WO2021067355A1 - Appareil, systèmes et procédés de fabrication de produits en papier isolés retriturables - Google Patents

Appareil, systèmes et procédés de fabrication de produits en papier isolés retriturables Download PDF

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Publication number
WO2021067355A1
WO2021067355A1 PCT/US2020/053402 US2020053402W WO2021067355A1 WO 2021067355 A1 WO2021067355 A1 WO 2021067355A1 US 2020053402 W US2020053402 W US 2020053402W WO 2021067355 A1 WO2021067355 A1 WO 2021067355A1
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WO
WIPO (PCT)
Prior art keywords
paper
insulating material
mixture
forming wire
nozzle
Prior art date
Application number
PCT/US2020/053402
Other languages
English (en)
Inventor
Nigel J. Flynn
Taylor Kopacka LEIGH
Jason Lye
Ryan D. LISS
Lon E. II PSCHIGODA
Original Assignee
Outlier Solutions Llc
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
Priority claimed from US16/590,224 external-priority patent/US11247446B2/en
Priority claimed from US16/837,715 external-priority patent/US20200283957A1/en
Application filed by Outlier Solutions Llc filed Critical Outlier Solutions Llc
Publication of WO2021067355A1 publication Critical patent/WO2021067355A1/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
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21F—PAPER-MAKING MACHINES; METHODS OF PRODUCING PAPER THEREON
    • D21F11/00—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines
    • D21F11/02—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines of the Fourdrinier type
    • D21F11/04—Processes for making continuous lengths of paper, or of cardboard, or of wet web for fibre board production, on paper-making machines of the Fourdrinier type paper or board consisting on two or more layers
    • 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
    • D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
    • D21H13/36—Inorganic fibres or flakes
    • D21H13/38—Inorganic fibres or flakes siliceous
    • D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/63—Inorganic compounds
    • 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
    • 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

Definitions

  • the present invention relates generally to apparatus and systems for making insulated paper products.
  • the present invention further relates to methods of making insulated paper products.
  • Expanded polystyrene While cheap to produce, manufacture, and highly insulating, expanded polystyrene has many disadvantages. Expanded polystyrene (1) is persistent in the environment, contributing to ocean pollution and long term landfills, (2) is frequently litter that is unsightly and may cause obstruction in the guts of smaller animals when ingested, (3) is not recyclable in most municipalities, (4) has to be separated from the box prior to recycling, (5) has to be inserted inside the box, and (6) does not nest, meaning that it is expensive to ship, and bulky to store.
  • FIG. 25 shows how a stack of freshly made corrugated cardboard sheets are cut into an unfolded box by a rotary die/roller, ready to be inspected by quality control and shipped off to the customer. Card cuttings and trimmings from this process, along with any reject box, are shredded and then fed directly back into the repulping process (FIG. 7) as pre-consumer scrap card. This is made back into furnish. Introducing treatments, coatings, liners, and other materials into the cardboard box that cannot be fed directly back into the re-pulping process complicates the production process and risks increasing paper machine (FIG. 8) down-time if mistakes are made.
  • Using an incompatible material means that the scrap, and any trimmings from that cardboard material must be segregated, and handled separately from the usual cardboard.
  • inserts are either expanded poly(styrene) foam (sold under the tradename Styrofoam), and or poly(olefm) bubble wrap which may or may not be metalized to decrease radiative heat transfer.
  • expanded polyurethane foam is used in combination with a plastic film liner. None of these materials can be used in a cardboard box manufacturing line because any scrap containing these synthetic polymers would have to be segregated from the regular pulp. For this reason, cardboard boxes are made separately from the insulating material. Furthermore, the insulating material has to be removed prior to recycling the box as many municipalities do not recycle plastic films or expanded polystyrene.
  • paper beverage cups are also difficult to recycle. They are coated with a low molecular weight polyethylene, which causes problems when introduced into the pulp.
  • What is needed is a highly thermally insulating paper structure that provides one or more of the following benefits: (1) is non-toxic and safe for use with food, (2) maintains frozen or chilled food temperatures for the time needed to ship foods, (3) is curb-side ready - that is recyclable by municipal recycling services without separation or segregation from other papers in the waste stream, (4) trimmings generated during the paper product (e.g., cardboard box) manufacture are able to be repulped and directly sent back into the paper product (e.g., cardboard box) production stream without having to be segregated, (5) is able to withstand crushing by stacking, (6) is able to maintain integrity with condensation formation after being placed in a freezer then exposed to humid air, and (7) is biodegradable or biodestructable.
  • the present invention is directed to machine configurations that can be used to make insulated paper products that (1) insulate food positioned therein and/or surrounded thereby, (2) are biodegradable or biodestructable, recycleable, repulpable, and (3) do not require additional inserts to keep food cold or hot.
  • the disclosed insulated paper products utilize multiple ways to introduce insulating materials into and/or onto a variety of paper products. For example, thermally insulating materials may be introduced into the paper furnish prior to casting the furnish onto a paper-forming wire mesh. Alternatively, or in addition, the insulating material may be introduced between layers of paper as they are formed. Alternatively, or in addition, insulating materials may be incorporated into adhesives used to bond paper layers to one another. Alternatively, or in addition, insulating materials along with adhesives may be incorporated into a layer used to bond paper layers to one another.
  • the present invention is directed to machine configurations that can be used to produce insulated paper products.
  • the insulated paper product of the present invention comprises an insulated paper product comprising two or more paper layers and insulating material, wherein (1) when two or more paper layers are present, the two or more paper layers form an integral paper product, and (2) at least one of (a) one layer in combination with the two or more paper layers comprises the insulating material, and (2)(b) the integral paper product itself has a non- uniform distribution of insulating material therethrough.
  • the insulated paper product produced by the present invention comprises a corrugated integral paper product comprising: a first linerboard layer comprising one or more first paper layers, a second linerboard layer comprising one or more second paper layers, and a fluted paper layer comprising one or more fluted paper layers or a honeycomb layer positioned between the first linerboard layer and the second linerboard layer, wherein (i) the first linerboard layer, (ii) the second linerboard layer, and (iii) the fluted paper layer or the honeycomb layer may each independently comprise insulating material that has a low thermal conductivity and/or low emissivity.
  • the insulated paper product produced by the present invention comprises a corrugated integral paper product comprising: a first linerboard layer comprising one or more first paper layers, a second linerboard layer comprising one or more second paper layers, and a fluted paper layer comprising one or more fluted paper layers or a honeycomb layer positioned between the first linerboard layer and the second linerboard layer, wherein (i) the first linerboard layer, (ii) the second linerboard layer, and (iii) the fluted paper layer or the honeycomb layer may each independently comprise insulating material therein or thereon.
  • the insulated paper product comprises a fully recyclable, re- pulpable, biodegradeable, biodestructable, and thermally insulated cardboard box.
  • the present invention is further directed to methods of making insulated paper products.
  • the method of making an insulated paper product comprises: forming an insulated paper product comprising: one or more paper layers and insulating material, wherein (1) when two or more paper layers are present, the two or more paper layers form an integral paper product, and (2)(a) at least one of: (i) one layer in combination with the one or more paper layers comprises the insulating material and (ii) one paper layer within the one or more paper layers has a non-uniform distribution of insulating material therein, or (2)(b) the integral paper product itself has a non-uniform distribution of insulating material therethrough.
  • FIG. 1 depicts a perspective view of an exemplary paper product of the present invention
  • FIGS. 2A-2C depict exemplary cross-sectional views of the exemplary paper product shown in FIG. 1 as viewed along line 2-2 shown in FIG. 1;
  • FIG. 3 depicts a perspective view of another exemplary paper product of the present invention.
  • FIGS. 4A-4F depict exemplary cross-sectional views of the exemplary paper product shown in FIG. 3 as viewed along line 4-4 shown in FIG. 3;
  • FIGS. 5A-5B depict perspective views of other exemplary paper products of the present invention (also referred to herein as “an integral paper product”);
  • FIGS. 6A-6D depict exemplary cross-sectional views of the exemplary paper product shown in FIG. 5B as viewed along line 6-6 shown in FIG. 5B;
  • FIG. 7 depicts a schematic view of process steps and process components used to form the exemplary paper products of the present invention.
  • FIGS. 8A-8C depict an exemplary process flow in an exemplary papermaking process suitable for use in forming the exemplary paper products of the present invention
  • FIG. 9 depicts a side view of a paper layer forming process step suitable for forming a single paper layer within any of the exemplary paper products of the present invention.
  • FIG. 10 depicts a side view of another paper product forming process step suitable for forming an exemplary three-layered paper product of the present invention
  • FIG. 11 depicts a side view of another paper product forming process step suitable for forming an exemplary paper product of the present invention
  • FIG. 12 depicts a side view of another paper product forming process step suitable for forming an exemplary paper product of the present invention comprising a layer of insulating material;
  • FIGS. 13A-13I depict side views of seven paper layer forming processes, each of which is suitable for forming a paper within any of the exemplary paper products of the present invention
  • FIGS. 14A-14C depict exemplary storage containers comprising any one of the exemplary insulated paper products of the present invention
  • FIG. 14D depicts an exemplary cross-sectional view of the wall structure of the exemplary hot beverage cup shown in FIG. 14C;
  • FIGS. 15-18A depict additional exemplary storage containers comprising any one of the exemplary insulated paper products of the present invention;
  • FIG. 18B depicts a close-up cross-sectional view of the wall structure of the exemplary shipping container shown in FIG. 18A;
  • FIG. 19 depicts an exemplary cross-sectional view of a wall structure of an exemplary shipping container
  • FIGS. 20A-20B depict a paper layer having a uniform distribution of insulating particles and a paper layer having a non-uniform distribution of insulating particles;
  • FIGS. 21A-21B depict possible heat pathways through (i) the paper layer having a uniform distribution of insulating particles shown in FIG. 20A and (ii) and the paper layer having a non- uniform distribution of insulating particles shown in FIG. 20B;
  • FIGS. 22-23 depict views of an apparatus that may be used to determine the rate of heat transfer of paper samples and/or insulating materials with FIG. 22 depicting a cross sectional view of the apparatus and FIG. 23 depicting an exploded cross-sectional view of the apparatus;
  • FIG. 24 graphically shows the heat transfer rates of various materials
  • FIG. 25 depicts a schematic view of known processes for forming boxes from a rectangular corrugated sheet with waste (e.g., trimmings and defective boxes) generated from the process;
  • FIG. 26 depicts a corrugated stmcture of the present invention with one side coated and
  • FIG. 27 depicts single faced corrugate paper hot beverage cup sleeves including the net and cross section.
  • the present invention is directed to machines for making insulated paper products comprising fibers 11 (e.g., wood pulp fibers 11) and insulating material 12.
  • fibers 11 e.g., wood pulp fibers 11
  • insulating material 12 e.g., wood pulp fibers 11
  • each paper layer 10 comprises fibers 11 (e.g., wood pulp fibers 11) with or without other paper layer additives including, but not limited to, the insulating material 12.
  • the term “paper” is used to identify a type of non-woven material in which fibers are randomly oriented in all directions. Fibers principally made from cellulose are poured as a slurry on a mesh screen. As the paper is formed, the fibers come into contact with each other, and physically bond with neighboring fibers via a variety of interactions, including hydrogen bonding. The fibers originally come from plants including trees, although synthetic and mineral fibers, or other types of fibers, may optionally be included. Often, the paper also contains recycled fiber. Wood may be sourced from direct harvesting of trees from forest land, or from lumber industry byproducts (such as sawdust).
  • Paper fibers may include the fibrous portions from many parts, including softwoods (such as those plants with needles instead of leaves, for example, loblolly pine) and hardwoods.
  • Other plants that yield useful paper fibers include but are not limited to bamboo, sugar cane, wheat straw, reed grass, mischanthus grass, coconut fiber, hemp fiber, cotton fiber, jute, palm, reeds, and papyrus.
  • Cellulose fibers in many plants are bound together with lignin.
  • Recycled paper may include fibers from corrugated, fiber board, writing paper, pressboard, card, newspaper, tissue paper, specialty papers, linerboard, containerboard, boxboard, PE-lined paperboard, carton material, cup stock, or foodboard.
  • Pulping methods may include a) thermomechanical pulping, which involves the use of steam and sheer forces generated between a spinning and a stationary plate, b) chemical pulping, which uses strong chemicals to break down the pulp by dissolving the lignin, and/or c) the semi-chem process, which uses a combination of mechanical and chemical methods.
  • thermomechanical pulping which involves the use of steam and sheer forces generated between a spinning and a stationary plate
  • chemical pulping which uses strong chemicals to break down the pulp by dissolving the lignin
  • the semi-chem process which uses a combination of mechanical and chemical methods.
  • fluted medium board e.g., fluted medium board 23
  • Other types of pulp include solid bleached sulfate pulp, chipboard, and kraft.
  • Paper and paper layer 10 (and paper ply 10), as used herein, may broadly include any material that includes 5% or more cellulose fibers (discussed further below). Other additives, including insulating material 12, other particles/additives/components that impart grease resistant and/or water resistant, as well as other particles/additives/components to impart strength. Non-paper (and non paper layer 30) is anything containing less than 5% of cellulose fibers (discussed further below).
  • insulating material such as insulating material 12
  • insulating material 12 is used to described inorganic or organic materials that provide some degree of insulation.
  • the term insulating material, as in insulating material 12, does not include air alone or any other gas alone, although air and/or another gas could be trapped within one or more inorganic or organic insulating material 12.
  • Paper products 10/100V60 comprising fibers 11 (e.g., wood pulp fibers 11) and insulating material 12, can either be made flat (e.g., insulated paper products 100/100’) using a screen to make flat materials, or alternatively be molded, vacuum formed, or thermoformed from a pulp suspension to form essentially three-dimensional (non-flat) objects (e.g., molded or otherwise formed containers 60 shown in FIGS. 14A-18B).
  • Such three-dimensional paper products include certain packaging, for instance, egg crates and egg cartons, packaging that protects the corners of products shipped in the mail, biodegradable compost containers, biodegradable plant pots, disposable urinals and bed pans used in hospitals, disposable cat litter boxes, and the like.
  • Additives including insulating material 12, may be included within the paper products 10/100760 to impart thermal insulation properties, strength under moist or wet conditions, impart water repellency or water proofing, impart grease absorption resistance, increase strength, improve the color, improve printability, or other aesthetic aspects.
  • pre-consumer scrap corrugate may be added to a disintegrator and agitated to form a thick recycled pulp.
  • This pulp may be further refined using a Holland Beater, subjecting the paper fibers to high sheer, and reducing the pulp freeness.
  • the refined pulp may be diluted and further refined by being screened for large and small particles prior to use.
  • the thick pulp is diluted with water, and placed into an agitated stock tank. Retention aids and other additives may be added to the stock tank prior to use.
  • Pulp is pumped from the stock tank and mixed in-line with water to further reduce the consistency of the pulp, on the way to the headbox.
  • the headbox is set up with a series of weirs that allow diluted pulp to uniformly flow onto a moving wire.
  • water drains from the pulp leaving the fibers on the wire.
  • the fibers stop moving, and begin to interlock forming a sheet.
  • Foils and rollers beneath the wire assist in the water drainage. Vacuum slots are then used to actively remove free water trapped in the pulp layer by capillary action.
  • the pulp may also be heated to reduce the viscosity of water, allowing for faster drainage.
  • the paper machine may have more than one headbox, and more than one forming wire. Following vacuum slot treatment, the two sheets may be combined by bringing them into contact. The combined sheet is then trimmed and transferred onto the felt press for further water extraction. From the felt press, the sheet is fed into a series of steam-heated rollers which dry the remaining moisture from the sheet using heat. The paper may be calendared, coated or subjected to other treatments prior to rolling the sheet at the end of the machine.
  • Additives, including insulating material 12 may be added to the paper pulp prior to casting on the paper wire or otherwise molding the pulp into a product 10/100V60. Alternatively, additives, including insulating material 12, may be added at the size press, or after the steam can dryers. Additives, including insulating material 12, can also be added to a clay coating (e.g., coating 30) often applied to liner board (e.g., liner board 21/22) to make clay coated kraftback, or clay coated newsback.
  • a clay coating e.g., coating 30
  • liner board e.g., liner board 21/22
  • Additives may also be added to layers of paper using other means such as spray nozzles, slot- die coaters, curtain coating, or other means. Additives may be added to the paper as a slurry, that includes other materials besides water, such as starches, modified starches, paper fibers, dewatering additives, flocculants, pH buffers, and other additives.
  • Nozzles 229 may be arranged on spray booms 262 in a variety of ways to spray mixtures of paper pulp fibers and insulating materials onto the wet or dry paper.
  • the spray nozzle plume is flattened to give a fan shaped spray pattern, verses a conical spray emission.
  • the nozzles may be arranged in series, so that one spray boom sprays on top of the deposit made by a spray-boom further up line, there by depositing multiple layers of pulp and or insulating material layers on top of one another.
  • the spray nozzles are arranged in such a way that the spray plumes intersect, so that most points of the web receive deposition from more than one spray nozzle.
  • the fan of the spray nozzles is angled with respect to the web direction. This allows multiple nozzles to direct to the web without the fans interfering with the momentum of neighboring spray fans.
  • the spray nozzles may be used in combination with a slot-die or similar deposition technology.
  • Atomization or spray systems are numerous with many known in the art. Pressurized spray systems force liquids at high pressure through a narrow opening under moderate pressure, such as around 40 psi. If the pressure drops before and after the nozzle is sufficient, the liquid will form small droplets in a plume instead of a stream of liquid.
  • the shape of the spray plume may be changed by the shape of the exit nozzle, thereby making a fan shaped plume or a conical shaped plume. The shape of the plume can also be altered using compressed air, forcing the plume into a fan.
  • Industrial hydraulic spray nozzles may be used in the present invention.
  • the spray action does not disturb the bottom layer to a great extent.
  • several different approaches may be employed to reduce the impact momentum of the droplets hitting the laid pulp layer.
  • the nozzle spray may be first forced to impact a hard surface, which then deflects the spray plume toward the web.
  • the hard surface may be an integral part of the nozzle, or it may be a separate component. Deflecting the stream in this way can reduce the momentum of the pulp-filler stream, as well as broadening the spray plume and flattening it into a flat sheet (vs. a cone of spray).
  • Nozzles that deflect the stream are sold by various companies, including FloodJet® type K nozzles sold by Spraying Systems Co. based in Glendale Heights, IL. Nozzles can also be run at lower pressure, for instance, at 10 psi (or any value below about 25 psi, in increments of 0.1 psi) vs. 40 psi. Other types of hydraulic nozzles also make a flattened spray fan vs. a spray cone, and may be used for the invention including VeeJet® nozzles, sold by Spraying Systems Co. Such nozzles can be machined to provide a range of spray plume angles, including 65°, 40°, and 100°, at various different flow rates.
  • Air- assisted atomization uses an air venturi to suck a stream of liquid into a fast-moving airstream. The liquid breaks up into small droplets as it leaves the nozzle. Additional air may be used to shape the plume from a cone into a fan shape.
  • a bell coater could be used to generate a cloud of atomized coating. A bell coater works by allowing coating to run onto a either a disk or bell-shaped device spinning at high speed. Coating is flung off the disc in very small drops.
  • atomization nozzles that include an acoustic horn or an acoustic transducer can be used to atomize a mixture of insulating elements and fiber.
  • the acoustic horn can be housed directly behind an atomization orifice, or the nozzle itself may be energized with acoustic energy supplied by a transducer.
  • the acoustic energy may be audible - around 1000 Hz to 15,000 Hz, or it may be ultrasonic from 15,000 Hz to 40,000 Hz.
  • Paper packaging (e.g., containers 60 shown in FIGS. 14A-18B), formed from the insulated paper products 100/1007100” made using the present invention, may include a wide variety of formats, including: regular slotted container (RSC), overlap slotted container, full overlap slotted container, special center slotted container, Bag-in-Box, center special overlap slotted container, center special full-overlap slotted container, snap- or 1-2-3 -bottom box with tuck top, snap- or 1-2- 3-bottom box with RSC top, Full Bottom File Box, Hamper Style, Ft.
  • RSC regular slotted container
  • overlap slotted container full overlap slotted container
  • special center slotted container Bag-in-Box
  • center special overlap slotted container center special full-overlap slotted container
  • snap- or 1-2-3 -bottom box with tuck top snap- or 1-2- 3-bottom box with RSC top
  • Full Bottom File Box Hamper Style
  • Ft Ft.
  • Medium board used in the insulated paper products 100/1007100” made using the present invention may be fluted with flutes of different dimensions. See, for example, exemplary fluted medium board 23 shown in FIGS. 6A-6D).
  • the Fiber Box Handbook defines flutes and flute dimensions as: A, B, C, E, F, G, K, N, as well as R/S/TVD.
  • the liner and medium papers may also be tested and rated by different burst grade: 125-350 SW, 23-55 ECT, 200-600 DW, 42-82 ECT DW, 700-1300 TW, 67-112 ECT TW.
  • the carton or box (e g., box 61) may then be folded into the following industry known styles: reverse tuck, snap lock, automatic bottom, straight tuck, tuck top snaplock bottom, tuck top automatic bottom, seal end, beers, mailing envelopes, folder, and simplex.
  • the insulated paper products of the present invention may comprise a single paper layer with insulating material dispersed therein or thereon, or may comprise two or more paper layers in combination with insulating material, wherein the insulating material is within one or more of the paper layers of the insulated paper product and/or is present as a component within the insulated paper product (e.g., as a separate layer from the paper layers and/or as a filler within a layer or component of the insulated paper product). See, for example, exemplary insulated paper products 100/1007100” in FIGS 1-6D
  • the insulated paper products made using the present invention may further comprise one or additional layers other than the one or more paper layers and possible layers of insulating material.
  • Suitable additional layers may include, but are not limited to, a coating that provides enhanced emissivity of the insulated paper product, a coating that provides a desired color and/or surface texture for the insulated paper product, and a coating that provide enhanced water-repellency (e.g., waterproofing properties) to the insulated paper product. See, for example, exemplary insulated paper products 100/1007100” in FIGS. 6A-6D.
  • a corrugated cardboard structure 100/1007100” comprises two liner boards 21/22 bonded to a fluted medium board 23.
  • One (or both) of the liner boards 21/22 may be coated (e.g., clay coated) with coating layer 30 for aesthetics.
  • the fluted medium 23 may have a range of flute dimensions, which are classified by the industry as A-flute through F-Flute.
  • Each liner board 21/22 may be made from one ply of paper 10/100’, or it may comprise two or more plies 10/100’.
  • pressboard - pressed fiber board e.g., two liner boards 21/22 with a honeycomb spacer in between.
  • any of the insulated paper products made using the present invention described herein may be configured into a variety of shapes.
  • the insulated paper product is in the form of an insulated cup or mug that may be used to house a hot beverage such as coffee.
  • Such insulated paper products may be used instead of STYROFOAM ® cups, eliminating the disposal and environmental problems associated with STYROFOAM ® cups.
  • the insulated paper product is in the form of insulated packaging for temporary storage and transport of items such as food, medicines, etc.
  • Such insulated paper products may be in the form of an insulated box, corrugated or not corrugated, as well as many other packaging items discussed herein. See, for example, exemplary insulated paper products 100/1007100” in FIGS. 14A-18B
  • the insulated paper products 100/1007100” made using the present invention provide a degree of insulation due to the construction of one or more paper layers 10 within a given insulated paper products 100/1007100”.
  • FIGS. 20A- 20B depict cross-sectional representations of exemplary paper composite layers 10 containing insulating material particles 12, represented as circles, and fibers 11. Both paper composite layers 10 contain the same number of circles, representing the insulating material particles 12.
  • the paper composite layer 10 shown in FIG. 20A has a substantially uniform distribution of insulating material particles 12, whereas the paper composite layer 10 shown in FIG. 20B has a non-uniform distribution of insulating material particles 12.
  • FIGS. 21A-21B provide a representation of possible conductive pathways that heat could take through exemplary paper composite layers 10 shown in FIGS. 20A-20B. While materials made using the present invention should not be limited by theory, in the case of the paper composite layer 10 shown in FIG. 20A, it is believed that the insulating particles 12, evenly distributed, lengthen the pathway of the conducted heat, thereby slowing heat transfer down. While the paper composite layer 10 shown in FIG. 20B has the same number of particles 12 (represented by the same number of circles), the particles 12 are concentrated in a narrow layer of the paper composite layer 10. Heat is partially blocked by the high concentration of insulating particles 12, reducing heat flow considerably in the paper composite layer 10 shown in FIG. 20B compared to the paper composite layer 10 shown in FIG. 20A.
  • the present invention is further directed to methods of making and using the herein disclosed and described insulated paper products.
  • the insulated paper products may be made using papermaking equipment and techniques so as to produce one or more paper layers.
  • the methods of making the insulated paper products of the present invention involve the strategic placement of one or more insulating materials within a given insulated paper product and/or the strategic placement of one or more optional coatings on the insulated paper product so as to provide superior insulating properties, as well as other properties to the insulated paper product. Exemplary method steps and procedures for forming insulated paper products of the present invention are shown/described in FIGS. 7-131.
  • FIG. 7 describes an exemplary method 200 for forming paper from wood pulp and pre consumer trimmings/scrap cardboard.
  • a wood composition of tree-wood is approximately 1/3 cellulose, 1/3 lignin, and 1/3 water.
  • Wood is fed into a disintegrator 201, which grinds the wood and feeds it into a beater 202.
  • Pulp is made in the beater 202.
  • the fibers undergo morphological changes. Fibers tend to collapse from round fibers into more of a kidney shaped cross-section, and the fibers become slightly more hydrophobic as beating continues.
  • trimmings and rejected card e.g., damaged, warped, etc.
  • the card is washed in a wash clean device 203 to the extent possible to remove inks etc., then fed back into the beater 202.
  • FIGS. 8A-8C depict an exemplary process of forming paper sheets 10.
  • pulp furnish
  • the fiber content of the furnish is approximately 1- 2 wt% at this stage.
  • a gate 205 allows furnish to flow out onto the moving forming wire (a fine mesh conveyor.) 206.
  • the forming wire 206 may be 75-100 feet long. Initially, water drains via gravity, however, further down, vacuum boxes 207 beneath the wire 206 assist water removal, increasing the fiber content to around 20-30 wt%.
  • the material (-20-30 wt% fiber) is then fed through one or more felt presses 208, which “blot” the precursor paper (i.e., precursor to paper layer 10), removing more water, and increasing the fiber content to around 45-50 wt%. If starch or another additive is to be applied, then that may be done at the size press 209 prior to drying.
  • drying may be affected in a number of ways, including running over steam cans 210, or entering a long hot air-drying tunnel (not shown). After passing through calendar rolls 211 and prior to winding, the paper 10 may be between 6 to 10% moisture content.
  • FIG. 9 depicts an exemplary furnish flowing out of a header box gate 205 onto the moving forming wire (a fine mesh conveyor.) 206, showing water draining through the moving forming wire 206, and fibers coalescing and concentrating as the wire 206 moves along.
  • FIG. 10 depicts an exemplary process step for forming a multiple ply linerboard 100.
  • the linerboard 100 may be made from more than one paper ply 10 during the manufacturing process. More than one header box 204 and wire line 206 may be running simultaneously, so that two or more wet paper sheets 10 are combined at laminator nip rolls 212 prior to entering the felt press 208.
  • FIG. 10 shows three plies 10 being combined to make a thicker linerboard 100 prior to entering a felt press 208
  • FIG. 11 depicts details of an exemplary linerboard 100 suitable for use in forming an insulated paper product 100/1007100” of the present invention or a component (e.g., a layer or outer linerboard) of an insulated paper product 100/1007100” of the present invention.
  • exemplary linerboard 100 comprises two sheets of paper 10 laminated to one another.
  • Exemplary linerboard 100 further comprises a first clay coating 30 directly on an outer surface 13 of one of the paper layers 10, and an outermost second white clay coating 30 so as to provide a printable surface/layer 38 for exemplary linerboard 100.
  • First clay coating 30 evens out the valleys and troughs of the rough paper 10, leaving a smooth surface for high-quality printing.
  • FIG. 12 depicts details of another exemplary linerboard 100 suitable for use in forming an insulated paper product 100/100’ of the present invention or a component (e g , a layer or outer linerboard) of an insulated paper product 100/100’ of the present invention.
  • a thermally insulating additive layer 20 comprising insulating material 12 may be incorporated into an exemplary linerboard 100 via an additive applicator 213.
  • layer 20 of insulating material 12 is positioned between two layers of paper 10 within exemplary linerboard 100 comprising three layers of paper 10.
  • a second additive applicator 213 could be used to provide another layer of additives (e ., insulating material 12 or some other material) between the other two layers of paper 10 within exemplary linerboard 100 comprising three layers of paper 10.
  • FIGS. 13A-13I depict various ways of incorporating insulating material 12 within or on a given paper layer 10 or an insulated paper product 100/100’.
  • thermally insulating material 12 is added to the pulp, wherein the thermally insulating material 12 has a density that that is close to that of water.
  • the insulating materials 12 are incorporated evenly, substantially uniformly throughout the paper 10 thickness.
  • a non-uniform distribution of insulating material 12 results from the use of insulating material 12 having a density lower (or much lower) than that of water. In this case, gravitational forces cause water to drain downward, but insulating material 12 tends to move upward as the furnish proceeds along moving wire 206. This leads to a higher concentration of insulating particles 12 on an upper side/surface of the paper 10.
  • it has been surprisingly discovered that the insulating properties of a paper layer 10 are enhanced when the insulating additives 12 are concentrated on one face of the paper 10 versus distributed substantially uniformly throughout the thickness.
  • FIG. 13C another procedure is shown so as to result in a non-uniform distribution of insulating particles 12 within an insulated paper product 100/100’.
  • a second head box 204 may be used to deposit a layer of insulating mater 12 and optional fibers on top of a lower layer of fibers (e.g., furnish) as the combined furnish proceeds along moving wire 206.
  • FIG. 13D another procedure is shown so as to result in a non-uniform distribution of insulating particles 12 within an insulated paper product 100/100’.
  • a third head box 204 may be used to deposit a layer of insulating mater 12 and optional fibers on top of a lower layer of fibers (e.g., furnish) as the combined furnish proceeds along moving wire 206.
  • FIG. 13E another procedure is shown so as to result in a non-uniform distribution of insulating particles 12 within an insulated paper product 100’.
  • a first and a second head box 204 may be used to form two plies of fiber.
  • a middle layer containing insulating material 12 is deposited as a liquid via a slot-die coater 261, or via a spray boom 262, or as a solid via a shilling roller 263.
  • the top layer of pulp is first cast onto a separate wire 206, and then transferred onto the middle layer of the non-uniform composite 100’.
  • the slot-die coaters 261 are well known, being similar to curtain coaters.
  • Slot-die coaters 261 may include an agitation means (not shown) within the head 265 to ensure that feed is consistent and settling is avoided. More advanced slot-die coaters 261 include such inventions as the Hydra-Sizer technology supplied by GL&V Pulp & Paper Group, Lawrenceville GA.
  • FIG. 13F another procedure is shown so as to result in a non-uniform distribution of insulating particles 12 within an insulated paper product 100’.
  • a nozzle 229 is used to feed pulp 11 into the gap 268 between a vacuum roll 267 and a forming felt 206.
  • a middle layer containing insulating material 12 is deposited as a slurry in layer 20.
  • the top layer of pulp 11 is applied by a second head box nozzle 229.
  • Such nozzle pulp applicators 229 are described in U S. Patent No. 5,645,689 entitled “Multilayer Headbox” to Voith SulzerPapiermaschinen GmbH.
  • Inventia disclose ‘Aq-Vane’ technology for preventing mixing of layers as they are delivered by a multi-layered head.
  • Aq-Vane incorporates an interstitial layer of water between layers of pulp as they are laid down.
  • FIG. 13G depicts another method of making an insulated paper product 100’ with non- uniform cross section containing an uneven distribution of insulating material 12.
  • a multi-layer headbox 204 is used to put down the first two layers (e.g., each of which independently comprises pulp 11 and/or insulating material 12) on a forming wire 206, which are then pressed with felt.
  • Consecutive layers e.g., layers 3 and 4, each of which independently comprises pulp 11 and/or insulating material 12
  • FIG. 13H depicts details of another procedure to result in a non-uniform distribution of insulating particles 12 within an insulated paper product 100’.
  • a first and a second head box 204 may be used to form two plies 10 of fiber 11. Zones A through G represent various observable stages of water removal from the pulp 11.
  • the first header bo204 lays down a low-solids pulp slurry 10 onto a first moving wire 206, on top of a forming plate 241.
  • the forming plate 241 gives the pulp 11 time to spread out before fast draining begins in Zone B.
  • Foils 243 touching beneath the wire 206 assist in pulling water from the pulp 11 in Zones B through E.
  • Zone A-B The pulp 11 on the wire 206 in Zone A-B is very fluid, as the pulp 11 is still moving within the water.
  • Zone B-C the pulp 11 has ‘settled’ on the wire 206, and the surface tension of the pulp 11 on wire 206 is flat. Beginning at C, the surface tension of the pulp 11 on the wire 206 is no longer flat, however, the pulp layer 10 is still wet enough to be visually ‘shiny.’
  • Zone C-E the wet pulp 11 on the wire 206 appears to become less and less smooth as the water drains and fiber 11 is left behind. As the pulp 11 travels over the first vacuum box 244 in Zone E, the pulp 11 becomes lighter, and non-reflective as much more of the moisture is removed than by gravity.
  • Zone G By the time that the pulp 11 reaches Zone G, or Zone G2, the pulp 11 is at around 22 wt% of the sheet (i.e. 78 wt% water) and the two layers of paper 10 are able to bond together. If the pulp is significantly dryer than 22 wt% fiber / 78 wt% water, then bonding between the two plies becomes weaker because the fibers are less free to interact as the sheet further dries. If the pulp is significantly wetter than 22 wt% fiber, then the two plies may bond less and the combined sheet may not be dry enough for transfer from the couch roll to the felt. Zones E2, F2, and G2 on the second forming wire 206 correspond to Zones E, F, G on first forming wire 206
  • a steam shower may be used to heat up the wet paper.
  • the elevated temperature reduces the viscosity of water, allowing it to be drained from the paper faster.
  • the wet paper may be formed using hot water in the headbox.
  • Another alternative could be that the moving web is heated using gas-fired or electrically powered infra-red heaters suspended above the wet paper web, to heat the web and reduce the viscosity of water.
  • the wire carrying the wet sheet passes over a couch roll.
  • the couch roll is a perforated cylinder connected to a vacuum line which sucks additional water from the paper as it is peels off the wire and onto the felt press.
  • the felt press is the first part of the drying section, effectively pressing the wet sheet between two felts in a continuous manner.
  • One or more spray nozzle boom 262 with one or more nozzles 229 and/or slot-die coaters 261 were placed at various zones A-G and E2-G2 to apply a layer of insulating material 12 between the two paper layers 10, and assessed for various properties.
  • FIG. 131 depicts various different exemplary configurations of the spray nozzles 229 and spray booms 262
  • Nozzles 229 may be arranged on spray booms 262 in a variety of ways to spray mixtures of paper pulp fibers 11 and insulating materials 12 onto the wet or dry paper 10 Typically, the spray nozzle plume is flattened to give a fan shaped spray pattern, verses a conical spray emission.
  • the nozzles 229 may be arranged in series, so that one spray boom 262 sprays on top of the deposit made by a spray-boom 262 further up line, there by depositing multiple layers of pulp 11 and/or insulating material 12 layers on top of one another.
  • the spray nozzles 229 are arranged in such a way that the spray plumes intersect, so that most points of the web 10 receive deposition from more than one spray nozzle 229
  • the fans of the spray nozzles 229 are angled with respect to the web direction. This allows multiple nozzles 229 to direct to the web 10 without the fans interfering with the momentum of neighboring spray fans.
  • the spray nozzles 229 may be used in combination with a slot-die 261 or similar deposition technology.
  • Atomization or spray systems are numerous with many known in the art. Pressurized spray systems force liquids at high pressure through a narrow opening under moderate pressure, such as around 40 psi. If the pressure drops before and after the nozzle is sufficient, the liquid will form small droplets in a plume instead of a stream of liquid.
  • the shape of the spray plume may be changed by the shape of the exit nozzle, thereby making a fan shaped plume or a conical shaped plume. The shape of the plume can also be altered using compressed air, forcing the plume into a fan.
  • Air-assisted atomization uses an air venturi to suck a stream of liquid into a fast-moving airstream. The liquid breaks up into small droplets as it leaves the nozzle. Additional air may be used to shape the plume into a fan shape.
  • a bell coater could be used to generate a cloud of atomized coating. A bell coater works by allowing coating to run onto a either a disk or bell-shaped device spinning at high speed. Coating is flung off the disc in very small drops.
  • atomization nozzles that include an acoustic horn or an acoustic transducer can be used to atomize a mixture of insulating elements and fiber.
  • the acoustic horn can be housed directly behind an atomization orifice, or the nozzle itself may be energized with acoustic energy supplied by a transducer.
  • the acoustic energy may be audible - around 1000 Hz to 15,000 Hz, or it may be ultrasonic from 15,000 Hz to 40,000 Hz.
  • the insulated paper products made using the apparatus, systems and methods of the present invention may further comprise one or more of the following features:
  • Fiber Blend. Recycling and Strength Short length fibers tend to come from refined hardwood, while longer fibers come from softwood. A good ratio of 75% softwood 25% hardwood balances the properties of the two types of fiber, optimizing tensile strength.
  • hemp fibers have come under increasing attention as a paper additive. Hemp fibers are far longer than other pulp fibers, help increase strength due to increasing contact points and bonding, and so may be subjected to multiple recycling steps - far more than regular wood fibers. Hemp fibers, being much longer than softwood may be recycled around 40 times vs. 6 for other types of fiber.
  • One or more of these materials/features could be incorporated into any of the here-in described insulated paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60
  • the fibers may be subjected to an extreme high-shear environment, such as a colloid mill.
  • the high sheer environment of two plate spinning in contact fibrillates cellulose fiber aggregates, increasing bonding, as well as the propensity to retain filler solids.
  • Other ways to fibrillate the fiber can include prolonged beating in a mechanical Hollander pulp beater such as disclosed in the U.S. Patent No. 1,883,051 or by high- sheer mixing, high-speed mixing, or media milling.
  • a further way to form fibrillated cellulose fibers is to agitate the fibers in the presence of a filler.
  • the filler may behave as a milling media, adding to the sheer, and causing the fibrillated fibers to entangle with the filler.
  • Companies such as FiberLean Technologies Ltd. (Cornwall, UK - a joint venture between Imerys and Omya) specialize in generating such mineral-fibrillated cellulose composites. Fibrillated cellulose may increase porosity of the paper and paper strength due to enhanced bonding area between fibers. Other ways to increase strength is by including nanocellulose into the paper formulation.
  • One or more of these materials/features could be incorporated into any of the here-in described paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60.
  • the inventors have also found that when paper fibers are forced through a pressurized spray system, they may appear to fibrillate as if they had been further refined in a pulp beater or a colloid mill. Without wishing to be limited by theory, the inventors speculate that the sheer forces created by the pressure drop experienced by the fibers as they leave the nozzle may fibrillate and further refine the pulp. The fibrillation is believed to contribute to higher bond strength between the plies.
  • Rosin is often used as part of a two-part system to impart moisture resistance in paper (e.g., paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60).
  • the second part is post addition of aluminum salt solutions - e.g. aluminum chloride or aluminum sulfate.
  • the aluminum reacts with the rosin soap to make a hydrophobic coating, which may impact repulpability yield.
  • including a chelating agent somewhere in another component of the paper product may remove the aluminum from the rosin, thereby increasing the repulpability yield.
  • Vapor-Guard R5341B or Barrier Grip 9471A are also useful as barrier coatings that provide the paper with a degree of grease and water resistance, and are described along with other suitable materials in Georgia Pacific Patent Application Publication No. US2019/0077537.
  • any feature and/or component described herein may be present alone or in combination with any other feature and/or component or combination of features and/or components described herein to form the here-in described paper layer 10 and/or insulated paper product 100/100’ and/or corrugated paper product 100” and/or storage container 60 of the present invention.
  • the numbered embodiments provided below describe many embodiments of the present invention, some claimed and some unclaimed. Even though some of the features in the numbered embodiments provided below may not be claimed, the unclaimed feature(s) in the numbered embodiments provided below do form part of the present invention, and may optionally be incorporated into any claimed product.
  • Thermally insulating fillers for addition at the wet end tend to be of very low density. These may include perlite, perlite coated with copper ions, expanded perlite, perlite hollow microspheres (such as available from Richard Baker Harrison Ltd., UK, or CenoStar Corporation (US), or Sil-Cel® microcellular aluminum silicate filler particles made by creating a structure of multicellular spherical bubbles comprising perlite, available from Silbrico (US), Sil-Cel® microspheres are available in a range of particle sizes, and may be coated or uncoated, or Dicaperl HP-2000 perlite microspheres, as sold by Dicalite (US), or flaked or milled perlite (such as Dicaperl LD1006, cryogenic grades of perlite, for instance, Dicaperl HP-100, HP-200, and HP100-40 grades, also sold by Dicalite), porous volcanic materials (such as pumice), vermiculite (including MicroLite® vermiculite dispersions, available from Dicalite), hollow expanded
  • organic aerogels such as those disclosed in PCT WO 2019121242 to Henkel AG & Co. KGAA which comprise thiol-epoxy based aerogels, xerogels (i.e., collapsed aerogels), seagels (i.e., microfoams made from agar and alginates), foamed starch, foamed paper pulp, agar, foamed agar, alginates, foamed alginates, bismuth oxychloride, metalized ceramics, metalized fibers, cadmium yellow pigment (cadmium disulfide), or any combination thereof.
  • thiol-epoxy based aerogels i.e., collapsed aerogels
  • seagels i.e., microfoams made from agar and alginates
  • foamed starch foamed paper pulp
  • agar foamed agar
  • alginates foamed alginates
  • bismuth oxychloride
  • Examples of commercially available insulating materials 12 include, but are not limited to, FOAMGLAS ® products commercially available from Owens Corning (Pittsburg PA); and Growstone products commercially available from Growstone, LLC, a subsidiary of Earthstone International Inc. (Santa Fe, NM).
  • Recycled glass suitable for use as insulating materials 12 is typically crushed to a finely divided powder and mixed with a blowing agent, e.g., carbon or limestone. It is then passed into a furnace hot enough to begin to melt the glass. As the glass powder particles begin to fuse, the blowing agent gives off a gas or vapor, forming bubbles inside the glass. This generates a porous, mostly closed cell glass foam, with high thermal and sound insulation properties.
  • a blowing agent e.g., carbon or limestone
  • Vermiculite may also be used as a suitable insulating material 12
  • Vermiculite is a hydrous phyllosilicate mineral that undergoes significant expansion when heated. Exfoliation occurs when the mineral is heated sufficiently, and the effect is routinely produced in commercial furnaces. Yermiculite is formed by weathering or hydrothermal alteration of biotite or phlogopite.
  • An apparatus for making insulated paper products 10/100/100’ with an uneven cross-sectional distribution of insulating material 12 therethrough comprising: a first paper forming wire 206 moving along a first papermaking path; a first headbox 204 positioned to deposit a first pulp slurry onto the first paper forming wire
  • first formation plate 241 positioned below the first paper forming wire 206 proximate the first headbox 204; at least one first nozzle 229 positioned to deposit first insulating material 12 onto the first paper slurry 10 on the first paper forming wire 206; one or more vessels 242, each vessel 242 being (i) sized to house the first insulating material 12, and (ii) in fluid communication with the at least one first nozzle 229; a second paper forming wire 206 moving along a second papermaking path; a second headbox 204 positioned to deposit a second pulp slurry 10 onto the second paper forming wire 206; and a second formation plate positioned below the second paper forming wire 206 proximate the second headbox 204; wherein the second paper forming wire 206 is positioned to deposit a second paper ply 10 onto a first paper ply 10 with first insulating material 12 deposited thereon positioned along the first paper forming wire 206 so as to form the insulated paper product 10/100/100
  • the one or more vessels comprises (a) a first set of one or more first vessels (i) sized to house the first insulating material 12, and (ii) in fluid communication with the at least one first nozzle 229, and (b) a second set of one or more second vessels (i) sized to house the second insulating material 12, and (ii) in fluid communication with the at least one second nozzle 229.
  • the one or more vessels contains (i) a mixture of from about 50.0 weight percent (wt%) to about 98.0 wt% of the first insulating material 12 and from about 50.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, (ii) a mixture of from about 50.0 wt% to about 98.0 wt% of the second insulating material 12 and from about 50.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, or (iii) both (i) and (ii).
  • the one or more vessels contains (i) a mixture of from about 90.0 wt% to about 98.0 wt% of the first insulating material 12 and from about 10.0 weight percent (wt%) to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, (ii) a mixture of from about 90.0 wt% to about 98.0 wt% of the second insulating material 12 and from about 10.0 weight percent (wt%) to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, or (iii) both (i) and (ii).
  • the spray action does not disturb the bottom layer (e g., the first paper slurry) to a great extent.
  • the at least one second nozzle 229 is capable of depositing a high solids mixture (i.e. from about 2.0 wt% to about 30.0 wt% solids; or any value or range therebetween, in increments of 0.1 wt%) comprising water and from about 50.0 wt% to about 98.0 wt% of the second insulating material 12 and from about 50.0 weight percent (wt%) to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, onto the second paper slurry at a rate of between about 0.5 and about 5.0 US gallons per minute, and generating a dry basis weight of up to about 500 gsm of the mixture.
  • a high solids mixture i.e. from about 2.0 wt% to about 30.0 wt% solids; or any value or range therebetween, in increments of 0.1 wt%
  • a high solids mixture i.e. from about 2.0 wt% to about 30.0 wt% solids; or any value or range
  • each spray boom 262 (a) being positioned so as to extend over (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii) (e.g., in a width direction; perpendicular to the travel path of the paper slurry 10), and (b) being capable of supporting one or more nozzles 229.
  • each vacuum slot 244 (a) being positioned below (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii) (e.g., in a width direction; perpendicular to the travel path of the paper slurry 10) and (b) being capable of removing water from a paper slurry 10 (e.g., first and/or second paper slurry 10) positioned on (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii).
  • a paper slurry 10 e.g., first and/or second paper slurry
  • each foil 243 (a) being positioned below (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii) (e.g., in a width direction; perpendicular to the travel path of the paper slurry 10) and (b) being capable of removing water from a paper slurry 10 (e.g., first and/or second paper slurry 10) positioned on (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii).
  • a paper slurry 10 e.g., first and/or second paper slurry
  • each slot coater 261 (a) being positioned above (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii) (e g., in a width direction; perpendicular to the travel path of the paper slurry 10) and (b) being capable of depositing material (e.g., pulp, additives, insulating material 12, water, etc.) onto (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii).
  • material e.g., pulp, additives, insulating material 12, water, etc.
  • Process controller 245 capable of bringing the first paper ply 10 and the second paper ply 10 into contact with one another when the first paper ply 10 and the second paper ply 10 are still wet and able to bond to one another.
  • Process controller 245 may control one or more process variables including, but not limited to, independent forming wire 206 speeds, independent header box 204 material deposition rates, independent nozzle 229 material deposition rates, independent slot coater 261 material deposition rates, etc.
  • other apparatus/machine components that could be used in the present invention include, but are not limited to, one or more vacuum boxes, one or more couch rolls, one or more steam showers, one or more InfraRed heaters, or any combination thereof.
  • 25. The apparatus of any one of embodiments 1 to 24, wherein the insulated paper product 10/100/100’ formed by the apparatus comprises at least one layer of insulating material 12, wherein the layer of insulating material 12 comprises first insulating material 12 deposited by the at least one first nozzle 229 and second insulating material 12 deposited by the at least one second nozzle 229.
  • the insulated paper product 10/100/100’ formed by the apparatus comprises at least one layer comprising a mixture of insulating material 12 and pulp fiber 11, wherein the mixture comprises first insulating material 12 and pulp fiber 11 deposited by the at least one first nozzle 229 and second insulating material 12 and pulp fiber
  • the apparatus of any one of embodiments 1 to 26, wherein the insulated paper product 10/100/100’ formed by the apparatus comprises five layers, the five layers being: (a) the first paper ply 10, and (b) a layer of first insulating material 12 from the first paper forming wire 206, (c) a central layer of pulp fibers 11 deposited onto (i) the first paper forming wire 206, (ii) the second paper forming wire 206, or (iii) both (i) and (ii), and (d) a layer of second insulating material 12, and (e) the second paper ply 10 from the second paper forming wire 206. See, for example, FIG. 5A.
  • a system for making insulated paper products 10/100/100’ with an uneven cross-sectional distribution of insulating material 12 therethrough comprising: the apparatus of any one of embodiments 1 to 27; pulp fibers 11; and first insulating material 12.
  • any one of embodiments 28 to 30, further comprising: (i) a mixture of from about 90.0 wt% to about 98.0 wt% of first insulating material 12 and from about 10.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, (ii) a mixture of from about 90.0 wt% to about 98.0 wt% of second insulating material 12 and from about 10.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, or (iii) both (i) and (ii).
  • the second insulating material 12 independently comprises particles (i) having an average particle size of less than about 1000 microns (pm), and (ii) comprising perlite, expanded perlite, perlite hollow microspheres, perlite microspheres, milled expanded perlite, perlite flakes, cenospheres, glass bubbles, glass microbubbles, vermiculite, hollow expanded vermiculite, or any combination thereof.
  • a system for making insulated paper products 10/100/100’ with an uneven cross-sectional distribution of insulating material 12 therethrough comprising:
  • an apparatus comprising: a first paper forming wire 206 moving along a first papermaking path; a first headbox 204 positioned to deposit a first pulp slurry onto the first paper forming wire 206; a first formation plate 241 positioned below the first paper forming wire 206 proximate the first headbox 204; at least one first nozzle 229 positioned to deposit first insulating material 12 onto the first paper slurry 10 on the first paper forming wire 206; one or more vessels 242, each vessel 242 being (i) sized to house the first insulating material 12, and (ii) in fluid communication with the at least one first nozzle 229; a second paper forming wire 206 moving along a second papermaking path; a second headbox 204 positioned to deposit a second pulp slurry 10 onto the second paper forming wire 206; a second formation plate (not shown) positioned below the second paper forming wire 206 proximate the second headbox 204; and at least one second nozzle 229 positioned to deposit second
  • a method of making an insulated paper product 10/100/100’ with an uneven cross-sectional distribution of insulating material 12 therethrough comprising: forming one or more first paper layers 10 with first insulating material 12 thereon and/or therein on the first paper wire 206; forming one or more second paper layers 10 with optional second insulating material 12 thereon and/or therein on the second paper wire 206; and combining the one or more first paper layers 10 with first insulating material 12 with the one or more second paper layers 10 with optional second insulating material 12 so as to form the insulated paper product 10/100/100’ with the one or more first paper layers 10 forming a first outer surface of the insulated paper product 10/100/100’ and the one or more second paper layers 10 forming a second outer surface of the insulated paper product 10/100/100’ opposite the first outer surface.
  • the spray action does not disturb the bottom layer (e.g., the first paper slurry) to a great extent.
  • any one of embodiments 38 to 40 further comprising: depositing (i) a mixture of from about 50.0 wt% to about 98.0 wt% of the first insulating material 12 and from about 50.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, (ii) a mixture of from about 50.0 wt% to about 98.0 wt% of the second insulating material 12 and from about 50.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, or (iii) both (i) and (ii) onto the first paper forming wire 206 and/or the second paper forming wire 206.
  • any one of embodiments 38 to 41 further comprising: depositing (i) a mixture of from about 90.0 wt% to about 98.0 wt% of the first insulating material 12 and from about 10.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, (ii) a mixture of from about 90.0 wt% to about 98.0 wt% of the second insulating material 12 and from about 10.0 wt% to about 2.0 wt% of pulp fiber 11, based on total solids in the mixture, or (iii) both (i) and (ii) onto the first paper forming wire 206 and/or the second paper forming wire 206.
  • a high solids mixture i.e. from about 2.0 wt% to about 30.0 wt% solids; or any value or range therebetween, in increments of 0.1 wt%
  • a high solids mixture i.e. from about 2.0
  • a high solids mixture i.e from about 2.0 wt% to about 30.0 wt% solids; or any value or range therebetween, in increments of 0.1 wt%
  • a high solids mixture i.e from about 2.0 wt% to about 30.0 w
  • any one of embodiments 38 to 50 further comprising: incorporating one or more additives, other than the insulating material 12, into at least one paper layer 10 within the one or more first paper layers 10 and/or the one or more second paper layers 10.
  • Suitable additives include, but are not limited to, copper ions, waxes, synthetic (e.g., polymeric or glass) fibers, silica, surface modified silica, transition metal surface modified silica, cyclodextrin, sodium bicarbonate, silicones to impart grease and water resistance, metalized ceramic particles, metalized fibers, cationic starches, cationic polymers, such as cationic guar gum, poly(ethylene imine) (e g., poly(ethylene imine marketed as Polymin P and available from Aldrich Chemical), fillers, sizes, binders, clays including bentonite clay, kaolin clay, and other minerals, calcium carbonate, calcium sulfate, and other materials that may be added to paper products for different reasons, and any combinations thereof
  • the filler may make the paper more receptive to printing, for instance, or make the paper glossy.
  • Many fillers have a density greater than 1.0 g/cm 3 .
  • Flocculants and retention aids may also be included such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers. Sizes and binders may also be added to help provide strength to papers, and can include starches, hydrocolloids, artificial and natural polymer latexes, such as RHOPLEX ® acrylic resins from Dow Chemical and ROVENE ® binders from Mallard Creek Polymers (Charlotte NC). Water soluble polymers, such as poly(vinyl alcohol), and poly(acrylic acid) may also be added to the paper.
  • Vapor- Guard R5341B or Barrier Grip 9471A are useful as barrier coatings that provide a given paper layer 10 with a degree of grease and/or water resistance.
  • any one of embodiments 38 to 51 further comprising: coating an outer surface 13/15 of the insulated paper product 10/100/100’ with an insulating coating, the insulating coating comprising (i) one or more insulating materials comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, sericite, powdered silicon, silver-coated glass bubbles, aluminum oxide, hollow polymeric microsphere pigments, or any mixture or combination thereof, and (ii) a binder.
  • the insulating coating comprising (i) one or more insulating materials comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, seri
  • the insulating coating comprises one or more insulating materials comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, sericite, or any mixture or combination thereof.
  • the insulating coating comprises one or more insulating materials comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof.
  • the insulating coating comprises from about 50.0 weight percent (wt%) to about 99.9 wt% of the one or more insulating materials and from about 50.0 wt% to about 0.1 wt% of the binder.
  • the insulating coating comprises from about 90.0 wt% to about 99.9 wt% of the one or more insulating materials and from about 10.0 wt% to about 0.1 wt% of the binder.
  • each insulating coating independently comprises one or more coating layers with each coating layer comprising the insulating material and the binder.
  • the two or more coating layers comprise (i) a first coating comprising zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof, and (ii) a second coating applied onto the first coating and comprising bismuth oxychloride, bismuth oxychloride-coated mica, or any mixture or combination thereof.
  • any number of layers 10 of the one or more paper layers 10 may have an independent layer density, each of which is less than 1.0 g/cm 3 (or any value between 0.01 g/cm 3 and 0.99 g/cm 3 , in multiples of 0.01 g/cm 3 , e.g., 0.44 g/cm 3 , or any range of values between 0.01 g/cm 3 and 0.99 g/cm 3 , in multiples of 0.01 g/cm 3 , e.g., from 0.18 g/cm 3 to 0.85 g/cm 3 ).
  • any one of embodiments 38 to 62, wherein the insulated paper product 10/100/100’ has an integral paper product density of less than 1.0 g/cm 3 (or any value between 0.01 g/cm 3 and 0.99, g/cm 3 in multiples of 0.01 g/cm 3 , e.g., 0.77 g/cm 3 , or any range of values between 0.01 g/cm 3 and 0.99 g/cm 3 , in multiples of 0.01 g/cm 3 , e.g., from 0.18 g/cm 3 to 0.53 g/cm 3 ).
  • the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains”, “containing,” “characterized by” or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components.
  • an apparatus, system and/or method that “comprises” a list of elements is not necessarily limited to only those elements (or components or steps), but may include other elements (or components or steps) not expressly listed or inherent to the apparatus, system and/or method.
  • the transitional phrases “consists of’ and “consisting of’ exclude any element, step, or component not specified.
  • “consists of’ or “consisting of’ used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e , impurities within a given component)
  • the phrase “consists of’ or “consisting of’ appears in a clause of the body of a claim, rather than immediately following the preamble, the phrase “consists of’ or “consisting of’ limits only the elements (or components or steps) set forth in that clause; other elements (or components) are not excluded from the claim as a whole.
  • transitional phrases “consists essentially of’ and “consisting essentially of’ are used to define apparatus, systems and methods that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention.
  • the term “consisting essentially of’ occupies a middle ground between “comprising” and “consisting of’.
  • the herein-described apparatus, systems and methods may comprise, consist essentially of, or consist of any of the herein-described components, layers and features, as shown in the figures with or without any feature(s) not shown in the figures.
  • the apparatus, systems and methods of the present invention do not have any additional features other than those shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the apparatus, systems and methods.
  • the apparatus, systems and methods of the present invention do have one or more additional features that are not shown in the figures.
  • Insulated paper products similar to exemplary insulated paper products 100/1007100”/60 shown and described in FIGS. 1- 6D, 14A-21B and 26-27 were prepared on a Fourdrinier machine (see, for example, FIG. 8A) using a 24” wide wire with various machine configurations to lay down insulating material in layers on top of newly formed wet paper.
  • This pilot paper machine was also equipped with a second head box and a second Fourdrinier with the capability to add a second wet paper ply and lay it down on top of the first layer (FIG. 13H).
  • a polystyrene disposable weigh boat was accurately weighed to 4 decimal places (tare mass). Approximately 1-2 gram of liquid was placed in the weigh boat, and promptly weighed to four decimal places (gross-wet mass.) Subtracting the tare from the gross-wet mass gives the net-wet mass. The weigh boat was carefully tilted and rocked from side to side, allowing the liquid to coat the bottom of the weigh boat evenly, then it was placed in a cupboard for 24-48 hours to evaporate at room temperature. The dry weigh boat was re-weighed to four decimal places (gross-dry mass). Subtracting the tare from the gross-dry mass gives the net-dry mass.
  • Lee’s disk method is a known way to measure thermal conductivity in thin sheets with low conductivity.
  • a modified version of the Lee’s disk was used to measure the heat transfer rate of samples generated, assembled using available laboratory equipment, to enable a large number of tests to be conducted in a short period of time. Instead of allowing the materials to reach thermal equilibrium, a digital hotplate was used to maintain a set temperature for one side of the sample.
  • the apparatus is depicted in FIG. 34 (cross section) and FIG. 35 (exploded cross section). Materials/Equipment Used:
  • Circular cutting device set to cut 113 mm diameter circles (100 cm 2 )
  • Digital hot plate 70 that heats to at least 37°C (98.6°F) and with a heating surface 71 at least 113 mm in diameter • 10 x Aluminum disks 72, 113 mm in diameter (100 cm 2 ) and painted matte black on one surface (McMaster 1610T37)
  • Insulating hot plate guard 73 capable of withstanding temperatures greater than 37°C (98.6°F) and constructed to fit the hot plate 70 and the sample stack being used (McMaster 93475K65)
  • the average thickness of the samples was used to adjust the average temperature rise measurements over 3.5 mins.
  • a “standard” thickness was chosen based upon a target material thickness (dstd). The average temperature rise was adjusted using the formula:
  • Thickness Adjusted Delta T TADT T3 5mm-To * d / dstd.
  • the TADT is the heat transfer rate and is related to thermal conductivity in that the lower the TADT, then the lower the thermal conductivity of the sample.
  • Repulpability was tested by SGS Integrated Paper Services Inc., Appleton WI according to the “Voluntary Standard for Repulping and Recycling Corrugated Fiberboard treated to Improve its Performance in the Presence of Water and Water Vapor Protocol of 2013”, generated by the Fiber Box Association, headquartered in Elk Grove Village, IL, 60007.
  • Repulpable means the test material that can undergo the operation of re-wetting and fiberizing for subsequent sheet formation, using the process defined in this standard. In the repulpability test, materials are weighed, pulped in a specific manner using laboratory equipment, run through a laboratory disintegrator, and then run through a screen. The amount of rejected material is compared to the material that could be reused as pulp to make board as a % by mass.
  • the first is the acceptable recovery of the fiber based upon the mass of material first entered into the test, and the second is the percentage of the recovered fiber that is accepted, not rejected. These figures constitute the “% re-pulpability”, and the fiber box association has determined that a pass for both measures of repulpability is >85%. Other parameters recorded are: a) material fouling the equipment during pulping or forming b) material that does not disintegrate and has to be removed (becomes part of the rejects)
  • This test is used to measure the rate of drainage of water through pulp.
  • the drainage rate has been shown to be related to the surface conditions and the swelling of the fibers.
  • the pulp freeness was assessed at Western Michigan University according to TAPPI (Technical Association of Pulp and Paper Industries) test method T 227 om-09 as revised 2009, using a freeness tester apparatus, as described in the TAPPI test method.
  • Multi-ply paper sheets were assessed for ply bonding, and ranked from 1 to 6. This assessment was subjective, and based upon the difficulty or ease of separating the plies of the paper sheet. An assessment of 1 denotes that the two-ply separated with very little effort, whereas 6 denotes great difficulty in delamination. The assessment was based upon manually tearing, picking, and pulling the plies apart, observing and comparing the force needed to separate the plies. While subjective, we did find good general agreement between this assessment and the Scott Ply Bond test and Ring Crush data where it those were measured.
  • the Scott Plybond test measures the internal bonding strength of paper in the z-direction, using a lifting motion that is similar to peeling, however, performed in a repeatable manner. A pendulum strikes an aluminum angle bar that has been taped to the paper using double-sided sticky tape. If the paper has high internal bond strength, the energy in the pendulum is absorbed to a greater degree. This test can be used for both single-ply products and multi-ply products. Scott Ply Bond was tested by Western Michigan University, Kalamazoo MI, according to TAPPI test method: TAPPI/ANSI T 569 om-14.
  • Ring crush testing was performed by SGS Integrated Paper Services Inc., Appleton WI, according to TAPPI test method T 818 cm- 18 Ring crush of paperboard flexible beam method. Ring crush basically gives a measure of paper strength in the machine and cross web directions.
  • OCC Oled Corrugated Cartons
  • a disintegrator a mixture of clippings, as well as reject packaging
  • the pulp was then let down with water to give a freeness of around 500 CSF (Canadian Standard Freeness) at a consistency of approximately 1.75%.
  • Freeness of pulp is a measure of precisely how rapidly water can drain from a diluted fiber furnishes suspension. Drainage rate is related to the surface conditions and swelling of the fibers. Freeness of pulp tends to be decreased by refining and beating. The higher the freeness number, the more easily water will drain through the web.
  • a retention aid was also added to the pulp stock tank.
  • the insulating elements used to mitigate conductive heat transfer are very low in density.
  • 1 g of Innova aerogel powder occupies around 7 cm 3 of volume.
  • the perlite microspheres and milled and classified expanded perlite flake are of similarly low density, in the range of 100-200 kg.m 3 . If we assume that the density of paper fiber is approximately 1 g.cm 3 , then the following is approximately true regarding the % by volume: Paper Machine Modifications: Slot-die coater and spray nozzle:
  • the inventors explored placement positions of various combinations of spray nozzle(s) and slot-die along the Fourdrinier, in positions A-G and E2-G2 (FIG 13H) to form a multi-ply sheet of paper.
  • Second head box Fourdrinier laydown Target basis wt: 67 gsm dry
  • Spray nozzle 1 US gallon per minute at 40 psi, 12” nozzle height, 11” wide spray fan, : Positions A through C disrupted the pulp so much to cause web breaks. At positions D through G, the nozzle was able to deposit layers of various fillers and / or fiber pulp, which were then covered by a layer of fiber from the second headbox and Fourdrinier.
  • the sheet ply bonding was assessed visually, and manually and ranked 1 to 6 - with 6 being the best bonded and 1 being very easy to delaminate.
  • Sample ID LO 20 g of a solution of 0.5% cationic guar gum was added to the spray formulation as a retention aid.
  • the slot-die system was also tested for web destruction and additive laydown. Water was run through the slot-die, which laid down a 9” wide curtain on the base ply at 2.2 gallon per minute at positions A through D along the first wire. The slot-die was found to be gentle enough that it did not appear to disrupt the web, nor did it cause web breakage. Additives, such as 18 micron diameter glass microbubbles (sold as iM30k, supplied by 3M) were suspended in water, and were added to the pulp at positions B, C, and D. The additive was included into the paper web between two pulp sheets, one from the first headbox, and the other from the second headbox. However, the top and bottom ply did not bond at all in the areas in which the slot die laid down additive. This led to delamination of the plies in the final sheet.
  • Additives such as 18 micron diameter glass microbubbles (sold as iM30k, supplied by 3M) were suspended in water, and were added to the pulp at positions B, C, and
  • slot-die could be modified to allow laying down mixtures of pulp and additive
  • configuration of the slot-die and supporting equipment was not amenable to laying down mixtures of pulp and additive during this trial, due to clog formation.
  • a turbulizer was made by fastening commonly available multiple plastic self-locking nylon cable ties (such as UV resistant heavy duty cable ties, product model number TR88302 sold by TR Industrial, or sold as “Zip Ties” available for sale on www.ziptie.com) to a 1” OD schedule 40 PVC pipe, leaving the excess cable tie ends aligned and pointing away from the pipe.
  • the tips of the zip-ties were held just touching the top of the moving web at the point of introduction of the additive by the slot-die.
  • the makeshift turbulizer was tested just upstream from the slot-die introduction point and just downstream (in the machine direction) from the introduction point.
  • the turbulizers made a slight positive to bonding improvement, when the turbulizer was positioned approximately 3 -5mm downstream from the addition point, however the improvement was not sufficient to provide satisfactory inter-ply bonding (bonding ranking 2 vs. 1).
  • Three nozzles were suspended above the two Fourdriniers in various positions to explore formation of paper sheets exhibiting a non-uniform cross-sectional distribution of thermally insulating materials. Fittings allowed for larger or smaller nozzles to be installed above the web, giving nominally 1 US gallon per minute flow, 2 US gallon per minute, 3 US gallon per minute, 4 US gallon per minute, etc. The height from the web of each nozzle could also be adjusted to control the spread of the spray fan onto the web. Two spray heights were chosen, giving 11” wide spray width, or 23” wide spray width.
  • the pulp freeness was measured at 504 Standard Canadian Freeness, and thick pulp consistency was 1.75%.
  • 150 g of cationic guar gum was dispersed into 4 gallon of hot water over 40 minutes, after which the pH was adjusted with citric acid solution to pH 5.00 - 6.00. The mixture was stirred for a further 20 minutes before adding to approximately 4,500 lbs of pulp feedstock at 1.75% consistency.
  • the basis weight of both the bottom and top ply was set to 135 gsm, giving a total of 270 gsm basis weight, at 30 ft. / min.
  • the spray nozzles can also be used to lay down straight fiber pulp slurry. In this way, alternating sets of nozzles can lay down consecutive layers of perlite & fiber followed by fiber alone to help promote bond strength as well as build a more elaborate internal structure. Such a structure cross-section may be represented by those shown in FIG. 4D or FIG. 5A for instance, built up by successive spray layers.
  • Adding large amounts of an inorganic filler such as perlite, vermiculite, or glass bubbles to the interior of paper may reduce ply-bond strength while at the same time building improved thermal insulation properties. Because of this, it may be necessary to add a binder, such as a latex, or a starch or starch derivative, or some other types of binder such as microfibrillated cellulose, nanocellulose, or cellulose that has been subjected to high mechanical sheer. Addition of such materials will improve inter-ply bond strength of the resultant highly-filled sheet.
  • a binder such as a latex, or a starch or starch derivative, or some other types of binder such as microfibrillated cellulose, nanocellulose, or cellulose that has been subjected to high mechanical sheer. Addition of such materials will improve inter-ply bond strength of the resultant highly-filled sheet.
  • 7.5 g dry OCC fiber as a 1% pulp (-650 Std Canadian Freeness) was cast onto the wire and allowed to drain.
  • a spray pot was loaded with 247.5 g dry fiber as a 1% pulp as well as 80 g of 0.5% cationic guar gum acidified to pH -5-6.
  • the spray pot was pressurized to 40 psi, and the material was sprayed onto the wet formed sheet from a distance of 12” for 36 seconds. This composite sheet was left on the wire, and set to one side.
  • a second wire was used to cast another sheet of 7.5 g dry OCC fiber as a 1% pulp. The second sheet was allowed to drain, and then placed on top of the first wet sheet, so that pulp meets pulp.
  • the ‘ sandwich’ of pulp layers between wire mesh was run through a tabletop felt press, and the wires carefully removed. The sheet was dried, and then subjected to thermal and ply bond strength testing. This sheet was the control.
  • Highly filled thermally insulating test sheets were formed in a similar manner, laying down 7.5 g dry weight pulp first, then substituting the middle, sprayed layer with 165 g of Dicalite LD 1006 mixed into 82.5 g of dry OCC fiber at 1% pulp consistency, and finally laminating this to a second 7.5 g dry fiber mass sheet. These sheets showed far reduced ply strength due to the presence of insulating filler in the middle layer.
  • Additional sheets were formed, further substituting a portion of the fiber in the middle layer with various binders.
  • latex binders such as styrene butadiene latexes, styrene acrylic latexes, and synthetic latexes of various particle sizes
  • fibrillated cellulose In all cases, addition of a binder increased ply bond strength. Thermal conductivity was also to be measured using the modified Lee’ s Disk method testing for 3.5 minutes to determine how the addition of various binders effected the thermal conductivity of a given sheet.

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  • Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
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Abstract

L'invention concerne un appareil, des systèmes et des procédés de fabrication de produits en papier isolés.
PCT/US2020/053402 2019-10-01 2020-09-30 Appareil, systèmes et procédés de fabrication de produits en papier isolés retriturables WO2021067355A1 (fr)

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US16/590,224 US11247446B2 (en) 2018-10-01 2019-10-01 Re-pulpable insulated paper products and methods of making and using the same
PCT/US2019/054121 WO2020072527A1 (fr) 2018-10-01 2019-10-01 Produits de papier isolant repulpables et leurs procédés de fabrication et d'utilisation
US16/590,224 2019-10-01
USPCT/US2019/054121 2019-10-01
US16/837,715 2020-04-01
US16/837,715 US20200283957A1 (en) 2018-10-01 2020-04-01 Apparatus, systems and methods for making re-pulpable insulated paper products

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WO2023161663A3 (fr) * 2022-02-28 2024-01-11 Kiss House Ltd Procédé arid de matériau

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CN113265902B (zh) * 2021-04-28 2023-08-11 湖北盟科纸业有限公司 一种预冷处理的电弧喷铝铝箔纸制备装置
WO2023161663A3 (fr) * 2022-02-28 2024-01-11 Kiss House Ltd Procédé arid de matériau

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