DRUCKER TAYLOR (US)
MELTON NATASHA (US)
WO2022018621A1 | 2022-01-27 | |||
WO2021234559A1 | 2021-11-25 | |||
WO2020152635A1 | 2020-07-30 |
US20210025114A1 | 2021-01-28 | |||
EP3929355A1 | 2021-12-29 | |||
US197862633560P |
Docket No.23767-WOORD1 What is claimed is: 1. A cellulosic structure comprising: a cellulosic substrate comprising a first major side and a second major side opposed from the first major side; a single polyolefin aqueous polymer dispersion barrier layer on the first major side of the cellulosic substrate; and at least one non-polyolefin aqueous polymer dispersion barrier layer between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. 2. The cellulosic structure of Claim 1 wherein the cellulosic substrate comprises paperboard. 3. The cellulosic structure of Claim 1 or Claim 2 wherein the single polyolefin aqueous polymer dispersion barrier layer comprises a polyolefin binder. 4. The cellulosic structure of Claim 3 wherein the single polyolefin aqueous polymer dispersion barrier layer comprises a pigment. 5. The cellulosic structure of Claim 4 wherein a ratio of the polyolefin binder to the pigment is at least 1 to 2. 6. The cellulosic structure of any preceding claim wherein the single polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft2. 7. The cellulosic structure of any preceding claim wherein the non-polyolefin aqueous polymer dispersion barrier layer comprises a non-polyolefin binder. Docket No.23767-WOORD1 8. The cellulosic structure of Claim 7 wherein the non-polyolefin binder comprises at least one of a styrene acrylic binder, a styrene-butadiene binder, a vinyl acrylic binder, and a polyester dispersion binder. 9. The cellulosic structure of Claim 7 or Claim 8 wherein the non-polyolefin aqueous polymer dispersion barrier layer comprises a pigment. 10. The cellulosic structure of Claim 9 wherein a ratio of the non-polyolefin binder to the pigment is at least 1 to 2. 11. The cellulosic structure of any preceding claim wherein the non-polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft2. 12. The cellulosic structure of any preceding claim further comprising at least one water soluble polymer barrier layer between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. 13. The cellulosic structure of Claim 12 wherein the water soluble polymer barrier layer comprises a water soluble binder. 14. The cellulosic structure of Claim 13 wherein the water soluble binder comprises at least one of a polyvinyl alcohol binder, a carboxymethylcellulose binder, and an alginate binder. 15. The cellulosic structure of Claim 13 or Claim 14 wherein the water soluble polymer barrier layer further comprises a pigment. 16. The cellulosic structure of Claim 15 wherein a ratio of the water soluble binder to the pigment is at least 1 to 1. Docket No.23767-WOORD1 17. The cellulosic structure of any one of Claims 12–16 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft2. 18. The cellulosic structure of any preceding claim further comprising a barrier layer on the second major side of the cellulosic substrate. 19. The cellulosic structure of any preceding claim further comprising a non-barrier layer on the second major side of the cellulosic substrate. 20. The cellulosic structure of any preceding claim having a 30-minute-water-Cobb rating of at most about 20 g/m2. 21. The cellulosic structure of any preceding claim having a water vapor transmission rate of less than 1000 grams per square meter per day at 38 °C/ 90%RH. 22. The cellulosic structure of any preceding claim having oxygen transmission rate of less than 500 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. 23. The cellulosic structure of any preceding claim having a 3M kit test value is at least 5. 24. The cellulosic structure of any preceding claim wherein the cellulosic structure has a blocking rating of 2.0 or less. 25. The cellulosic structure of any preceding claim wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 50%. 26. A container comprising the cellulosic structure of any preceding claim. |
Docket No.23767-WOORD1 T A B L E 1 Product Description Pi 1 HYDROCARB ® 60 (Omya AG, coarse ground CaCO3 ) n e T A B L E 2 Polyolefin aqueous Docket No.23767-WOORD1 T A B L E 3 Sample ID A B C D E F G H 11 t 11 t 13 t 13 t 14 t 13 t 14 t ld [0053] The experimental results are shown in Table 3. The results show that the combination of barrier layers provide high barrier properties to water, moisture vapor, oil and grease, and oxygen transmission and provide non-blocking and repulpability. Docket No.23767-WOORD1 [0054] Water barrier property of the coatings was evaluated by water Cobb (TAPPI Standard T441 om-04) in g/m 2 per 30 minutes, using 23 °C water. In other words, the Cobb test determines how much water is absorbed after 30 minutes. [0055] Water vapor barrier properties test was performed: WVTR (water vapor transmission rate, in g/m 2 /d ) was measured at 38 °C and 90% relative humidity according to TAPPI Standard T464 OM-12. [0056] The oil and grease resistance (OGR) of the samples was measured on the “coated side” by the 3M kit test (TAPPI Standard T559 cm-02). With this test, ratings are from 1 (the least resistance to oil and grease) to 12 (excellent resistance to oil and grease penetration). [0057] Oxygen barrier properties test: OTR (oxygen transmission rate, in cm 3 /m 2 /d) was measured on a LabThink C230B OTR Test System under setting conditions of 0%RH, 23 °C, 100% O 2 . [0058] Repulpability was tested using an AMC Maelstom repulper. 110 grams of coated paperboard, cut into 1-inch by 1-inch squares, was added to the repulper containing 2895 grams of water (pH of 6.5±0.5, 50 °C), soaked for 15 minutes, and then repulped for 30 minutes. 300 mL of the repulped slurry was then screened through a vibrating flat screen (0.006-inch slot size). Rejects (caught by the screen) and fiber accepts were collected, dried and weighed. The percentage of accepts was calculated based on the weights of accepts and rejects, with 100% being complete repulpability. [0059] The blocking rating (50ºC/100psi/24hrs) was tested for all examples. Table 4 defines the blocking test rating system. Docket No.23767-WOORD1 T A B L E 4 Rating Description 0 Samples fall apart without any force [0060] The blocking behavior of the samples was tested by evaluating the adhesion between the barrier coated side and the other uncoated side. A simplified illustration of the blocking test is shown in Fig. 3. The paperboard was cut into 2-inch by 2-inch square samples. Several duplicates were tested for each condition, with each duplicate evaluating the blocking between a pair of samples 252, 254. (For example, if four duplicates were test, four pairs - eight pieces – would be used.) Each pair was positioned with the ‘barrier- coated’ side of one piece 252 contacting the uncoated side of the other piece 254. The pairs were placed into a stack 250 with a spacer 256 between adjacent pairs, the spacer being foil, release paper, or even copy paper. The entire sample stack was placed into the test device 200 illustrated in Fig. 3. [0061] The test device 200 includes a frame 210. An adjustment knob 212 is attached to a screw 214 which is threaded through the frame top 216. The lower end of screw 214 is attached to a plate 218 which bears upon a heavy coil spring 220. The lower end of the spring 220 bears upon a plate 222 whose lower surface 224 has an area of one square inch. A scale 226 enables the user to read the applied force (which is equal to the pressure applied to the stack of samples through the one-square-inch lower surface 224). [0062] The stack 250 of samples is placed between lower surface 224 and the frame bottom 228. The knob 212 is tightened until the scale 226 reads the desired force of 100 lbf Docket No.23767-WOORD1 (100 psi applied to the samples) or 60 lbf (60 psi applied to the samples). High pressure such as 1000psi is achieved by reducing the lower surface area of 224 contacting the stack 250 of samples to 0.11 square inch, with an applied force of 110 lb. The entire device 200 including samples is then placed in an oven at 50 °C for 24 hours or 2 hours. The device 200 is then removed from the test environment and cooled to room temperature. The pressure is then released, and the samples removed from the device. [0063] The samples were evaluated for tackiness and blocking by separating each pair of paperboard sheets. Blocking damage is visible as fiber tear, which if present usually occurs with fibers pulling up from the non-barrier surface of samples 254. If the non-barrier surface was coated with a print coating, then blocking might also be evinced by damage to the print coating. [0064] For example, in as symbolically depicted in Fig. 3, samples 252(0)/254(0) might be representative of a “0” rating (no blocking). The circular shape in the samples indicates an approximate area that was under pressure, for instance about one square inch of the overall sample. Samples 252(3)/254(3) might be representative of a “3” blocking rating, with up to 25% fiber tear in the area that was under pressure, particularly in the uncoated surface of sample 254(3). Samples 252(4)/254(4) might be representative of a “4” blocking rating with more than 25% fiber tear, particularly in the uncoated surface of sample 254(4). The depictions in Fig. 3 are only meant to approximately suggest the percent damage to such test samples, rather than showing a realistic appearance of the samples. [0065] Further, the disclosure comprises examples according to the following clauses [0066] Clause 1. A cellulosic structure comprising: a cellulosic substrate comprising a first major side and a second major side opposed from the first major side; a single polyolefin aqueous polymer dispersion barrier layer on the first major side of the cellulosic substrate; and at least one non-polyolefin aqueous polymer dispersion barrier layer between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. Docket No.23767-WOORD1 [0067] Clause 2. The cellulosic structure of Clause 1 wherein the cellulosic substrate comprises paperboard. [0068] Clause 3. The cellulosic structure of Clause 2 wherein the paperboard comprises solid bleached sulfate paperboard. [0069] Clause 4. The cellulosic structure of any one of Clauses 1–3 wherein the cellulosic substrate has a basis weight of at least about 25 lb/3000 ft 2 . [0070] Clause 5. The cellulosic structure of any one of Clauses 1–3 wherein the cellulosic substrate has a basis weight ranging from about 60 lb/3000 ft 2 to about 400 lb/3000 ft 2 . [0071] Clause 6. The cellulosic structure of any one of Clauses 1–3 wherein the cellulosic substrate has a basis weight ranging from about 80 lb/3000 ft 2 to about 300 lb/3000 ft 2 . [0072] Clause 7. The cellulosic structure of any one of Clauses 1–6 wherein the cellulosic substrate has a caliper ranging from about 2 points to about 30 points. [0073] Clause 8. The cellulosic structure of any one of Clauses 1–6 wherein the cellulosic substrate has a caliper ranging from about 11 points to about 18 points. [0074] Clause 9. The cellulosic structure of any preceding clause wherein the single polyolefin aqueous polymer dispersion barrier layer comprises a polyolefin binder. [0075] Clause 10. The cellulosic structure of Clause 9 wherein the single polyolefin aqueous polymer dispersion barrier layer comprises a pigment. [0076] Clause 11. The cellulosic structure of Clause 10 wherein the pigment comprises at least one of a clay and a calcium carbonate. [0077] Clause 12. The cellulosic structure of Clause 10 or Clause 11 wherein a ratio of the polyolefin binder to the pigment is at least 1 to 2. Docket No.23767-WOORD1 [0078] Clause 13. The cellulosic structure of any one of Clauses 1–12 wherein the single polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 . [0079] Clause 14. The cellulosic structure of any one of Clauses 1–12 wherein the single polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 0.5 lb/3000 ft 2 to about 20 lb/3000 ft 2 . [0080] Clause 15. The cellulosic structure of any one of Clauses 1–12 wherein the single polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 3 lb/3000 ft 2 to about 12 lb/3000 ft 2 . [0081] Clause 16. The cellulosic structure of any one of Clauses 1–12 wherein single polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 6 lb/3000 ft 2 to about 10 lb/3000 ft 2 . [0082] Clause 17. The cellulosic structure of any preceding clause wherein the non- polyolefin aqueous polymer dispersion barrier layer comprises a non-polyolefin binder. [0083] Clause 18. The cellulosic structure of Clause 17 wherein the non-polyolefin binder comprises at least one of a styrene acrylic binder, a styrene-butadiene binder, a vinyl acrylic binder, and a polyester dispersion binder. [0084] Clause 19. The cellulosic structure of Clause 17 or Clause 18 wherein the non- polyolefin aqueous polymer dispersion barrier layer comprises a pigment. [0085] Clause 20. The cellulosic structure of Clause 19 wherein the pigment comprises at least one of a clay and a calcium carbonate. [0086] Clause 21. The cellulosic structure of Clause 19 or Clause 20 wherein a ratio of the non-polyolefin binder to the pigment is at least 1 to 2. Docket No.23767-WOORD1 [0087] Clause 22. The cellulosic structure of any preceding clause wherein the at least one non-polyolefin aqueous polymer dispersion barrier layer comprises multiple non- polyolefin aqueous polymer dispersion barrier layers. [0088] Clause 23. The cellulosic structure of any one of Clauses 1–22 wherein the non- polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 . [0089] Clause 24. The cellulosic structure of any one of Clauses 1–22 wherein the non- polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 0.5 lb/3000 ft 2 to about 20 lb/3000 ft 2 . [0090] Clause 25. The cellulosic structure of any one of Clauses 1–22 wherein the non- polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 3 lb/3000 ft 2 to about 12 lb/3000 ft 2 . [0091] Clause 26. The cellulosic structure of any one of Clauses 1–22 wherein non- polyolefin aqueous polymer dispersion barrier layer has a coat weight, on a dry basis, ranging from about 6 lb/3000 ft 2 to about 10 lb/3000 ft 2 . [0092] Clause 27. The cellulosic structure of any preceding clause further comprising at least one water soluble polymer barrier layer between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. [0093] Clause 28. The cellulosic structure of Clause 27 wherein the water soluble polymer barrier layer is between the single polyolefin aqueous polymer dispersion barrier layer and the at least one non-polyolefin aqueous polymer dispersion barrier layer. [0094] Clause 29. The cellulosic structure of Clause 27 wherein the water soluble polymer barrier layer is between the at least one non-polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. Docket No.23767-WOORD1 [0095] Clause 30. The cellulosic structure of any one of Clauses 27–29 wherein the water soluble polymer barrier layer comprises a water soluble binder. [0096] Clause 31. The cellulosic structure of Clause 30 wherein the water soluble binder comprises at least one of a polyvinyl alcohol binder, a carboxymethylcellulose binder, and an alginate binder. [0097] Clause 32. The cellulosic structure of Clause 30 wherein the water soluble binder comprises a polyvinyl alcohol binder. [0098] Clause 33. The cellulosic structure of any one of Clauses 30–32 wherein the water soluble polymer barrier layer further comprises a pigment. [0099] Clause 34. The cellulosic structure of Clause 33 wherein the pigment comprises at least one of a clay and a calcium carbonate. [0100] Clause 35. The cellulosic structure of Clause 33 or Clause 34 wherein a ratio of the water soluble binder to the pigment is at least 1 to 1. [0101] Clause 36. The cellulosic structure of any one of Clauses 27–35 wherein the at least one water soluble polymer barrier layer comprises multiple water soluble polymer barrier layers. [0102] Clause 37. The cellulosic structure of any one of Clauses 27–36 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, of at least about 0.5 lb/3000 ft 2 . [0103] Clause 38. The cellulosic structure of any one of Clauses 27–36 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, ranging from about 0.5 lb/3000 ft 2 to about 20 lb/3000 ft 2 . Docket No.23767-WOORD1 [0104] Clause 39. The cellulosic structure of any one of Clauses 27–36 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, ranging from about 1 lb/3000 ft 2 to about 10 lb/3000 ft 2 . [0105] Clause 40. The cellulosic structure of any one of Clauses 27–36 wherein the at least one water soluble polymer barrier layer has a coat weight, on a dry basis, ranging from about 3 lb/3000 ft 2 to about 5 lb/3000 ft 2 . [0106] Clause 41. The cellulosic structure of any preceding clause further comprising one or more additional coating layers positioned between the single polyolefin aqueous polymer dispersion barrier layer and the first major side of the cellulosic substrate. [0107] Clause 42. The cellulosic structure of any preceding clause wherein the second major side of the cellulosic substrate is uncoated. [0108] Clause 43. The cellulosic structure of any one of Clauses 1–41 further comprising a barrier layer on the second major side of the cellulosic substrate. [0109] Clause 44. The cellulosic structure of any one of Clauses 1–41 and 43 further comprising a non-barrier layer on the second major side of the cellulosic substrate. [0110] Clause 45. The cellulosic structure of any one of Clauses 1–41, 43 and 44 further comprising a clay coating layer on the second major side of the cellulosic substrate. [0111] Clause 46. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 20 g/m 2 . [0112] Clause 47. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 10 g/m 2 . [0113] Clause 48. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 5 g/m 2 . Docket No.23767-WOORD1 [0114] Clause 49. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 4 g/m 2 . [0115] Clause 50. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 3 g/m 2 . [0116] Clause 51. The cellulosic structure of any one of Clauses 1–45 having a 30-minute- water-Cobb rating of at most about 2 g/m 2 . [0117] Clause 52. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 1000 grams per square meter per day at 38 °C/ 90%RH. [0118] Clause 53. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 500 grams per square meter per day at 38 °C/ 90%RH. [0119] Clause 54. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 400 grams per square meter per day at 38 °C/ 90%RH. [0120] Clause 55. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 300 grams per square meter per day at 38 °C/ 90%RH. [0121] Clause 56. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 200 grams per square meter per day at 38 °C/ 90%RH. [0122] Clause 57. The cellulosic structure of any one of Clauses 1–51 having a water vapor transmission rate of less than 100 grams per square meter per day at 38 °C/ 90%RH. [0123] Clause 58. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 500 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0124] Clause 59. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 200 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. Docket No.23767-WOORD1 [0125] Clause 60. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 150 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0126] Clause 61. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 140 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0127] Clause 62. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 130 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0128] Clause 63. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 120 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0129] Clause 64. The cellulosic structure of any one of Clauses 1–57 having oxygen transmission rate of less than 110 cc per square meter per day at 23 °C/ 0%RH/ 100% O2. [0130] Clause 65. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 5. [0131] Clause 66. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 6. [0132] Clause 67. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 7. [0133] Clause 68. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 8. [0134] Clause 69. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 9. [0135] Clause 70. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 10. Docket No.23767-WOORD1 [0136] Clause 71. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 11. [0137] Clause 72. The cellulosic structure of any one of Clauses 1–64 having a 3M kit test value is at least 12. [0138] Clause 73. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 2.0 or less. [0139] Clause 74. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 1.5 or less. [0140] Clause 75. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 1.0 or less. [0141] Clause 76. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 0.7 or less. [0142] Clause 77. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 0.2 or less. [0143] Clause 78. The cellulosic structure of any one of Clauses 1–72 wherein the cellulosic structure has a blocking rating of 0.1 or less. [0144] Clause 79. The cellulosic structure of any one of Clauses 1–78 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 50%. [0145] Clause 80. The cellulosic structure of any one of Clauses 1–78 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 70%. Docket No.23767-WOORD1 [0146] Clause 81. The cellulosic structure of any one of Clauses 1–78 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 80%. [0147] Clause 82. The cellulosic structure of any one of Clauses 1–78 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 85%. [0148] Clause 83. The cellulosic structure of any one of Clauses 1–78 wherein the cellulosic structure is repulpable to an extent that after repulping a percentage of accepts is at least 90%. [0149] Clause 84. A container comprising the cellulosic structure of any preceding clause. [0150] Although various examples of the disclosed cellulosic structures have been shown and described, modifications may occur to those skilled in the art upon reading the specification. The present application includes such modifications and is limited only by the scope of the claims.
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