WO2022219526A1 - Produit moulé multicouche et son procédé de préparation - Google Patents

Produit moulé multicouche et son procédé de préparation Download PDF

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Publication number
WO2022219526A1
WO2022219526A1 PCT/IB2022/053422 IB2022053422W WO2022219526A1 WO 2022219526 A1 WO2022219526 A1 WO 2022219526A1 IB 2022053422 W IB2022053422 W IB 2022053422W WO 2022219526 A1 WO2022219526 A1 WO 2022219526A1
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WO
WIPO (PCT)
Prior art keywords
layer
density
bulky
moulded
fibres
Prior art date
Application number
PCT/IB2022/053422
Other languages
English (en)
Inventor
Isto Heiskanen
Kaj Backfolk
Original Assignee
Stora Enso Oyj
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 Stora Enso Oyj filed Critical Stora Enso Oyj
Publication of WO2022219526A1 publication Critical patent/WO2022219526A1/fr

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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
    • 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
    • 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
    • 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
    • D21H11/16—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only modified by a particular after-treatment
    • D21H11/18—Highly hydrated, swollen or fibrillatable 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
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/10—Packing paper
    • 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
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J5/00—Manufacture of hollow articles by transferring sheets, produced from fibres suspensions or papier-mâché by suction on wire-net moulds, to couch-moulds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J7/00—Manufacture of hollow articles from fibre suspensions or papier-mâché by deposition of fibres in or on a wire-net mould
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers 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
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/72—Density

Definitions

  • the present invention concerns a multi-layered moulded product and a method of making the said product.
  • Lignocellulose or cellulose-based fibers have a special potential, as the most abundant renewable natural polymers on earth, and the availability of methods for preparing large volumes on an industrial scale, often presented in the forms of chemical or mechanical pulp with disintegrated cellulosic fibers.
  • Moulded cellulosic pulp provides for an environmentally friendly packaging material that is recyclable, compostable and biodegradable.
  • a moulded product formed by cellulose fibres provided with a layer of a lignophenol derivative and a surface layer of a microfibrillated cellulose has been disclosed in JP200513322 (Showa Marutsutsu Co Ltd).
  • JP2018062718A (Daio Paper Corp) presents manufacturing of a cellulose nanofibre moulded component.
  • An acoustic diaphragm prepared by immersing a substrate in a liquid dispersion of microfibrillated pulp and depositing the pulp on the substrate by suction is disclosed in US5473121A (Sony Corporation).
  • SE541435 (Stora Enso) presents a process for spraying microfibrillated cellulose (MFC) onto a moulded article to provide the article with a coating layer.
  • MFC microfibrillated cellulose
  • SE541435 presents a process for spraying microfibrillated cellulose (MFC) onto a moulded article to provide the article with a coating layer.
  • MFC microfibrillated cellulose
  • SE541435 Stora Enso presents a process for spraying microfibrillated cellulose (MFC) onto a moulded article to provide the article with a coating layer.
  • MFC microfibrillated cellulose
  • An object of the present disclosure is to provide a multilayered moulded product and a method of making the said product, which overcomes or mitigates at least some of the disadvantages of such products in the prior art.
  • a high-density layer comprising highly refined cellulose is positioned on at least one side of a bulky layer comprising cellulose thus creating a multilayer moulded product.
  • Figure 1A illustrates the moulding of a bulky layer (A);
  • Fig. IB illustrates the moulding of a high-density layer (B).
  • Fig. 1C illustrates a multilayered product, wherein a high-density layer (B) is positioned on the inside of a bulky layer (A).
  • One aspect of the present invention is a multilayered moulded product comprising at least one bulky layer (A) comprising cellulose fibers and having a density of 100-700 kg/dm 3 , and at least one high- density layer (B) comprising fibres and at least 20 wt% highly refined cellulose, as calculated on the total fiber weight of said high-density layer, wherein the high-density layer (B) has a density 3700 kg/dm3 and is arranged on at least one side of a bulky layer (A).
  • said bulky layer (A) has a density between 200 - 700 kg/dm 3 , or more preferably 250 - 600 kg/dm 3 .
  • Another aspect of the present invention is a process for the preparation of a multilayered moulded product comprising fibers, wherein the process comprises providing at least one bulky layer (A) comprising cellulose fibres and having a density of 200-700 kg/dm 3 ; providing at least one moulded high-density layer (B) having a density 3700 kg/dm 3 , such as between 700 - 1400 kg/dm 3 , comprising fibres and at least 20 wt% highly refined cellulose as calculated on the dry weight of said high-density layer, and joining the bulky layer (A) to the high-density layer (B).
  • each of the provided bulky layer (A) and moulded high-density layer (B) respectively has a dry content of at least 15wt%, preferably at least 30wt%.
  • each of the two layers (A) and (B) are moulded layers comprising a 3D shape.
  • each of the two layers (A) and (B) is wet moulded separate from each other before being joined into a multi-layered product.
  • each of the two layers (A) and (B) are provided as free-standing and self-supporting structures i.e. not necessarily supported by any mould to retain the shape, and are joined together to form the multi-layered moulded product.
  • a free-standing moulded structure (A) and (B) preferably has a dry content of at least 30wt%, preferably at least 40wt%. It is advantageous to manufacture the high-density layer (B) by means of wet moulding into a separate structure (i.e.
  • the bulky layer (A) comprising fibres, such as natural fibres, such as lignocellulose fibres or cellulose fibres, according to the present invention, can be moulded using methods known in the art.
  • formation moulds typically descend in a vat filled with pulp. A vacuum then sucks the pulp mixture onto the formation moulds.
  • the formation moulds may contain a stainless steel mesh, which ensures an even vacuum through the mould and provides for an even distribution of the pulp over the mould surface.
  • Moulded layers produced in this way typically have a rough surface.
  • the term moulded article encompasses a wet, semidry, dry moulded article as well as an interim product.
  • the bulky layer (A) may be moulded in a female mould or a male mould.
  • Fibres used in the bulky layer (A) can be, for example, lignocellulose fibres derived from wood or agriculture sources. It can also be recycled fibre such as deinked pulp. Other examples of pulps included are kraft pulp, dissolving pulp, CTMP, TMP, NSSC, reinforcement pulps, cellulose fines, sulphite pulps, pulps obtained from e.g. organosolv processes. The pulp can further be unbleached or bleached or even coloured.
  • the suspension used to form the bulky layer (A) comprises at least 5wt% or preferably at least 10wt% or more preferably at least 15wt% such as 15-90 wt% pre- consumer waste or reject.
  • Said reject is free from PFAS i.e. per- and polyfluoroalkyl substances.
  • Said reject contains preferably less than 1 wt% wet strength additives.
  • Said reject is preferably free from NIAS (non-intentionally added substances).
  • Said reject is preferably thermo-chemically treated in at least one step in order to reduce microbial activity and to allow reduced amount of biocides.
  • the bulky layer (A) and/or the high-density layer (B) may further contain process and performance chemicals.
  • process chemicals are e.g. drainage chemicals, slip or lubricants, wet strength chemicals, and fillers.
  • performance chemicals are such that affects the final end product properties such as hydrophobicity (AKD, ASA, Rosin sizes, SMA, waxes preferably ⁇ 15 kg/tn), wet strength (various resins e.g. PAE), strength (polysaccharides such as starches or cellulose derivatives), rub resistance, oil and grease resistance (barrier chemicals esp. PVOH of derivatives thereof, cellulose derivatives), electrostaticity (metal salts), printability (Metal salts, cationic polymers, pigments), etc.
  • Some of the additives can improve both process and performance.
  • the bulky layer (A) should preferably be low density, bulky and designed for providing rigidity and stiffness at low material usage.
  • One desired feature of the bulky layer (A) is that it is permeable such that the high-density layer (B) can be applied on the partly dried bulky layer (A).
  • the grammage of the bulky layer (A) is 50-500 g/m 2 or more preferably 50-400 and most preferably 50-350 g/m 2 .
  • the high density layer (B) comprises a highly refined pulp with degree of Schopper Riegler of 70-94.
  • the high-density layer of the moulded product of the present invention comprises at least 20wt% highly refined pulp based on the total fiber weight of the high-density layer (B), or more preferably between 50-99 wt%, based on the total fiber weight of the high-density layer.
  • the highly refined pulp has been prepared in presence of at least one polysaccharide co-additive at a concentration between 0.1-20 wt%.
  • the preferred polysaccharide is cellulose derivative such as sodium carboxymethyl cellulose.
  • the grammage for the high-density layer (B) is 5-100 g/m 2 , more preferably 5-80 g/m 2 and most preferably 5-60 or 5-50 g/m 2 .
  • An advantage according to the inventive approach is quick and easy drainage and dewatering. Also, concentrating barrier chemicals to the high-density layer (B) will be more efficient than if adding barrier chemicals to the bulky layer (A). Both the bulky layer (A) and the high-density layer (B) can comprise process or functional chemicals.
  • Using highly refined cellulose/highly refined pulp in said high-density layer (B) provides rigidity to the moulded end product.
  • a further advantage of using highly refined pulp is that it may act as a barrier especially against greases and fats but also e.g. aroma or gases. If combining with other performance chemicals, barrier properties can be further improved.
  • the high-density layer (B) may be made in a different moulding unit than the bulky layer (A). Such a solution would e.g. allow for use of different furnishes upon manufacturing.
  • the moulding of the bulky layer (A) may be carried out in a female mould, and the high- density layer (B) is moulded in a male mould.
  • the moulding of the high-density layer (B) is made in a female mould and the bulky layer (A) is made in a male mould.
  • the male mould part as inserted in the female mould part may form a slot between said moulds, wherein said slot the multi-layered moulded product would fit.
  • the bulky layer (A) is dewatered to at least >5 wt% and more preferably >10 wt% and most preferably 15-85 wt%.
  • a second layer i.e. layer (B)
  • the bulky layer (A) will also have high wet strength so it can be dipped in a second solution without dissolving or contaminating such a second furnish.
  • the moulded high- density layer (B) may be placed onto one side of the bulky layer (A) while the bulky layer (A) is still in the mould.
  • a vacuum may still be applied to the mould with the bulky layer (A) when the high-density layer (B) is placed onto the bulky layer (A).
  • the moulded bulky layer (A) may be placed onto one side of the high-density layer (B) while the high-density layer (B) is still in its mould.
  • a vacuum may still be applied to the mould with high-density layer (B) when the bulky layer (A) is placed onto the high-density layer (B).
  • the dry content of the moulded article according to the present invention may be more than 50% by weight, such as more than 60% by weight, more than 70% by weight, more than 80% by weight or more than 90% by weight.
  • the bulky layer (A) is at least partly dried prior to applying at least one high-density layer (B) thereon.
  • the moulded article is, at least partly, being dried or dewatered after that at least one high-density layer (B) has been applied to at least one bulky layer (A).
  • the contact angle of a water drop placed on the surface of the coated moulded article is more than 60° such as more than 80° or more than 90°.
  • the contact angle can be determined using methods known in the art.
  • the oil and grease resistance according to the KIT method is at least 6 or more preferably at least 8 such as between 8-12 (KIT Standard ISO 16532- 2). Definitions
  • cellulose fibers corresponds to material comprising natural cellulose-based fibers and/or lignocellulose fibres, including aqueous pulp compositions and/or fiber-based sheet or web materials.
  • Non-limiting examples of cellulose fibers suitable for use in this invention are cellulose fibers derived from softwoods such as pines, firs and spruces, as well as fibers derived from eucalyptus, bagasse, bamboo and other ligneous and cellulose sources.
  • a cellulose fibre is significantly longer than it is wide.
  • Cellulose fibres can have a mean width of 10 to 50pm.
  • the fibre length of softwood can be from 2.5 to 4.5 mm, while hardwood can have a fibre length from 0.7 to 1.6 mm, and Eucalyptus from 0.7 to 1.5 mm. However, the fibre length can vary considerably with different growing place, etc.
  • the cellulose fibres in the material disclosed herein can have a length from 0.1 mm to 65 mm, from 0.1 mm to 10 mm, or 0.5 mm to 65 mm, or from 0.5 mm to 10 mm, or from 0.5 mm to 7 mm.
  • the fibre lengths may provide different mechanical characteristics to the material.
  • the aspect ratio i.e. the ratio of the fibre length to the fibre width, of the cellulose fibres in the material according to the present invention can be at least 10, at least 25, at least 50, at least 75, or at least 100.
  • the aspect ratio can be up to 6500, or preferably up to 2000.
  • said "highly refined pulp” / "highly refined cellulose” is cellulose refined to an SR value in the range of 70-94, preferably in the range of 70-90, and wherein the cellulose fibers have a length of ⁇ 1 mm.
  • the Schopper-Riegler value can be obtained through the standard method defined in EN ISO 5267-1. This SR value is determined for a pulp, with or without additional chemicals, thus the fibers have not consolidated into a film or started any hornification or such. To determine the Schopper Riegler value it is preferable to take a sample just after the disintegration when consistency is relatively low. The skilled person understands that paper making chemicals, such as retention agents or dewatering agents, have an impact on the SR value.
  • the SR value specified herein, is to be understood as an indication but not a limitation, to reflect the characteristics of the material itself.
  • An advantage of highly refined pulp is that it has high surface area and provides better strength due to presence of long fibers. Also, it has very low infiltration behaviour, believed by the inventors to be important for enabling a layered structure.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention se rapporte à un produit moulé multicouche comprenant au moins une couche volumineuse (A) comprenant des fibres et présentant une densité de 100 à 700 kg/dm3, et au moins une couche de haute densité (B) comprenant des fibres et au moins 20 % en poids de cellulose hautement raffinée calculée sur le poids total de ladite couche de haute densité, et présentant une densité ≥ 700 kg/dm3, la couche de haute densité (B) étant agencée sur au moins un côté d'une couche volumineuse (A), ou entre deux couches volumineuses (A).
PCT/IB2022/053422 2021-04-12 2022-04-12 Produit moulé multicouche et son procédé de préparation WO2022219526A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2150450 2021-04-12
SE2150450-1 2021-04-12

Publications (1)

Publication Number Publication Date
WO2022219526A1 true WO2022219526A1 (fr) 2022-10-20

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024201096A1 (fr) * 2023-03-27 2024-10-03 Ftt S.R.L. Procédé de formation de fibres hautement affinées

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002080025A (ja) * 2000-06-27 2002-03-19 Toppan Printing Co Ltd ガスバリア性容器
EP1439264A1 (fr) * 2001-08-03 2004-07-21 Kao Corporation Produit en pate moule, dispositif et procede de production correspondants
JP2018059254A (ja) * 2016-09-29 2018-04-12 栗原紙材株式会社 パルプモールド
JP2018199872A (ja) * 2017-05-26 2018-12-20 栗原紙材株式会社 積層パルプモールドの製造方法および積層パルプモールド製造装置
SE541435C2 (en) * 2016-10-31 2019-10-01 Stora Enso Oyj Process for providing coating layer comprising microfibrillated cellulose
JP2020200545A (ja) * 2019-06-07 2020-12-17 トヨタ車体株式会社 成形品及びその製造方法

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2002080025A (ja) * 2000-06-27 2002-03-19 Toppan Printing Co Ltd ガスバリア性容器
EP1439264A1 (fr) * 2001-08-03 2004-07-21 Kao Corporation Produit en pate moule, dispositif et procede de production correspondants
JP2018059254A (ja) * 2016-09-29 2018-04-12 栗原紙材株式会社 パルプモールド
SE541435C2 (en) * 2016-10-31 2019-10-01 Stora Enso Oyj Process for providing coating layer comprising microfibrillated cellulose
JP2018199872A (ja) * 2017-05-26 2018-12-20 栗原紙材株式会社 積層パルプモールドの製造方法および積層パルプモールド製造装置
JP2020200545A (ja) * 2019-06-07 2020-12-17 トヨタ車体株式会社 成形品及びその製造方法

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024201096A1 (fr) * 2023-03-27 2024-10-03 Ftt S.R.L. Procédé de formation de fibres hautement affinées

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