polypropylene with melt flow rates of less than 3 g / 10 minutes, and more preferably less than 1 g / 10 min. Resins can be purchased as virgin materials, or obtained as small pieces or waste resins, since these materials are less expensive. A preferred source is used polyethylene milk bottles. Mixed materials also include coupling agents. The coupling agents help to bind the hydrophilic fibers of poly-coated paper to the hydrophobic resins. Examples of coupling agents include polyethylenes modified by maleic anhydride, such as those in the FUSABODN® series (available from Dupont, Delaware) and POLIBOND® (available from Uniroyal Chemical, Connecticut). A preferred coupling agent is a high density polyethylene modified with maleic anhydride such as FUSABOND® MB 100D. Mixed materials may also include cellulosic or lignocellulosic fibers. These fibers provide extra resistance to the mixed material. The amount of fiber that is incorporated in the mixed materials can vary, depending on the physical and mechanical properties The desired products of the final products. Preferred mixed materials contain from about 5% to about 50%, more preferably from about 10% to about 30% by weight of the cellulose or lignocellulosic fiber. Examples of such fibers include paper and paper products, wood, wood fibers and wood-related materials, as well as materials derived from "Kenaf", fats, rice husks, bagasse, cotton, jute, and other cellulosic materials or lignocellulosic Preferred fibers include jute and "Kenaf". The fibers may have, for example, an L / D ratio of at least 10, or at least 25 to 50. The mixed materials may contain additives known to those skilled in the art of composition, such as plasticizers, lubricants , antioxidants, opacifiers, heat stabilizers, dyes, impact modifiers, fofostabilizers, flame retardants, biocides and antistatic agents. Preparation of starting materials If poly-coated paper is used in small pieces, it should be clean and dry. The poly-coated paper can then be textured before it is combined with the resin. The poly-coated paper can be textured using any one of a number of mechanical means, or combinations thereof. During the texturing process, the polymer layers are released from the layers of paper, thus exposing the paper fibers. A preferred method of texturing includes first cutting the poly-coated paper into pieces of 0.635 to 1.27 centimeters using an apparatus for cutting plain paper. These pieces are then cut with a rotating blade, such as one (available from Sprout, Waldron Companies) described by Perry's Chem. Eng. Handbook, 6a. Edition, in 8-129 (1984). The textured material is then passed through a 2 mm mesh screen. The textured poly-coated paper can be stored in sealed bags. It should be dried at approximately 105 ° C for 4-18 hours (until the moisture content is less than 0.5%) immediately before use. The Figure is a photograph of SEM 10 of textured poly-coated paper. The resin can be purchased as pellets or pellets and used without further purification or drying. The wet surface is present in resins in the form of pellets or pellets, however, it must be dried before use. 15 If the cellulosic or lignocellulosic fibers are used, then they can be texturized, using the process described above. Preparation of mixed materials Mixed materials can be prepared in the following manner. A 2-roll mill composed of rubber / normal plastic was heated to 325-400 ° C. The resin (usually in the form of pellets or granules) was added to the hot roller mill. After about 20 minutes, the coupling agent was added to the roller mill. After an additional five minutes, the textured poly-coated paper was added to the resin mixture c aUi? i ****. ^ *. ,. ^ ,. J_ ^ w «.- -_ * .._ * ._- - > _. "-__- .. ^ .a *** * ** *». ^ _., __. «_._ * _ _. ^ -_ ^ _, __ ,, _. _ ..,. > _.....____. ^^ fused / coupling agent. The textured poly-coated paper was added over a period of about 10 minutes. The mixed material was removed from the roller mill, cut into sheets and allowed to cool to room temperature. It was then molded 5 by compression into plates using normal compression molding techniques. Alternatively, a mixer, such as the mixer Internal Banbury, loaded with the ingredients. The ingredients were mixed, while the temperature was maintained at less than approximately 190 ° C. The mixture was then molded by compression. In another embodiment, the ingredients can be mixed in an extruder mixer, such as a MARIS (Turin) TM 85 extruder equipped with co-rotating screws. The resin and the coupling agent are introduced into the feed neck of the extruder; the poly-coated paper (and cellulosic or lignocellulosic fiber, if used) are introduced in about 1/3 of the downstream path of the length of the extruder in the molten resin. The internal temperature of the extruder is maintained at less than about 20-190 ° C. At the exit, the mixed material is formed into pellets by cutting cold wires. Alternatively, the mixture can first be prepared in a mixer, then transferred to an extruder for extruding the steps to cut into pellets. _Íl¡_ÉÍ ____________ ¡__ ^ ___________ Í ___ tÍgi_ii¡_? In another embodiment, the mixed material can be formed into filaments for weaving, wrapping, weaving and weaving texturing, and for forming non-woven products. In a further embodiment, the mixed material can be made in films. Properties of mixed materials Mixed materials include fiber net urn, encapsulated within a resin matrix. The exposed fibers of a lattice network, which provides the mixed material with resistance. Because the polycoated paper is texturized, the amount of surface area available to bond to the resin is increased, as compared to mixed materials prepared with untexturized poly-coated paper. The resin is bonded to the surfaces of the exposed fibers, creating an intimate blend of the fiber network and the resin matrix. The intimate mixing of the fibers and the resin matrix also reinforces the mixed materials. The cellulose or lignocellulosic fibers are also added to the strength of the additional mixed material. Uses Mixed poly-coated paper / resin materials can be used in a number of applications. Mixed materials are strong and lightweight; they can be used, for example, as substitutions for wood. The resin coating makes the mixed materials water resistant, so they can be used in outdoor applications. For example, mixed materials can be used to form pellets that are stored outdoors for an extended time. The mixed material can also be used, for example, as the base or cover of a plywood product. In addition, mixed materials, when found, can have a treated, grooved, milled, shaped, printed, textured, compressed, pasted, colored, etc. surface. The surface can be smooth or rough. EXAMPLES The following examples were prepared in the following manner. A 2 roll mill for forming rubber / normal plastic compounds was heated at 325-400 ° C. The resin (usually in the form of pellets or granules) was added to the hot roller mill. After approximately 10 minutes, the resin was attached to the rollers (ie, melted and fused to the rollers). The coupling agent was then added to the roller mill. After an additional five minutes, the poly-coated paper was added to the fused resin / coupling agent mixture. The poly-coated paper was added over a period of about 10 minutes. The mixed material was then removed from the roller mill, cut into sheets, and allowed to cool to room temperature. Batches of approximately 80 g each were compression molded into 15.24 cm x 15.24 cm x 0.3175 cm plates using normal compression molding techniques. A composition contains the following ingredients: Composition No. 1 - .., -_. _-_-..- Ingredient Quantity (g) High density polyethylene1 160 Poly-coated paper2 240 Coupling agent08 1 Merlex 6007, melt flow index 0.65 g / 10 minutes, commercially available from Phillips 2 Textured using the cutter 3mm POLIBOND® 3009 swivel with mesh, commercially available from Uniroyal Chemical The plates were turned on appropriate test specimens and tested in accordance with the procedures described in the specific method. There are different specimens that were tested for each property and the average value for each test was calculated. The properties of Composition No. 1 were as follows: Tension module (105 kg / cm2) 0.606 (ASTM D638) Resistance to tensile stress (kg / cm2) 20.46 (ASTM D638) Final elongation (%) < 5 (ASTM D638) Bending Resistance (kg / cm2) 857.66 (ASTM D790) Bending module (105) 6.61 (ASTM D790) Another composition contains the following ingredients: Composition No. 2 Ingredient Quantity (g) High density polyethylene1 160 Poly-coated paper 240 Coupling agent '8 1 Discarded milk cylinders, index of melt flow approximately 0.8 g / 10 minutes 2 Texturing using the rotary cutter with 2mm mesh 3 POLIBOND® 3009 5 The properties of Composition No. 2 are as follows Tension module (105 kg / cm2) 0.51 (ASTM D638 ) Resistance to tensile stress (kg / cm2) 456.95 (ASTM D638) Final elongation (%) < 5 (ASTM D638) 10 Flexural strength (kg / cm2) 836.57 (ASTM D790) Flexural modulus (105) 6.50 (ASTM D790) A third composition is as follows: Composition No. 3 Ingredient Quantity (g) 15 Polyethylene high density1 160 Poly-coated paper2 240 Coupling agent3 8 1 Discarded milk cylinders, melt flow rate approximately 0.8 g / 10 minutes 20 2 Textured using the 2mm 3 mesh rotary cutter FUSABOND® MD 100D, commercially available from DuPont . The properties of Composition No. 3 are as follows Tension module (105 kg / cm2) 0.497 (ASTM D638) 25 Resistance to tensile stress (kg / cm) 455.5 (ASTM D638) ^ ^ ¡^^ - "" ifltfiwi? - >; - _ »., -. ^ _« A ^ -. Ia -. ^ -_ .. ^ __ ^^ _. ^^, _ - «« ^ «-__, -.._ ..-- . »...« _... * _.-_-. > , -.

Final elongation (%) < 5 (ASTM D638) Bending Strength (kg / cm2) 717.06 (ASTM D790) Bending Modulus (105) 5.73 (ASTM D790) A fourth composition contains the following ingredients: 5 Composition No. 4 Ingredient Quantity (g) High Polyethylene density1 160 Poly-coated paper2 240 Coupling agent3 8 10 1 Marlex 6007, melt flow rate approximately 0.65 g / 10 minutes 2 Texturing using the rotary cutter with 2mm mesh 3 FUSABOND® MD 100D The properties of Composition No. 4 are as follows: Tension module (105 kg / cm2) 5.0 (ASTM D638) Resistance to tensile stress (kg / cm2) 482.2 (ASTM D638) Final elongation (%) < 5 (ASTM D638) Flexural strength (kg / cm2) 857.66 (ASTM D790) 20 Flexural modulus (105) 7.50 (ASTM D790) Other embodiments are within the claims. i fffirt? go - "• '- * - - > --- • -" ""' faith '--- ---- - - ~~ < »* > ~ > * á i > '^.-_-

Claims (21)

1. CLAIMS 1. A mixed material comprising a poly-coated paper and a resin, wherein at least about 2% by weight of the poly-coated paper is textured.
2. 2. The mixed material of claim 1, wherein at least about 5% by weight of the poly-coated paper is textured.
3. 3. The mixed material of claim 1, wherein the poly-coated paper comprises polyethylene and paper.
4. 4. The mixed material of claim 3, wherein the poly-coated paper further comprises aluminum.
5. The mixed material of claim 1, wherein the resin is a thermoplastic resin.
6. 6. The mixed material of claim 5, wherein the thermoplastic resin is polyethylene.
7. The mixed material of claim 5, wherein the thermoplastic resin is polypropylene.
8. The mixed material of claim 1, wherein the mixed material comprises from about 50% to about 20 70% by weight of the poly-coated paper and approximately 50% by weight of the resin.
9. 9. The mixed material of claim 1, wherein the mixed material further comprises lignocellulosic fiber.
10. The mixed material of claim 1, wherein the mixed material further comprises cellulosic fiber. ^ h & j ^^^^ ¡z ^^^^^^^^^^^ $ & ^^^^^^^^^^^^
11. 11. A mixed material comprising poly-coated paper and polyethylene, wherein at least about 50% by weight of the poly-coated paper is texturized.
12. 12. A mixed material comprising poly-coated paper and a resin, wherein the mixed material has a flexural strength of at least 210.9 kg / cm2.
13. The mixed material of claim 12, wherein the mixed material has a bending strength of at least 421.8 kg / cm2.
14. The mixed material of claim 12, wherein the mixed material has a bending strength of at least 703 kg / cm2.
15. 15. A mixed material comprising poly-coated paper and a resin, wherein the mixed material has a tensile strength of at least about 210.9 kg / cm2.
16. 16. The mixed material of claim 15, wherein the mixed material has a tensile strength of at least 351.5 kg / cm2. The mixed material of claim 15, wherein the mixed material has a tensile strength of at least
17. 421. 8 kg / cm2.
18. 18. A process for manufacturing a mixed material comprising cutting the poly-coated paper to form the textured poly-coated paper, and combining the poly-coated paper with a resin.
19. 19. The mixed material of claim 18, wherein the resin is a thermoplastic resin.
20. The mixed material of claim 18, wherein the cutting step of the poly-coated paper comprises cutting with a blade in a rotating manner.
21. 21. A process for the manufacture of a mixed material, the process comprising cutting the poly-coated paper and combining the poly-coated paper with a resin.