• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    hybrid fiber compositions and uses in corrugated cardboard packaging. The present invention relates to a corrugated cardboard packaging material comprising at least one alternative non-wood derived pulp material, characterized in that said alternative non-wood derived pulp is present in an amount of from about 5% to about 100% and where said material replaces at least a part of conventional fiber materials.
    公开号:BR112015004673B1
    申请号:R112015004673-8
    申请日:2013-09-11
    公开日:2021-06-29
    发明作者:Bo Shi；Mark M. Mleziva；Brent M. Thompson；Robert J. Zelenak
    申请人:Kimberly-Clark Worldwide, Inc；
    IPC主号:
    专利说明:

    FIELD OF THE INVENTION
    [1] The present invention relates to the use of alternative non-wood natural fibers in corrugated media for corrugated cardboard packaging. A replacement for conventional hardwood fiber can be achieved by using a hybrid fibrous composition that provides sufficient mechanical strength for corrugated cardboard packaging applications. HISTORY OF THE INVENTION
    [2] Traditionally, pulp derived from fast-growing trees such as pine has been used as a raw material for packaging corrugated cardboard. Corrugated cardboard consists of cardboard and a half. Board is generally made from softwoods, which have the longest fibers and produce the strongest corrugated board. On the other hand, the medium is made from hardwood fibers, which tend to be shorter and stiffer than softwood fibers. In recent years, the use of recycled old corrugated cardboard (OCC) material has grown in popularity as a cardboard or corrugated medium because of environmental sustainability concerns. However, OCC often requires pulp recycling and bleaching processes. As such, recycled fibers are shortened, weakened and contaminated as the number of recyclings increases. Along with an increase in demand and use of recycled fiber by many corrugated cardboard producers, the cost of recycled fiber has also increased. The move to single stream recycling is causing an increase in contamination (staples, plastic tapes and hot-applied adhesives) of existing recovered fiber streams. Critical performance requirements such as strength (compression, edge crush, breakage and tensile strength), hardness or stiffness, moisture resistance, grease resistance and freeze/thaw tolerance may be more difficult to achieve with paper or paperboard recycled.
    [3] Hybrid fiber compositions comprising alternative natural fibers not derived from wood, such as those derived from algae, corn husks, wheat straw, rice straw and the like, would be an option to address these aforementioned issues. Substitution of fiber in corrugated medium using terrestrial non-wood derived alternative fibers, such as wheat straw alone, can be contested on a high level of inclusion. One of the factors is related to the fine particles associated with the pulp fibers. Wheat straw fibers contain more fine particles (about 38 - about 50%) than hardwood fibers (about 20 to 40%) or corrugated cardboard (OCC) (about 20 about 25%) . This being the case, the dimensions of wheat straw fibers (fiber length and diameter) are comparable to hardwood fibers, such as those in maple and oak pulp, but shorter than OCC fibers due to the presence of resinous wood fibers in recycled cardboard materials. Fines can be considered as a filler material; however, having finer wheat straw pulp compared to the others does not contribute to strength.
    [4] Red algae is a type of alga that belongs to the division Rhodophyta, part of the Gelidiaceae family. Its fiber obtained after extracting agar or bioethanol has a high aspect ratio and surprisingly enhances the mechanical properties of corrugated board, such as tensile strength index, ring crush, rupture index and tear index, etc., in hybrid fiber compositions. The presence of red algae fibers allows the corrugated medium to meet or exceed the primary requirements for mechanical property which allows a high proportion of non-wood-derived fibers, such as wheat straw, to be effectively utilized and still satisfy performance demands of product. Thus, the use of alternative non-wood fibers would be more environmentally friendly, represent a significant change from the use of conventional raw materials (hardwood pulp or OCC) and result in potential cost savings for many manufacturers.
    [5] Therefore, there is a need to provide alternative wood pulp materials to replace a part of the conventional fiber materials used in corrugated cardboard packaging. In addition, there is a growing need for lighter and stronger corrugated materials that allow for packaging weight reduction. Despite previous attempts to use alternative fibers to produce composite cardboard for construction and furniture, there is a lack of sustainable attempts to produce corrugated media based on natural non-wood fiber for use in corrugated cardboard packaging applications. As a result, the present invention fills these gaps by providing alternative materials to wood that can be used for environmentally sustainable corrugated cardboard packaging. SUMMARY OF THE INVENTION
    [6] The present invention relates to a corrugated cardboard packaging material comprising at least one alternative non-wood derived pulp material, wherein said alternative non-wood derived pulp is present in an amount of from about 5% to about 100% and where said material replaces at least a part of conventional fiber materials. The hybrid fibrous composition can be processed by existing papermaking, fluting and box converting machines for rigid packaging applications. BRIEF DESCRIPTION OF THE DRAWINGS
    [7] Figure 1 shows a 300x SEM micrograph of a 100% blend of semi-chemical hardwood pulp on a handsheet surface.
    [8] Figure 2 shows a 300X SEM micrograph of 100% wheat straw fiber on a hand leaf surface.
    [9] Figure 3 shows a 300X SEM micrograph of a hybrid fiber composition for a handsheet surface where the composition contains a combination of hardwood fibers, wheat straw and red algae. DETAILED DESCRIPTION OF THE INVENTION
    [10] Although the specification concludes with the claims particularly pointing to and distinctly claiming the invention, it is believed that the present invention will be better understood from the description below.
    [11] All percentages, parts and proportions are based on the total weight of the compositions of the present invention, unless otherwise specified. All of these weights as belonging to the ingredients listed are based on the active level and therefore; do not include solvents or by-products that may be included in commercially available materials, unless otherwise specified. The term "weight percent" may be referred to as "wt.%" in this document. Except where specific examples of actual measured values are presented, numerical values referred to herein should be considered to be qualified by the word "approximately".
    [12] As used here, "understanding" means that other steps and other ingredients that do not affect the final result can be added. This term encompasses the terms "consisting of" and "consisting essentially of". The compositions and methods/processes of the present invention may comprise, consist of and consist essentially of the essential elements and limitations of the invention described herein, as well as any of the ingredients, components, additional or optional steps or limitations described herein.
    [13] As used here, the term "non-wood derived" or "alternative to wood" generally refers to agricultural crop processing residues such as wheat straw, wetland plants excluding trees - such as reeds, plants aquatic algae such as water hyacinth, microalgae such as Spirulina and macroalgae such as red or brown algae. Examples of natural non-wood materials of the present invention include, but are not limited to, wheat straw, rice straw, flax, bamboo, cotton, jute, hemp, sisal, bagasse, hesperaloe, grasses, miscanthus, seaweed, or seaweed. fresh water and its combinations.
    [14] As used herein, the term "red algae fiber" refers to any cellulosic fibrous material derived from Rhodophyte. Particularly preferred fiber from red seaweed includes cellulosic fibrous material, derived from Gelidium amansii, Gelidium corneum, Gelidium asperum, Gelidium chilense and Gelidium robustum. Red algae fibers generally have an aspect ratio (measured as the average fiber length divided by the average fiber width) of at least about 80.
    [15] As used herein, the term "OCC" refers to old corrugated containers that have layers of paper glued together in an inner corrugated layer. This is the material used to make corrugated cardboard boxes (the most recycled product in the country). Four main components of OCC pulps are unbleached resinous wood kraft pulp (mainly derived from paperboard), semi-chemical hardwood pulp (derived from corrugated medium), starch (as an adhesive) and water (often 8% or more) .
    [16] As used herein, the term "pulp" or "pulp fiber" refers to fibrous material obtained by conventional pulping processes known in the art. This can be for wood-based and non-wood-derived materials.
    [17] As used herein, the term "fines" refers to the fraction that passes through a 200 mesh (75pm) sieve. The average size of the fines is a few microns. Fines consist of cellulose, hemicellulose, lignin and extractives. There are two types of fines: primary fines and secondary fines. The content of primary fines seems to be a genetic characteristic of the plant. For hardwood pulp, this is about 20% to about 40%, while for wheat straw, it is about 38% to about 50%. Secondary fines are pieces of fibrils from the outer layers of fibers that are broken down during refinement.
    [18] As used herein, the term "base weight" generally refers to the dry weight per unit area of a board or medium. The basis weight is measured here using: TAPPI test method T-220. A sheet of pulp, usually 30 cm x 30 cm or other convenient dimension, is weighed and then oven dried to determine solids content. The sheet area is then determined and the ratio of oven dry weight to sheet area is reported as the dry basis weight in grams per square meter (g/m). The basis weight of the board is at least about 130 grams per square meter (g/m2) or greater and the basis weight of the middle is about 90 g or greater. The moisture content of the card and a half is less than about 10 percent.
    [19] As used herein, the term "corrugated cardboard" refers to a sheet containing cardboard as a half face and half corrugated. There are several configurations: single face, single wall, also called double face, double wall and triple wall for different product packaging applications.
    [20] As used herein, the term "rib" refers to an inverted S-shaped "arc" or "wave" of a ribbed half that is normally positioned parallel to the depth of the container and provides rigidity and crush resistance ( stacking). The flutes of the present invention can range from about 98 flutes per meter to about 492 flutes per meter. The top five flute size and classifications are: 1) Flute A: the largest arc size, between about 105 to about 121 flutes per meter. 2) Flute B: the second largest arc size, about 148 to about from 171 flutes per meter,3) Flute C: intermediate between A and B, between about 128 to about 141 flutes per meter.4) Flute E: has about 302 to about 322 flutes per meter e5) Flute F: the latest flute size, about 420 flutes per meter.
    [21] These flutes can also be combined to form multi fluting grades ranging from AAA (triple wall), AA (double wall) to E/F (micro flute) combinations. Individual flute heights range from A (0.477 cm) to F (0.079 cm).
    [22] As used herein, the terms "single face, "single wall", "double wall", "triple wall" refer to packaging material formed by gluing one or more sheets of corrugated cardboard (corrugated cardboard) between one or more sides of corrugated cardboard. There are four common types:1) "Single face" refers to a corrugated medium glued to a flat sheet of corrugated cardboard (two sheets total).2) "Single wall" refers to to a corrugated half sandwiched between two sheets of corrugated cardboard. Also known as "double sided" (three sheets total).3) "Double wall" refers to two corrugated half sandwiched between three sheets of corrugated cardboard (total of five sheets). sheets).4) "Triple wall" refers to three corrugated halfs sandwiched between four sheets of corrugated cardboard (seven sheets total).
    [23] As used herein, the term "Tensile Strength Index" is expressed in Nm/g and refers to the quotient of the tensile strength, usually expressed in Newton-meters (N/m) divided by the basis weight.
    [24] As used herein, the term "Rest Rate" refers to the breaking strength quotient, usually expressed in kilopascals (kPa) divided by basis weight, usually expressed in grams per square meter (gsm).
    [25] As used herein, the term "half-corrugated test" (CMT) refers to the crush strength of a corrugated strip of half-corrugated, usually expressed in pounds force (lbf) or Newton (N).
    [26] As used herein, the term "ring crush" refers to the strength of paper and board to edge compression, usually expressed in kilonewtons per meter (kN/m).
    [27] As used herein, the term "compression" refers to the ability of corrugated shipping containers to resist external compressive forces, which is related to the stacking force of the containers being subjected to the forces encountered during transportation and storage. . Usually expressed in Newton (N).
    [28] As used herein, the term "edge crush" refers to the strength to lateral compression, parallel to the flutes of corrugated board, usually expressed in kilonewtons per meter (kN/m).
    [29] As used herein the term "fabric forming apparatus" generally includes a fourdrinier former, twin yarn former, cylinder machine, press former, crescent former and the like known to those skilled in the art.
    [30] As used herein the term "Canadian standard freeness" (CSF) generally refers to the rate at which fiber slurry is drained and is measured as described in the TAPPI standard test, method T 227 OM- 09. The CSF unit is ml.
    [31] Straws (wheat, rice, oats, rye, barley, flax and grass) and stalks (corn, sorghum and cotton) represent large potential global sources (more than 1 million dry metric tons annually) of alternative natural fibers based on agricultural crops, respectively. With any annual crop, the harvest must be done at a certain time and storage, drying, cleaning and separation are necessary before the product is manufactured. The advantages of using annual-growing lignocellulosic fibers for corrugated media applications are: 1) a much shorter harvest cycle than traditional wood pulp sources, 2) low cost due to their residual nature, 3) does not require bleaching the fiber, which leads to less energy consumption and 4) removes carbon dioxide from the air to reduce the global greenhouse effect, which increases environmental sustainability. With these ecologically correct and well-deserved characteristics of natural non-wood fibers, companies around the world have quickly integrated agrofibers into their product lines.
    [32] The present invention relates to at least one alternative non-wood-derived pulping material to be used in corrugated cardboard packaging, to replace a large part of the conventional fiber materials that are used in the manufacture of corrugated media, fluting and box conversion Alternative natural fibers such as using fibers from field crops or agricultural residues instead of wood fibers are considered to be more sustainable. Examples of natural non-wood materials of the present invention include, but are not limited to, wheat straw, rice straw, flax, bamboo, cotton, jute, hemp, sisal, bagasse, hesperaloe, grasses, miscanthus, seaweed, or seaweed. fresh water and its combinations. The composition of the present invention comprises at least one alternative non-wood pulp material that is selected from marine algae, such as red algae, corn husk, straw, wherein these straws are selected from wheat, rice, oat straw, barley, rye, flax and turf, and their combinations; other natural terrestrial fibers, selected from linen, bamboo, cotton, jute, hemp, sisal, bagasse, kenaf, hesperaloe, switchgrass and miscanthus and their combinations; and combinations of these materials. The individual fibrous material from non-wood derived materials can be derived from conventional pulping processes such as thermal mechanical pulping, Kraft pulping, chemical pulping, enzyme-assisted biological pulping or organ-solvent pulping known in the art. Pulping red algae (US Patent 7,622,019 to You et al.) on the other hand, involves less energy and capital costs as it does not contain lignin, which makes red algae distinctly different from other cellulose materials. Furthermore, a low basis weight can be obtained when red algae fiber is used in hybrid compositions.
    [33] Corrugated medium is typically made from a semichemical or recycled pulp. About 75% of production within current production practices uses about 80% semi-chemical pulp and 20% recycled fiber. The rest of the production is made from 100% recycled material and is often called "half fake". The corrugated medium is a light weight cardboard used for corrugated inner folds of corrugated box material. The base weight of the half rib ranges from about 18 pounds to about 36 pounds per 1000 ft2. The preferred basis weight is from about 26 to about 32 pounds per 1,000 ft2. The corrugated medium of the present invention can have a basis weight from about 90 g/m2 to about 200 g/m2.
    [34] The alternative non-wood derived pulp material of the present invention is a unique blend comprising natural alternative non-wood pulp fibers. For example, there may be a combination of natural hardwood pulp fiber and at least one alternative non-wood derived natural pulp fiber such as wheat straw or a combination of one or more alternative non-wood derived natural pulp fibers , such as wheat straw and algae which are useful as the present invention. Not only does such a mixture provide an advantage for the manufacture of environmentally sustainable corrugated cardboard packaging, it also reinforces the bonding of the other fibers within the mixture due to the presence of red algae fiber. Thus, the general mechanical properties of corrugated media and corrugated board are improved with the use of alternative natural fibers not derived from wood. A comparative picture of such distinctions can be seen in Figs. 1 and 2 versus FIG. 3. Although Figure 2 shows less corrections and improved strength compared to FIG. 1, the most enhanced fiber morphology can be seen in FIG. 3, where it shows that the presence of red algae (as represented by the tiny strand-like fiber), strengthens the connection of semi-chemical fibers from hardwood and wheat straw, through the strong hydrogen bond and large contact area of surface offered by the small fibers of red algae.
    [35] The key distinction is the high aspect ratio of red algae fiber of 80 or more to hardwood or wheat straw fibers. The length of hardwood fiber ranges from about 1 mm to about 1.85 mm. In the case of the OCC fiber length, it is closer to the end of the range, but it shortens as the number of recycles increases. Wheat straw fiber length ranges from about 0.8 to about 1.1 mm. It is commonly understood in the art that the shorter untreated fibers and the high content of wheat straw primary fines would not improve the mechanical properties of the finished product, such as tensile, tear, tear, etc. The longer the average length of fiber in the paper, the stronger the sheet. Strength aids can be added to improve the binding of short fibers, but in general, whenever a long fiber is replaced by a shorter one, the strength will decrease. Therefore, a successful replacement of conventional fibers (hardwood or OCC) used to make corrugated media from wheat straw fiber must rely on other fibers or chemicals. In this invention, embodiments are given to demonstrate that fiber replacement is unexpectedly achievable when red algae fiber is incorporated into hybrid fibrous compositions. The thinner red algae fiber offers more surface contact areas between a network of other different fibers via hydrogen bonds for better strength. Compositions of the present invention may comprise red algae as the alternative natural non-wood pulp. Red algae can be selected from Gelidium elegance, Gelidium corneum, Gelidium amansii, Gelidium robustum, Gelidium chilense, Gracelaria verrucosa, Eucheuma Cottonii, Eucheuma Spinosum, Beludul, and their combinations.
    [36] The pulp material compositions of the present invention may comprise various amounts of alternative non-wood derived natural pulp fibers. The composition can have a combination of elements, where there is at least one alternative natural pulp fiber not derived from wood alone, or it can be combined with a wood pulp fiber. For example, the amount of alternative non-wood derived natural pulp fibers of the present invention may be about 5%, 10%, 20%, 25%, 30% 40%, 50%, 60%, 75%, 100 % by weight of the composition. The pulp material compositions of the present invention may also comprise a hardwood short fiber pulp in an amount of about 5%, 10%, 20%, 30%, 40%, 50%, 60% or 70% by weight. of makeup. When the alternative non-wood-derived pulp materials are not present alone, in combination with each other or in combination with a wood pulp fiber, the composition can then be used for a corrugated cardboard packaging, which replaces a portion of the conventional fiber materials.
    [37] The compositions of the present invention may show combinations, without limitation, in which the ratio of chemical hardwood pulp: alternative natural non-wood pulp may be about 70:30, about 60:40, about 50 :50, about 30:70, about 5:95, or about 0:100. In any of the alternative natural non-wood pulps, one or two or more types of alternative natural non-wood derived pulp may be used in combination. For example, a composition may comprise a 30:70 ratio of hardwood pulp: alternative natural non-wood pulp, wherein the non-wood alternative is wheat straw alone or a combination of wheat straw and red seaweed. . As mentioned, any combination of alternative non-wood derived natural pulps can also be used.
    [38] This invention was further demonstrated through the fabrication of corrugated media, fluting, and box conversion. For example, in papermaking, embodiments of hardwood pulp and wheat straw (30:70) and 100% OCC papers at a low basis weight of 112 g/m2 were made as a basis for comparison, respectively. Another example of the same inclusion of 30% hardwood with a combination balance of 70% wheat straw and red algae (85.7:14.3) was made on a pilot paper machine. A cationic starch was used as a dry strength additive of about 0.1%, 0.5%, from 0.1% to about 2%, 5% by weight of the composition. Any starch derived from corn, wheat or potato, etc., would be suitable after the cationic modification.
    [39] In fluting, cardboard was a standard flat-faced corrugated cardboard material, which is assembled with the corrugated (corrugated) middle using a pilot corrugator. Average line speeds of 76 meters per minute were maintained throughout the fluting and corrugated sheet assembly operation. Water-soluble cornstarch-based adhesives and some resins such as polyvinyl acetate can be used as adhesives. There are several configurations for corrugated board: "single sided", "single wall", "double sided", "double wall" and "triple wall". Each configuration has special applications. Flutes come in several standard shapes or fluting profiles. Different fluting profiles can be combined into one piece of combined cardboard. For example, on a triple wall sheet, one middle layer might be A-flute while the other two layers might be C-flute. Mixing flute profiles in this way allows designers to manipulate compressive strength, damping strength, and thickness total of the combined plate.
    [40] Box sizes 34.4 cm x 34.3 cm x 39.1 cm were converted using corrugated cardboard sheets by an FFG (flexo-folder-gluer) printer with markings and grooves applied prior to gluing the manufacturer's gasket . Various tests such as edge crush, ring crush, and three-dimensional compression test [top to bottom (TB), end to end (EE) and side to side (SS)] were selected to evaluate the boxes for packaging. corrugated cardboard. Results from corrugated medium containing natural non-wood derived wood fibers exceed all control samples.
    [41] All handsheet samples and samples produced by the pilot machines were selectively tested for their mechanical properties (tear, tensile, rupture and density) using TAPPI T220, basis weight TAPPI T410, ring crush using TAPPI T822, edge crush using TAPPI T839, corrugated medium tests using TAPPI T809 and compression test using TAPPI T804. All samples were conditioned at 50% humidity and 75oF for 24 hours before performing any tests. EXAMPLES
    [42] The following examples describe and demonstrate further embodiments within the scope of the present invention. The examples are given for illustrative purposes only and are not to be construed as limitations of the present invention, as many variations from these are possible. Example 1
    [43] Hardwood pulp was made following a traditional semi-chemical corrugated cooking. The hardwood chips used to make the pulp were standard hardwood species from the northern hemisphere, consisting of Birch, Ash and Oak (60/30/10). 1500 grams of kiln-dried mixed chips were placed in a digester - Model M/K 602-2 (M/K Systems, Inc., Peabody, MA) with a 10% solution of sodium carbonate (Na2CO3), with a liquor to wood ratio of 4:1. The chips were brought to a cooking temperature of 125 °C for 60 minutes, cooked for 30 minutes at temperature and then cooled. The cooked chips were placed in a laboratory refiner - Model 105-A (Sprout-Waldron, Muncy, PA), then screened on a flat vibrating screen with 0.02 cm slits. The fibers were then centrifuged to remove water to make them ready for making a handsheet. Example 2
    [44] The pulp mixture from Example 1 was used to make the handsheets as a control. Ten handsheets were manufactured for each code, according to TAPPI T205, in which a web forming apparatus was specified and used. The basis weight of the handsheet was concentrated to 112 grams per square meter (gsm) with a dry weight of 2.24 grams for each handsheet. The actual basis weight of the sample showed a significant deviation. To minimize the effect of basis weight for data comparison, index values are converted based on test data, and shown in Table 1, while Example 1 refers to a semichemical pulp blend made from Example 1, WS stands for wheat straw pulp, purchased from Shandong Pulp and Paper Co., Ltd. (Jinan, China) and seaweed refers to red seaweed, purchased from Pegasus International (Daejeon, Republic of Korea). Example 3
    [45] A mixture of 70% of Example 1 and 30% natural non-wood-derived alternative fibers (20% wheat straw pulp and 10% red seaweed fiber) was prepared to create hand leaves. Other steps of making handsheets and the parameters for handsheets are similar to Example 2, including the examples shown below. Consequently, they are not repeated for the sake of brevity. Example 4
    [46] A blend of 50% of Example 1 and 50% alternative natural non-wood fibers (40% wheat straw pulp and 10% red seaweed fiber) was prepared to create hand leaves. Example 5
    [47] A blend of 30% of Example 1 and 70% alternative natural non-wood fibers (50% wheat straw pulp and 20% red seaweed fiber) was prepared to create hand leaves. Example 6
    [48] A 60% blend of Example 1 was prepared to create handsheets containing 40% wheat straw pulp, without the presence of red algae fibers. Example 7
    [49] This is a comparative example. Hand sheets made with alternative 100% natural non-wood fibers were manufactured without the presence of hardwood pulp as shown in Example 1. The material composition contained 80% wheat straw pulp and 20% algae fibers red. For this non-wood-derived natural fiber composition, the tear index of the handsheet has been weakened, although other mechanical properties are comparable. Example 8
    [50] This is a comparative example. Hand sheets made from alternative 100% natural non-wood fibers were manufactured without the presence of hardwood pulp as shown in Example 1. The material composition contained 90% wheat straw pulp and 10% algae fibers red. For this non-wood-derived natural fiber composition, the handsheet's CMT, its tear index and tensile strength index, etc., were all lower than the control (Example 2). Example 9
    [51] This is a comparative example. Handsheets made with alternative 100% natural fibers not derived from wood were manufactured without the presence of hardwood pulp as shown in Example 1 or without red algae fibers. The material composition contained 100% wheat straw pulp, which is much weaker than the control (Example 2), and did not meet corrugated medium performance standards.
    [52] The results shown in Table 1 indicate that the highest tear, tensile and tear strength along with the corrugated half test (CMT) was found with handsheets made from 80% wheat straw and 20% of red algae, while the lowest values of these properties were found with hand leaves with 100% wheat straw. It appears that thickness and porosity are inversely proportional. Hand sheet density did not change significantly from one sample to the next. Examples with improved mechanical properties of the handsheet (Examples 3-7) over control (Example 2) are indicative of this invention to allow the use of alternative non-wood fibers in corrugated media for corrugated board packaging applications. However, a complete replacement of hardwood pulp using a combination of wheat straw fibers and red algae is challenged to meet technical criteria (such as CMT, ring crush, density, tear index, tensile strength index and rupture index as shown) to produce useful corrugated medium. Table 1 Summary of Mechanical Properties of Handsheet
    Example 10
    [53] Fabrication of corrugated media using weft forming apparatus such as the Fourdrinier 36" paper machine (Sandy Hill Corporation, Hudson Falls, NY) is shown in Table 2. The Hogenkamp headbox was used. The table It has a forming length of 4.1 meters, the slice width of 83.8 cm and the machine is operated with edge waves.
    [54] The press section of the machine consists of two double felted presses. Each pressure clamp is pneumatically charged. The first press is limited to 1,245 per linear centimeter (plc) and the second press to 2489 plc, which is a standard measure for pressing and calendaring. All press rolls are rubber coated and have blind holes.
    [55] The machine's drying section consists of 2 dryer benches 91.4 cm in diameter, 9 dryers in the first section and 5 dryers in the second section. The size press sits between the drying sections and was used for testing. After the second dryer section, there is a stack of 3 tongs and 4 calender rolls. Two 45.7 cm nylon mild steel rollers and two 45.7 cm tempered steel rollers can be configured for calendering in various configurations. The maximum pressure is 5080 plc and the maximum temperature is 550 °F.
    [56] There were three corrugated media produced by the pilot papermaking machine: Example 10A is a blend of hardwood fibers and wheat straw (30/70), Example 10B is 100% OCC and Example 10C is a blend of 30% hardwood fibers, 60% wheat straw fibers and 10% red algae fibers. The respective fibrous compositions are shown in Table 2. A cationic starch was used in papermaking at 0.5% fiber.

    [57] Wheat straw pulp and red seaweed fiber are the same as those used in the production of hand leaf samples. Hardwood fiber was pulped from hardwood purchased from Newpage Corporation (Miamisburg, OH). Its CSF is 730 ml. Refining short fiber cellulose to 350400 ml CSF was performed using the Beloit Double Disc 4000 16" refiner (Beloit Corporation, Lenox Dale, MA) prior to paper manufacture. OCC materials and straw were not refined. of wheat as the CSF values were within 350400 ml.The average paper should be 112 g/m2, the average paper width is 83.8 cm and the paper length is 915 meters per sample.
    [58] Paper production speed was 0.38-0.48 feet per minute. The thickness of these papers is 0.015-0.020 centimeters. The medium paper was on a 10.2 cm core size for further processing ie middle fluting and container sheet assembly. The diameter of each sample roll ranged between 46-60 cm. Example 11
    [59] This is an example of medium paper fluting and corrugated sheet assembly using a pilot corrugator. Kraft corrugated board (35 pounds per 1000 ft2) was purchased from the Georgia-Pacific Corporation (Atlanta, GA), and is composed of 20% post-consumer and 5% pre-consumer with balance (75%) fibers virgins. Polyvinyl acetate is a water-based adhesive purchased from Wisdom Adhesives (Elgin, IL) and the starch is Clinton corn starch, purchased from ADM (Decatur, IL). All of these materials were used in the fluting paper and corrugated cardboard sheet assembly.
    [60] The Asitrade MF250 Modulefacer was used to manufacture corrugated board that includes a single single sided sheet (inner liner) combined with the corrugated middle using an average starch application rate on the single sided side of the sheet, which is 2.45 pounds per 1,000 ft2. The glue formulation is an industry standard corrugator adhesive comprising 363 kg of corn starch, 5 kg of borax, 6.4 kg of caustic soda and 871 liters of water. The single face liner was joined to the double support liner (outer) to form the finished sheet using the Asitrade laminator. This process involved the use of a cold PVA adhesive at an application rate of 4.74 lb per 1000 ft2 on flute B. Flute B designates flutes per linear meter of 154 ± 10 and flute thickness of 3.2 mm . All corrugated cardboard sheets were produced in B flute with a conversion factor of 1.31. Example 12
    [61] Boxes of size 34.4 cm x 34.3 cm x 39.1 cm were converted using corrugated cardboard sheets from example 11 by an FFG (flexo-folder-gluer) printer with markings and grooves applied prior to gluing the manufacturer's gasket.
    [62] Containers were conditioned at 50% humidity and 75°F before the tests listed below were performed. The container edge crush, ring crush and three-dimensional box compression tests were performed, and the results are shown in Table 3, TB means compression made from the top of the container to the bottom, EE means edge to edge and SS means width to width. The respective test methods are: 1) Edge crush test using TAPPI T839, 2) Ring crush test using TAPPI T822, 3) compression test using TAPPI T804 and 4) basis weight for fluted medium B, support double and single cutter using TAPPI T410.Table 3 Physical Test Results for Boxes Made Using Three Different Panned Half

    [63] The sample basis weights of corrugated medium and single cut corrugated board are similar except for 100% OCC as corrugated medium, which is slightly higher especially for the double support. A value of 22 lb/1,000 ft2 corresponds to about 112 g/m2. Thus, this composition of the invention also creates a lightweight corrugated medium for packaging box applications. ECT RCT results indicate containers using a combination of natural fiber alternatives of wheat straw and red algae as the corrugated medium are better than just wheat straw, where the hardwood pulp is at the same level. The difference in the ECT and RCT results are a reflection of the changes in the composition of the medium, as the corrugated boards are of the same material for each assembled box. The improvements in ECT and RCT results are more pronounced when Example 10C is compared to Example 10B, which used 100% OCC as the corrugated medium.
    [64] In three-dimensional compression tests, the E-E compression of Example 10C is weaker than the 100% OCC control and the hardwood and wheat straw mixture. All other data (T-B and SS compressions) are better for Example 10C, indicating that red algae fiber plays an important role in allowing wheat straw pulp to be useful.
    [65] The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each dimension is intended to signify the quoted value and a functionally equivalent range around this value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".
    [66] All documents cited in the "Detailed Description of the Invention" are, in relevant part, incorporated herein by reference; citation of any document is not to be construed as an admission that it is prior art in relation to the present invention. To the extent that any meaning or definition of a term in this written document conflicts with any meaning or definition of the term in a document incorporated by reference, the meaning or definition ascribed to the term in this written document shall control.
    [67] Although specific embodiments of the present invention have been illustrated and described, it will be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications which are within the scope of this invention.
    权利要求:
    Claims (8)
    [0001]
    1. A corrugated cardboard packaging material comprising a hardwood pulp and an alternative non-wood pulp material comprising a combination of corn husk and red seaweed, characterized in that: the combination of wheat straw and of red algae is present in the composition in an amount of 5% to 75% by weight; wherein the hardwood pulp is present in the composition in an amount of 25% to 90% by weight; wherein the red algae are present in the composition in an amount of 5% to 30% by weight; wherein said material replaces at least a part of conventional fiber materials.
    [0002]
    2. Corrugated cardboard packaging material according to claim 1, characterized in that said red alga is selected from Gelidium elegance, Gelidium corneum, Gelidium amansii, Gelidium robustum, Gelidium chilense, Gracelaria verrucosa, Euchema Cottonii, Euchema spinosum , Beludul and their combinations.
    [0003]
    3. Corrugated cardboard packaging material according to claim 1, characterized in that it comprises 20% to 75% by weight of wheat straw pulp and red seaweed pulp combined.
    [0004]
    4. Corrugated cardboard packaging material according to claim 1, characterized in that said material contains a corrugated medium having a basis weight of 90 g/m2 to 200 g/m2.
    [0005]
    5. Corrugated cardboard packaging material according to claim 1, characterized in that said corrugated cardboard sheets comprise an adhesive selected from starch, polyvinyl acetate and combinations thereof.
    [0006]
    6. Corrugated cardboard packaging material according to claim 4, characterized in that the corrugated medium is a flute that varies in size from 105 flutes per meter to 420 flutes per meter.
    [0007]
    7. Corrugated cardboard packaging material according to claim 5, characterized in that said material is converted into rigid packaging containers suitable for packaging applications.
    [0008]
    8. Corrugated cardboard packaging material according to claim 1, characterized in that the ratio of hardwood pulp to alternative non-wood pulp is from 30:70 to 5:95.
    类似技术:
    公开号 | 公开日 | 专利标题
    BR112015004673B1|2021-06-29|CORRUGATED CARDBOARD PACKAGING MATERIAL
    US9908680B2|2018-03-06|Tree-free fiber compositions and uses in containerboard packaging
    Sibaly et al.2017|Production of paper from pineapple leaves
    KR101467421B1|2014-12-01|Method of producing a paper product
    CN204343106U|2015-05-20|Couch board
    AU2016285836B2|2020-04-30|Wood-free fiber compositions and uses in paperboard packaging
    Mossello et al.2010|A review of literatures related of using kenaf for pulp production |
    US20110036525A1|2011-02-17|Method of Manufacturing an opaque paper using Genus Typha L.
    CN102127878B|2012-03-07|Novel cigarette packet paperboard
    Hurter2010|Nonwood plant fiber uses in papermaking
    CN107438687A|2017-12-05|Agricultural fibre class paper
    JP2009091690A|2009-04-30|Paper for paper bag and method for producing the same
    BR112016005635B1|2022-01-25|cardboard packaging material
    RU2355840C1|2009-05-20|Fiber sheeting mainly for corrugating and packaging made of it
    KR102369548B1|2022-03-03|Tree-free fiber compositions and uses in containerboard packaging
    Passas2012|Natural fibres for paper and packaging
    KR20090114963A|2009-11-04|Method of manufacturing an opaque paper using genus typha l
    Lee et al.2011|Effective Utilization of Hemp Fiber for Pulp and Papermaking |-Characteristics of hemp-wood paper made of hemp fiber cooked at low temperature
    RU2233929C1|2004-08-10|Cardboard for flat layers of corrugated cardboard and container using the same
    Samariha et al.2013|Newsprint from NSSC bagasse pulp mixed with hardwood CMP pulp and bleached softwood kraft pulp
    RU175017U1|2017-11-15|Corrugated cardboard with increased rigidity
    Zhao2017|Comparison between non-wood fiber paper and Finnish traditional wood-fiber paper by mechanical properties
    Engida et al.2017|Kraft pulping of wheat straw
    BR112019021492A2|2020-05-12|TISSUE PAPER SHEET, AND, METHOD FOR CUSTOMIZING THE TRACTION INDEX AND CANADIAN FIBER CLEARING PATTERN ON A TISSUE PAPER SHEET.
    Ahmed2019|Evaluation of Paper Properties Made from Bagasse and kenaf Fiber, and their Blends
    同族专利:
    公开号 | 公开日
    US20140093704A1|2014-04-03|
    KR101876009B1|2018-07-06|
    MX2015003247A|2015-06-10|
    AU2013322298B2|2017-06-22|
    EP2900869B1|2019-08-07|
    EP2900869A4|2016-06-22|
    AU2013322298A1|2015-04-23|
    EP2900869A1|2015-08-05|
    KR20150059758A|2015-06-02|
    MX354117B|2018-02-13|
    US9816233B2|2017-11-14|
    BR112015004673A2|2017-07-04|
    WO2014049476A1|2014-04-03|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US1829852A|1928-12-13|1931-11-03|Cornstalk Products Company Inc|Manufacture of cellulose from straw|
    GB508671A|1937-05-05|1939-07-04|Thomas Dillon|Method of making pulp or "stuff" from seaweed|
    US2388592A|1940-03-21|1945-11-06|Defibrator Ab|Process of making ligno-cellulose pulps from straw|
    GB702025A|1952-02-01|1954-01-06|Samuel Isaac Aronovsky|Cellulosic pulp and method of manufacturing the same|
    US2862813A|1952-12-23|1958-12-02|Process Evaluation Devel|Semi-chemical pulping process|
    US2965436A|1956-05-17|1960-12-20|Toulmin And Toulmin|Process for improving the wet strength of products obtained from cellulosic pulp|
    GB1423253A|1972-05-17|1976-02-04|Isovolta|Process for the manufacture of a paper fluting or cardboardand products manufactured by the process|
    GB1400879A|1972-07-03|1975-07-16|Clupak Inc|Production of high strength packaging papers from straw|
    NL7311586A|1973-08-22|1975-02-25|Inst Voor Bewaring|PROCESS OF PROCESSING CELLULOSE FIBERS AND LIGNIN CONTAINING VEGETABLE MATERIALS.|
    DE2506919C3|1975-02-19|1978-10-12|Instituut Voor Bewaring En Verwerking Van Landbouwprodukten, Wageningen |Process for the production of lignin-rich fiber material and the use of this material for the production of paper and cardboard|
    CA1047208A|1975-06-12|1979-01-30|Lock-Lim Chan|Dry strength paper and process therefor|
    US4102738A|1977-01-17|1978-07-25|American Cyanamid Company|Use of chitosan in corrugating medium|
    US4597930A|1983-07-11|1986-07-01|Szal John R|Method of manufacture of a felted fibrous product from a nonaqueous medium|
    US5258087A|1989-03-28|1993-11-02|Plascon Technologies Limited|Method of making a composite structure|
    NO179682C|1990-11-29|1996-11-27|Mitsubishi Heavy Ind Ltd|Process for preparing cellulose-containing pulp|
    IT1262021B|1992-04-16|1996-06-18|Favini Cartiera Spa|PROCEDURE FOR THE PRODUCTION OF MARINE ALGAE PAPER AND PAPER SO OBTAINED|
    WO1994004745A1|1992-08-12|1994-03-03|International Technology Management Associates, Ltd.|Algal pulps and pre-puls and paper products made therefrom|
    FR2744735B1|1996-02-13|1998-04-10|Beghin Say Eridania|USE OF SUGAR BEET PULPES IN THE MANUFACTURE OF PAPER OR CARDBOARD|
    AT405847B|1996-09-16|1999-11-25|Zellform Ges M B H|METHOD FOR PRODUCING BLANKS OR SHAPED BODIES FROM CELLULOSE FIBERS|
    FR2756571B1|1996-12-02|1999-02-19|Creca|MICROBIOLOGICAL PROCESS FOR THE SURFACE TREATMENT OF A MATERIAL, FILMS AND SUPPORTS OBTAINED BY SAID MATERIAL|
    US5985147A|1997-04-01|1999-11-16|Science Applications International Corporation|Integrated system and method for purifying water, producing pulp, and improving soil quality|
    KR20070012759A|1998-06-17|2007-01-26|나일 화이버 펄프 앤드 페이퍼 인코포레이티드|Arundo donax chip and flake|
    US20080046277A1|2001-02-20|2008-02-21|Stamets Paul E|Living systems from cardboard packaging materials|
    TW592629B|2003-02-26|2004-06-21|Yuen Foong Yu Paper Mfg Co Ltd|The manufacturing method for a plant fiber mulching mat|
    US20040256065A1|2003-06-18|2004-12-23|Aziz Ahmed|Method for producing corn stalk pulp and paper products from corn stalk pulp|
    BRPI0416504A|2003-11-13|2007-01-16|Hack-Churl You|pulp and paper made from rhodophyta and their method of manufacture|
    US7648772B2|2005-06-28|2010-01-19|International Paper Co.|Moisture resistant container|
    KR100547492B1|2005-06-30|2006-01-31|이권혁|The production method of pulps and its paper products from bamboo|
    EP1913199A1|2005-07-11|2008-04-23|International Paper Company|A paper substrate containing a functional layer and methods of making and using the same|
    US20070062656A1|2005-09-20|2007-03-22|Fort James Corporation|Linerboard With Enhanced CD Strength For Making Boxboard|
    KR100811193B1|2005-10-12|2008-03-17|페가서스인터내셔널|Pulp made from rhodophyta and manufacturing method thereof|
    KR100754890B1|2005-10-12|2007-09-10|페가서스인터내셔널|Method for Making Pulp Using Rhodophyta|
    US20070202283A1|2006-02-27|2007-08-30|John Meazle|Reducing top ply basis weight of white top linerboard in paper or paperboard|
    CN101405457B|2006-03-16|2011-08-17|巴斯夫欧洲公司|Method for producing paper, paperboard and cardboard having high dry strength|
    US20080081135A1|2006-09-29|2008-04-03|Weyerhaeuser Co.|Container|
    AU2008338415A1|2007-12-17|2009-06-25|Cornell University|High-strength, environmentally friendly corrugated boards|
    US20110036525A1|2008-04-30|2011-02-17|Nanotox Tech|Method of Manufacturing an opaque paper using Genus Typha L.|
    KR101019329B1|2008-07-25|2011-03-07|충남대학교산학협력단|Korean paper comprising red algae fiber|
    EP2315875B1|2008-08-18|2014-03-05|Basf Se|Method for increasing the dry strength of paper, paperboard and cardboard|
    SI2406243T1|2009-03-10|2014-08-29|Takeda Pharmaceutical Company Limited|Benzofuran derivatives|
    KR101088455B1|2009-10-21|2011-11-30|충남대학교산학협력단|Method for manufacturing food packaging paper and its pulp from Rhodophyta|
    WO2011071668A1|2009-12-08|2011-06-16|International Paper Company|Method of production of fiber additive made from non - woody material and use|
    EP2380731B1|2010-02-26|2018-01-03|Korea Institute of Energy Research|Eco-friendly incombustible biocomposite and method for preparing the same|
    US8795469B2|2010-06-25|2014-08-05|Prairie Paper Ventures Inc.|Method for preparing nonwood fiber paper|
    WO2012010181A1|2010-07-19|2012-01-26|Benvegnu Francesco|Marine plants processing method for the production of pulp for the production of paper|
    JP5639272B2|2010-09-10|2014-12-10|ヘンケル・ユーエス・アイピー・リミテッド・ライアビリティ・カンパニーＨｅｎｋｅｌ ＵＳ ＩＰ ＬＬＣ|Adhesive with improved thermal insulation|
    FR2972009B1|2011-02-25|2013-04-26|Arjo Wiggins Fine Papers Ltd|METHODS FOR PREPARING PAPER PULP AND MANUFACTURING PAPER FROM ALGAE POWDER|
    WO2013050436A1|2011-10-07|2013-04-11|Akzo Nobel Chemicals International B.V.|Paper and board production|DE102014002446A1|2014-02-25|2015-08-27|J. Rettenmaier & Söhne Gmbh + Co Kg|Additive for a pulp|
    AU2015397126B2|2015-05-29|2020-07-30|Kimberly-Clark Worldwide, Inc.|Soft tissue comprising non-wood fibers|
    MX2017014267A|2015-05-29|2018-04-20|Kimberly Clark Co|High bulk hesperaloe tissue.|
    EP3302200B1|2015-05-29|2020-10-07|Kimberly-Clark Worldwide, Inc.|Highly durable towel comprising non-wood fibers|
    AU2016285836B2|2015-06-30|2020-04-30|Kimberly-Clark Worldwide, Inc.|Wood-free fiber compositions and uses in paperboard packaging|
    US10669675B2|2015-10-16|2020-06-02|General Mills, Inc.|Paperboard product|
    CL2016001910A1|2016-07-28|2016-12-23|Univ Concepcion|Bioactive paper comprising as base a algal paper, which is composed of secondary cellulose fibers in combination with brown algae biomass; and an antimicrobial extract, obtained from brown algae, which is added to the algal paper.|
    US10337149B2|2016-11-23|2019-07-02|Kimberly-Clark Worldwide, Inc.|High strength and low stiffness hesperaloe tissue|
    US10337148B2|2016-11-23|2019-07-02|Kimberly-Clark Worldwide, Inc.|Hesperaloe tissue having improved cross-machine direction properties|
    US10337147B2|2016-11-23|2019-07-02|Kimberly-Clark Worldwide, Inc.|Highly dispersible hesperaloe tissue|
    CA3059901A1|2017-02-23|2018-08-30|Vericool, Inc.|Thermally insulating packaging|
    BR112019014276A2|2017-02-22|2020-03-03|Kimberly-Clark Worldwide, Inc.|TISSUE PAPER PRODUCT, AND, METHOD FOR FORMING A TISSUE PAPER PRODUCT|
    US10618690B2|2017-02-23|2020-04-14|Vericool, Inc.|Recyclable insulated stackable tray for cold wet materials|
    US10625925B1|2018-09-28|2020-04-21|Vericool, Inc.|Compostable or recyclable cooler|
    法律状态:
    2018-03-06| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-13| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2018-03-20| B06I| Publication of requirement cancelled [chapter 6.9 patent gazette]|Free format text: ANULADA A PUBLICACAO CODIGO 6.6.1 NA RPI NO 2462 DE 13/03/2018 POR TER SIDO INDEVIDA. |
    2021-05-04| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2021-06-29| B16A| Patent or certificate of addition of invention granted|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/09/2013, OBSERVADAS AS CONDICOES LEGAIS. |
    优先权:
    申请号 | 申请日 | 专利标题
    US13/631,183|2012-09-28|
    US13/631,183|US9816233B2|2012-09-28|2012-09-28|Hybrid fiber compositions and uses in containerboard packaging|
    PCT/IB2013/058466|WO2014049476A1|2012-09-28|2013-09-11|Hybrid fiber compositions and uses in containerboard packaging|
    [返回顶部]