WO2001057311A2 - Procede de fabrication de papier et papier ainsi realise - Google Patents

Procede de fabrication de papier et papier ainsi realise Download PDF

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Publication number
WO2001057311A2
WO2001057311A2 PCT/US2001/003307 US0103307W WO0157311A2 WO 2001057311 A2 WO2001057311 A2 WO 2001057311A2 US 0103307 W US0103307 W US 0103307W WO 0157311 A2 WO0157311 A2 WO 0157311A2
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WO
WIPO (PCT)
Prior art keywords
substrate
papermaking
fibers
paper
biodegradable plastic
Prior art date
Application number
PCT/US2001/003307
Other languages
English (en)
Other versions
WO2001057311A3 (fr
Inventor
Sachiko Iwasaki
Original Assignee
Sachiko Iwasaki
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 Sachiko Iwasaki filed Critical Sachiko Iwasaki
Priority to JP2001555933A priority Critical patent/JP3942894B2/ja
Priority to AU2001231274A priority patent/AU2001231274A1/en
Publication of WO2001057311A2 publication Critical patent/WO2001057311A2/fr
Publication of WO2001057311A3 publication Critical patent/WO2001057311A3/fr

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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
    • D21H27/32—Multi-ply with materials applied between the sheets
    • D21H27/34—Continuous materials, e.g. filaments, sheets, nets
    • D21H27/36—Films made from synthetic macromolecular compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/24—Organic non-macromolecular coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/067—Wood fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2272/00—Resin or rubber layer comprising scrap, waste or recycling material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/51—Elastic
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/54—Yield strength; Tensile strength
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/56—Damping, energy absorption
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/582—Tearability
    • B32B2307/5825—Tear resistant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
    • B32B2307/7163—Biodegradable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2554/00—Paper of special types, e.g. banknotes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B32B2607/02—Wall papers, wall coverings
    • 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
    • D21H11/12—Pulp from non-woody plants or crops, e.g. cotton, flax, straw, bagasse
    • 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
    • D21H15/00—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution
    • D21H15/02—Pulp or paper, comprising fibres or web-forming material characterised by features other than their chemical constitution characterised by configuration
    • D21H15/06—Long fibres, i.e. fibres exceeding the upper length limit of conventional paper-making fibres; Filaments

Definitions

  • the present invention relates to processes for making paper, and more particularly to processes using agricultural crop material or recycled paper products, and to paper products made from the process.
  • virgin wood fibers are commonly used for making various types of paper and paper board products.
  • the treatment of virgin wood fibers prior to paper formation may include debarking of logs, wood chipping or mechanical defibration, chemical cooking, various washing and chemical bleaching steps and refining or other further mechanical conditioning of the fibers. Screening, cleaning, thickening and diluting steps may be repeated numerous times through out the relatively complex process.
  • the treatment of virgin wood fibers is energy intensive, is dependent on many chemical processes, and is expensive. Many of the cooking and bleaching processes used for pulp delignification are sulfur or chlorine based, producing significant environmental hazards from the chemical processes themselves and from the by-product handling and disposal. Alternatives to chlorine based bleaching are often very expensive.
  • Conventional papermaking processes also use large volumes of water for transporting and treating the fiber. While many mills are converting to closed loop systems, process requirements remain complex and expensive.
  • wood fibers As an alternative to wood fibers, other cellulosic materials have been used for papermaking. These alternative materials have included agricultural based materials such as corn stalk, kenaf, sugar cane, banana and pineapple leaves. Many of the agricultural crop based fiber sources can be harvested in one growing season, and can be grown in regions not suitable for tree growth. An additional advantage occurs in that lignin content is lower in grassy plants than in wood fibers, and bleaching or washing requirements are less, even when a white sheet is desired. For example, the inner core of industrial hemp, called hurd, is naturally white, and little or no bleaching is required if herd is used to form writing papers.
  • hurd the inner core of industrial hemp, called hurd, is naturally white, and little or no bleaching is required if herd is used to form writing papers.
  • the pulping and pulp treating processes for alternative fiber papermaking differ from those used for wood fiber papermaking.
  • the papermaking process itself once the pulp is prepared, is substantially similar to that used for wood fiber papermaking.
  • a very dilute slurry of papermaking fibers is discharged from a headbox onto a forming wire. Water is drained from the slurry on the wire, referred to as a web.
  • the web passes through a plurality of stages for the removal of water, including pressing the web between nipped rollers and drying the web by passing the web through an area of heated air and/or heated rollers.
  • the web must be fully supported, as the wet strength of the web is insufficient to support the web by itself. The need to support the web on felts or fabrics complicates the structure and operation of conventional paper machines.
  • pins or fines undesirable short wood fibers called pins or fines. While a small amount of pins or fines can be used in conventional papermaking processes, the use of too many short fiber components weakens the sheet. If a process generates more fines or pins than can be used, the excess is wasted. It would be advantageous to have a papermaking process that can make use of fines and pins.
  • a feature of the present invention is a papermaking process with reduced energy, water and chemical requirements as compared to conventional papermaking processes.
  • Another feature of the present invention is a papermaking process which can utilize agricultural crop based materials, with lessened reliance on virgin wood fibers.
  • a further feature of the present invention is a papermaking process which can utilize lower quality papermaking materials than needed for conventional papermaking processes, and which can make a higher quality paper from recycled paper products.
  • the present invention comprises a process from making paper in which a biodegradable plastic is used to provide strength in a paper web.
  • a biodegradable plastic substrate is provided, and a surface material of papermaking fibers is deposited on the substrate.
  • the substrate is wetted, and the surface material is powdered.
  • the powdered material is applied to the wetted surface of the substrate, which is thereafter pressed and dried.
  • the powdered surface material is mixed with vegetable mucilage or slime, to create a paste which is then applied to the substrate. Drying may occur with or without the application of heat.
  • recycled paper products are repulped, deinked if necessary and fiberized.
  • a slurry of the recycled pulp is applied to the biodegradable plastic substrate, which is dried.
  • Another aspect of the invention is the use of biodegradable plastic fibers as an additive to paper pulp slurry, to increase strength.
  • Discrete filaments may be added to the papermaking slurry.
  • Hollow fibers may be filled with powdered or fine papermaking fibers.
  • Yet another aspect of the present invention is a paper product comprising a biodegradable plastic substrate with at least one surface coated with papermaking materials selected from agricultural crop based grassy plants and recycled paper products.
  • Figure 1 is a process diagram of the papermaking process according to the present invention.
  • Figure 2 is a more detailed process diagram of a first embodiment of the present invention of a process for papermaking
  • Figure 3 is a process diagram of a second embodiment of the present invention for a papermaking process
  • Figure 4 is a process diagram of the present invention for a papermaking process as utilized for recycled fiber
  • Figure 5 is an enlarged cross sectional view of paper made according to the present invention.
  • FIG. 6 is a process diagram of yet another papermaking process in accordance with the present invention.
  • numeral 10 designates the papermaking process of the present invention, and more particularly the preferred life cycle of paper made according to the present invention.
  • Papermaking process 10 is useful in the formation of a paper product 12, shown in Figure 5.
  • Paper product 12 has a substrate 14 and top and bottom layers 16 and 18 respectively. The nature and content of substrate 14, top layer 16 and bottom layer 18 will be described and explained in greater detail hereinafter.
  • papermaking process 10 includes a surface material preparation subprocess 20 and a substrate preparation subprocess 22.
  • the prepared surface material and substrate are combined in a paper formation subprocess 24.
  • the formed paper product continues through a converting and use subprocess 26. Thereafter, the paper product may be, and preferably is, recycled in a recycling subprocess 28, and returned in one of several ways, to be described hereinafter, to the surface material preparation subprocess 20.
  • Substrate material 14 used in the present invention is a biodegradable plastic. Some biodegradable plastics contain aliphatic polyester resin skeletons. Others have poly vinyl alcohol molecular skeletons, while still others utilize molecular skeletons based on polysaccharides.
  • biodegradable plastic substrate may differ depending on the ultimate use of the paper product being formed. For example, if heavy weight material is to be formed, for possible use in containers, grocery bags, or the like, the desired strength characteristic may be different than if the product being formed is a light weight paper product to be used more for its appearance or surface characteristics than for strength.
  • biodegradable plastic for use in the present invention is marketed by Shimadzu Corporation of Japan under the product name Lacty.
  • Another suitable biodegradeable plastic is marketed by Kanebo, Ltd. Of Japan under the product name Lactron.
  • Each is a plant starch based product having characteristics similar to petroleum based plastics, except that each is biodegradable in nature, unlike petroleum based plastics.
  • the physical structure of substrate 14 may take several forms. A scrim or felt of randomly oriented fibers has been found to work well for some applications. In other applications, individual biodegradeable plastic fibers, hollow fibers, and fibers oriented as a strand or twine can be used. Alternatively, a fine mesh or screen with discrete openings may also be used.
  • Top layer 16 and bottom layer 18 are formed of the prepared surface material, which may include different types of agricultural fibers and/or recycled fibers.
  • the terms top and bottom are used herein only as a way of differentiating between the layers, as shown in Figure 5, separated by the substrate 14. It should be understood that the two layers may be the same, and used interchangeably. Alternatively, the components of the layers may differ, being selected for particular desirable characteristics of one compared to the other. The desirable characteristics may include color, texture, moisture resistance or the like. Virgin or recycled wood fibers may be used for top layer 16 and bottom layer 18.
  • one of the advantages of the present invention is that lower quality, lesser used but more easily grown and obtained fibers may also be used.
  • by-products or remains from agricultural crops can be used. Such can include the remaining portions after crop processing for other purposes.
  • corn stalk, grain husks, sugar cane, banana and pineapple leaves may be used as surface material.
  • hemp, wheat and rice stalks, jute, bamboo, coconut fibers, papyrus or virtually any kind of grassy plant may be used to provide unique surface appearance and characteristics.
  • Surface material preparation sub-process 20 of virgin fiber moist process 40 includes steps of crop growth 42, which may occur in a cultivated agricultural setting or may be natural growth of the desired material, and a harvesting and drying step 44.
  • the method of harvesting may differ for different plant sources, depending upon the nature of the agricultural crop or material being used.
  • Harvesting may include mechanized cutting and removal from cultivated fields, or harvesting may include a simple gathering step of naturally growing vegetation.
  • Harvesting may occur as part of a processing procedure for an agricultural crop grown principally for another purpose. Drying may be performed in mechanized crop dryers. Direct fired, rotary drum dryers can be used advantageous, as can waste heat dryers using heat from other processes.
  • the harvested crop of material may be air dried in fields or collection areas.
  • the complexity of the drying step may depend upon the nature of the material being used and the stage of dryness at which it is harvested. If by-product material is used, it may have been dried in previous processing.
  • the harvested and dried material is conditioned in a mechanical treatment step 46, which may include shredding and powdering of the dried material. Shredding and/or powdering may be accomplished with conventional apparatus including hammer mills, shredders, rolling mills, refiners, beaters and the like. Since paper made according the present invention does not rely on fiber to fiber bonding for strength, low quality material can be used, and fiber integrity is not critical. Even pins or fines from conventional papermaking pulp preparation processes can be used.
  • Preparation of the substrate includes a substrate presentation step 50 which, in a continuous process, may include unwinding substrate material from a supply roll of the material.
  • presentation step 50 may include flattening a sheet of substrate material.
  • a moistening step 52 readies the substrate for formation of the paper product. Moistening step 52 can be accomplished by passing an unrolling web of substrate material 14 through a shower or misting area wherein water or other liquid is deposited on the surface of substrate 14.
  • moistening step 52 can be performed by use of a hand sprayer, sprinkler of the like.
  • Paper formation subprocess 24 in accordance with virgin fiber moist process 40 shown in Figure 2, includes a deposit step 54 in which the prepared surface material is placed on the moistened substrate, and a subsequent pressing and drying step 56.
  • Deposit step 54 can be performed by blowing or spraying the dried powdered material onto the moistened substrate or, in a smaller process, may be performed by hand spreading the powdered material on the substrate.
  • Deposit step 54 may be performed on both sides of the substrate simultaneously, prior to rolling and drying step 56, or a first side may be prepared, rolled and dried, with the second side completed thereafter.
  • Rolling and drying step 56 may include pressing the substrate and deposited material between nipped rollers, or may include simply air drying the formed sheet without an initial or simultaneous pressing. Heat 58 may be used to assist in the process.
  • the temperature may be selected to slightly melt the biodegrable plastic substrate, causing the surface materials to adhere readily to the substrate. If nipped rollers are used, one or both may be heated, internally or externally. The roller surface characteristics should be such as to allow ready release of the sheet from the rollers, without sticking.
  • a heating step 58 is included with rolling and drying step 56, to partially melt the biodegradable plastic, the formed product can be created with a relatively hard surface. Such may be useful in forming tree plugs for nursery seedlings and the like. Slight melting of substrate 14 enhances bonding of top layer 16 and bottom layer 18 to substrate 14, and may improve moisture resistance.
  • converting and use subprocess 26 may directly follow paper formation subprocess 24, or the paper product formed may be rewound or otherwise accumulated and stored for later converting and use.
  • converting and use subprocess 26 may include sheeting to individual sheets, bonding in tablets, formation into bags, boxes and the like. Conventional slitters, sheeters, perforators, folders and the like may be used.
  • Recycling subprocess 28 follows converting and use subprocess 26. It should be recognized that while it is preferred that the used or discarded materials be recycled, and that the process of the present invention is particularly useful for subsequent recycling, recycling may not occur in all instances. In such situations, used product may be disposed of in landfills and will breakdown quickly, due to the biodegradability of the substrate as well as all other materials used.
  • One suitable recycling subprocess is shown in Figure 2, wherein the used product is acquired in a collecting step 60. Depending upon the manner in which the product is collected, cleaning and separating may be necessary to remove particularly undesirable elements. For example, in a municipal waste collecting process, screening and separating may be used to remove recyclable metals, glass and other objects. Thereafter, the remaining material is processed in a composting step 62.
  • the composted material may then be returned to the crop growth step 42 of surface material subprocess 20, wherein the composted material is used as a fertilizer or soil amendment for the growing crop.
  • a dry substrate process 70 is shown.
  • Substrate preparation subprocess 24 is similar to that described previously for virgin fiber moist process 40, except that it is not necessary to moisten the substrate.
  • Surface material preparation subprocess 20 in dry substrate process 70 also is similar to that shown and explained for virgin fiber moist process 40.
  • the powdered surface material is mixed with a mucilage or vegetable slime juice created in a vegetable slime juice preparation step 72. Pulp from Okra fruits may be mixed with water to create the mucilage or vegetable slime juice.
  • Suitable vegetable slimes may be obtained from other plants including Jew's Mellow leaves, Fenugreek seeds and tubers of Tororo Aoi, which is a vegetable additive used to increase bonding and improve fiber distribution in traditional Japanese papermaking processes.
  • These and other suitable vegetable components when mixed with water, produce a viscose, stringy mucilage slime, which can act as an adhesive.
  • the mucilages are polysaccharides, found in a number of plants, that form viscous, colloidal dispersions in water. Such mucilages are used in the preparation of certain ethnic dishes, and are valued for their slimy consistency.
  • the suitable substances differ from starch based adhesives in that mucilages produced from Okra, Tororo Aoi, Jew's Mellow and Fenugreek remain flexible when dried, as contrasted with starched based adhesives which become brittle upon drying.
  • a paste is made from the powdered surface material by mixing the powdered material with vegetable slime juice in a paste creating step 74.
  • Application step 76 may include spraying or spreading the paste on the substrate, depending upon the consistency of the paste.
  • the paste coated substrate is pressed to remove excess water, and is allowed to dry. Drying may occur naturally, or may be forced through the use of air movement, heated air or the like.
  • the vegetable slime juice works much as an adhesive in adhering the surface material to the substrate. Therefore, pressing of the coated substrate will not require the application of heat to bond the surface material to the substrate. Heat can be used, if desired, to obtain the physical characteristics, including moisture resistance, that result from slightly melting the biodegradable plastic. If paper products made in accordance with the dry mesh process 70 are not hardened by the application of heat, the paper made in accordance with dry mesh process 70 will remain soft and flexible.
  • the dry mesh process may be particularly suited for the preparation of thinner papers such as stationary and office paper or artistic papers.
  • a further advantage of the process using a vegetable slime adhesive is realized during recycling. Upon reliquification of the slime, the surface material is released readily from the substrate, allowing separate processing of each, and possible reuse of the substrate.
  • converting and use 26 and recycling 28 may occur as described previously for virgin fiber moist process 40. Converting will be as appropriate for the material being made and the use to which it is applied. Recycling again may include steps of collecting 60 and composting 62.
  • a recycled fiber process 80 is shown.
  • surface material preparation subprocess 20 recycled fibers are gathered and undergo a plurality of steps, including pulping 82, deinking 84 and cleaning 86.
  • Shredding 88 or powdering may be used to ready the fibers for application on the substrate.
  • a final slurry preparation step 90 includes consistency adjustment by adding water or by thickening to achieve the desired consistency.
  • the recycled fibers are then deposited on the substrate in a deposit step 92.
  • Pressing and drying step 56 follows, which normally will include the application of heat.
  • Converting and use subprocess 26, as needed, follows. Used or excess product is collected and recycled, being returned to the preparation step 82.
  • the recycling subprocess 26 of process 80 differs from that shown for process 40, in which recycling includes returning the recycled material to the soil as fertilizer or as a soil amendment.
  • recycled fiber process 80 recycled fibers are returned for use in another paper product.
  • recycled fiber process 80 will be used for recycling conventional papermaking fibers such as wood fibers, and recycling subprocess 28 will include the accumulation of suitable surface material from a number of sources. Because of the gluing effect created by heating the biodegradable substrate, low quality recycled fibers may be used. The problem associated with repeatedly recycling fibers, which reduces fiber length and fiber to fiber bonding strength, is overcome, since fiber to fiber bonding is not critical for the generation of strength in the completed paper product.
  • Biodegradable plastic can also be used advantageously as an additive in a more conventional papermaking process, and need not be used only as a substrate as described previously herein.
  • a biodegradable plastic fiber additive process 110 is shown, in which biodegradable plastic fibers are added to a papermaking slurry or pulp prior to web formation.
  • the biodegradable plastic substrate may then be fiberized and added to papermaking pulp in fiber additive process 110. Addition of the biodegradable plastic fibers adds strength to the resultant paper sheet, and can reduce the need for virgin fiber in paper products made using primarily recycled wood fiber.
  • biodegradable plastic fiber additive process 110 shown in Figure 6 may take several forms, as shown in Figure 6 process 110 includes several sources of material for the formation of the paper product.
  • An agricultural crop growth and harvesting step 112 supplies material to a conventional crop pulping step 114.
  • papermaking fibers may be provided from a repulping recycled fiber process step 116, supplying fiber to a deinking and screening step 118.
  • a recovery step 120 may provide material to a composting step 122 for fertilization or soil enhancement of the crop growth and harvesting step 112. Additionally, recovery step 120 may provide material to a recovered material separation step 124 which, depending upon the material having been recovered, may forward material to the repulping recycled fiber step 116 or may provide material directly to a combining organic material step 126.
  • Recovered material separation step 124 may also provide biodegradable plastic material to a fiberizing step 128, wherein discrete fibers or filaments are created. Additionally, virgin plastic fiber may be provided in a step 130 to the fiberizing biodegradable plastic step 128. Fiberized biodegradable plastic is combined with the organic fibers in a mixed fibers step 132. Thereafter, the mixed fibers are provided to formation, pressing, drying, converting and use step 134. While the formation, pressing, drying, converting and use step 134 may be conventional, it may also incorporate some of the processes described previously herein, and may utilize a vegetable slime preparation step 136, with deposit of the fibers on a substrate 14.
  • the various processes disclosed herein can be modified to achieve a variety of desired physical characteristics for the resulting product.
  • the application of heat during pressing or drying increases water resistance of the resulting material, by melting the surface of substrate 14 or of individual fibers in the fiber additive process shown in Figure 6.
  • Combining a number of the previously described methods can produce a variety of products, depending on the varying functions of the material.
  • Layering of the sheets, including a felt or scrim of recycled fiber, agricultural material residue powder and thin biodegradable plastic substrate may be suitable for diapers, feminine napkins and other hygienic products. Subsequent breakdown in landfills or the like is improved when compared with conventional products, since all materials are biodegradeable in nature.
  • hollow biodegradeable plastic filaments may be filled with recycled paper fibers or crop material, and woven conventionally into fabric. Surface coatings as described previously herein may then be applied.
  • strips or strands can be cut from the powder coated substrate, and subsequently woven or knitted into fabrics having elasticity and conformability.
  • Fabric made in such a manner may have particular suitability for wall coverings with distinctive textures and patterns, and for packaging materials with shock absorbability.
  • Processes according to the present invention are not complex when compared to conventional processes for making paper.
  • the biodegradable plastic substrate provides wet strength in the web being formed and in the end product, making handling easier.
  • Processes according the present invention readily make use of low quality fiber and easily renewable fiber sources such as agricultural products. Additionally, processes according to the present invention may utilize papermaking materials which otherwise would be wasted, such as left over leaf and stalk components from other agricultural processes and fines and pins from conventional papermaking. The present processes may also utilize naturally white materials, thereby reducing or eliminating the need for chemical bleaching of the papermaking material to achieve a white surface. Chemical pulping of the papermaking material is eliminated.
  • Processes according to the present invention are amenable to use in low tech configurations including manufacture by hand. Thus, art and specialty papers may be made in small batches at reasonable expense. Further, the processes are adaptable to use in emerging countries with readily available materials and can be used locally, at small volume locations where infrastructure necessary for conventional papermaking processes, such as utilities, roads for transporting materials and the like are not readily available.

Abstract

Cette invention concerne un procédé de fabrication de papier et un produit en papier ainsi obtenu dans lequel on ajoute un plastique biodégradable à la pâte à papier. Le plastique biodégradable peut faire office de substrat sur lequel est appliquée la pâte à papier. La pâte à papier peut renfermer des fibres de papier recyclé et/ou un matériau tiré de produits agricoles. Des fibres de bois recyclés peuvent être appliquées à l'état fibreux, et les matériaux d'origine agricole sous forme de poudre sur le substrat. Le matériau de surface est fixé sur le substrat par application de chaleur et de pression, ou bien collé au moyen d'un mucilage tiré de légumes.
PCT/US2001/003307 2000-02-02 2001-02-01 Procede de fabrication de papier et papier ainsi realise WO2001057311A2 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
JP2001555933A JP3942894B2 (ja) 2000-02-02 2001-02-01 紙形成工程およびそれから作られる紙
AU2001231274A AU2001231274A1 (en) 2000-02-02 2001-02-01 Papermaking process and paper made therefrom

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US49698100A 2000-02-02 2000-02-02
US09/496,981 2000-02-02

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WO2001057311A2 true WO2001057311A2 (fr) 2001-08-09
WO2001057311A3 WO2001057311A3 (fr) 2009-06-11

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US (1) US20040040680A1 (fr)
JP (2) JP3942894B2 (fr)
AU (1) AU2001231274A1 (fr)
WO (1) WO2001057311A2 (fr)

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JP2004166828A (ja) * 2002-11-18 2004-06-17 Suzuki Shiko Kk 折り紙
WO2006047348A1 (fr) * 2004-10-22 2006-05-04 Sachiko Iwasaki Procede de fabrication d'un objet a partir d'un produit et objet forme
WO2006120700A2 (fr) * 2005-03-22 2006-11-16 Arrow Coated Products Ltd. Papier tres resistant et procede de fabrication de celui-ci

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KR100851069B1 (ko) * 2006-10-13 2008-08-12 지형림 유도 기전력을 이용한 전압 발생장치 및 이를 포함한전원장치
US7807008B2 (en) * 2007-05-29 2010-10-05 Laminating Services, Inc. Coated fabric containing recycled material and method for manufacturing same
US9091073B2 (en) * 2012-12-10 2015-07-28 Brad Wells Method and apparatus for temporary surface protection
EP3954813A4 (fr) * 2019-04-10 2022-11-30 Rinnovation Co., Ltd. Fil de papier, toile de papier et produit de type toile
US10557105B1 (en) 2019-08-09 2020-02-11 Bao Tran Extraction systems and methods

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WO2006047348A1 (fr) * 2004-10-22 2006-05-04 Sachiko Iwasaki Procede de fabrication d'un objet a partir d'un produit et objet forme
WO2006120700A2 (fr) * 2005-03-22 2006-11-16 Arrow Coated Products Ltd. Papier tres resistant et procede de fabrication de celui-ci
WO2006120700A3 (fr) * 2005-03-22 2007-01-11 Arrow Coated Products Ltd Papier tres resistant et procede de fabrication de celui-ci
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Also Published As

Publication number Publication date
AU2001231274A1 (en) 2001-08-14
JP3942894B2 (ja) 2007-07-11
US20040040680A1 (en) 2004-03-04
AU2001231274A8 (en) 2009-07-30
WO2001057311A3 (fr) 2009-06-11
JP2004504176A (ja) 2004-02-12
JP2007009402A (ja) 2007-01-18

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