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EP3497282B1 - Carton compostable presentant une résistance à l'huile, à la graisse et à l'humidité - Google Patents

Carton compostable presentant une résistance à l'huile, à la graisse et à l'humidité Download PDF

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Publication number
EP3497282B1
EP3497282B1 EP17751962.6A EP17751962A EP3497282B1 EP 3497282 B1 EP3497282 B1 EP 3497282B1 EP 17751962 A EP17751962 A EP 17751962A EP 3497282 B1 EP3497282 B1 EP 3497282B1
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EP
European Patent Office
Prior art keywords
paperboard
binder
coating
coated
coated paperboard
Prior art date
Legal status (The legal status 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 status listed.)
Revoked
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EP17751962.6A
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German (de)
English (en)
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EP3497282A1 (fr
EP3497282C0 (fr
Inventor
Jiebin Pang
Natasha MELTON
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WestRock MWV LLC
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WestRock MWV LLC
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Priority claimed from US15/230,896 external-priority patent/US9670621B2/en
Application filed by WestRock MWV LLC filed Critical WestRock MWV LLC
Publication of EP3497282A1 publication Critical patent/EP3497282A1/fr
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Classifications

    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/38—Packaging materials of special type or form
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/50—Proteins
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H19/00—Coated paper; Coating material
    • D21H19/36—Coatings with pigments
    • D21H19/44—Coatings with pigments characterised by the other ingredients, e.g. the binder or dispersing agent
    • D21H19/54—Starch
    • 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
    • D21H21/00—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties
    • D21H21/14—Non-fibrous material added to the pulp, characterised by its function, form or properties; Paper-impregnating or coating material, characterised by its function, form or properties characterised by function or properties in or on the paper
    • D21H21/16—Sizing or water-repelling agents
    • 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

Definitions

  • This disclosure relates to paperboard substrates having good oil and grease resistance, yet with full recyclability and without a tendency toward blocking, and furthermore being compostable.
  • Oil and grease resistance is one of the top needs for paperboard packages in food and food service industries.
  • Several technologies including specialty chemical (wax, fluorochemicals, starch, polyvinyl alcohol (PVOH), sodium alginate, etc.) treatment, polymer extrusion coating (polyethylene, etc.) have been employed to provide oil and grease resistance of paperboard packaging.
  • the paper or paperboard treated with wax or coated with polyethylene which is currently used in oil and grease resistant packaging, has difficulties in repulping and is not as easily recyclable as conventional paper or paperboard.
  • Paper or paperboard treated with specialty chemicals such as fluorochemicals has potential health, safety and environmental concerns, and scientists have called for a stop to non-essential use of fluorochemicals in common consumer products including packaging materials.
  • Aqueous coating is one of the promising solutions to achieve these goals.
  • blocking the tendency of layers in a roll of paperboard to stick to one another
  • blocking is also a major technical hurdle for on-machine application of aqueous barrier coatings.
  • most aqueous barrier coatings are not fully repulpable.
  • US6548120B1 discloses a recyclable and repulpable coated paper stock, preferably for use as ream wrap, comprising a substrate coated on at least one surface with a base coat and at least one additional coat over said base coat. Both coats are water-based dispersions of a polymer selected from the group consisting of acrylic polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol, ethylene-vinyl acetate, polyvinyl chloride, styrene butadiene copolymers, polyvinylidiene chloride and its copolymers, or starch.
  • the wax free coating forms a pin-hole free continuous film on the substrate which is resistant to water and water vapor.
  • the invention also includes processes for making and recycling the invented coated paper stocks.
  • certain inventive coatings that have barrier properties have achieved the ASTM compostability standard, at least for paperboard that is 12 caliper (305 ⁇ m (.012")) or higher.
  • the coating(s) typically contribute a larger share of the total weight, with the result that the non-biodegradable organic constituent in the coatings becomes more than 1% of such lower-caliper paperboard.
  • the general purpose of the invention is to coat the 'barrier' side of a paperboard with at least one layer of aqueous coating containing a renewable natural material (modified starch) and a specialty synthetic binder, resulting in the coated oil and grease resistant paperboard (i.e., 305 ⁇ m (12 pt.) caliper and above) meeting the ⁇ 1% non-biodegradable composition requirement for the compostability standard.
  • the coating can either be applied on a paper machine or by an off-line coater, and can be applied in two coating steps (or two passes) for further enhanced barrier properties.
  • Paperboard coated according to the invention provides resistance to oil and grease, does not have any tendency to block, is compliant to safety and environmental regulations, is fully repulpable, is compostable, and can be produced at a low cost.
  • a coated paperboard which includes a paperboard substrate; a coating in contact with the paperboard substrate, the coating comprising binder and pigment, the pigment comprising at least one of a clay and calcium carbonate, the coating containing substantially no fluorochemical or wax; wherein the binder comprises synthetic and natural binders; wherein the binder to pigment ratio in the coating is between 25 to 40 parts binder per 100 parts pigment, by weight; wherein the coated paperboard has a caliper of at least 254 ⁇ m (0.010"); wherein the coated paperboard provides barrier properties to at least one of oil, grease, and moisture; and wherein the coated paperboard is compostable according to the ASTM D6868-11 standard for compostability.
  • the binder to pigment ratio in the coating is between 30 to 35 parts binder per 100 parts pigment, by weight.
  • the binder comprises a synthetic polymer including (i) a non-biodegradable component and (ii) a natural biodegradable component.
  • the binder further comprises (iii) an additional natural biodegradable component.
  • the additional biodegradable component (iii) is at least one of polysaccharide and protein.
  • the additional biodegradable component (iii) comprises between 1 to 7 parts starch per 100 parts pigment, by weight.
  • the 3M kit test value is at least 3.
  • the coated paperboard has a 30-minute oil Cobb test of at most 20 grams per square meter.
  • the coated paperboard is repulpable to the extent that after repulping the percentage accepts is at least 99%.
  • the percentage accepts is at least 99.9%.
  • the coated paperboard having no tendency toward blocking, defined as a blocking rating of "0" determined by evaluating the adhesion between the barrier coated side and the other uncoated side of samples of the coated paperboard using a test device (700) (illustrated in FIG. 5 ) and holding said samples for 24 hours at 50°C at a pressure of 689.5 kPa (100 psi).after being held for 24 hours at 50°C at a pressure of 689.5 kPa (100 psi).
  • a method of treating paperboard including providing a paperboard substrate; applying to the paperboard substrate a coating comprising binder and pigment, the pigment comprising at least one of a clay and calcium carbonate, and the coating containing substantially no fluorochemical or wax; wherein the binder comprises synthetic and natural binders; wherein the binder to pigment ratio in the coating is between 25 to 40 parts binder per 100 parts pigment, by weight; wherein the coated paperboard has a caliper of at least 254 ⁇ m (0.010"); wherein the coated paperboard is compostable according to the ASTM D6868-11 standard for compostability
  • the natural binder is starch.
  • the coating on the paperboard substrate has a coating weight, on a dry basis, of 8.1 g/m 2 to 19.5 g/m 2 (5 to 12 lbs per 3000 ft 2 ).
  • the coating applied to the paperboard substrate is applied in two passes for a total coat weight of coating on the paperboard substrate, on a dry basis, of 8.1 g/m 2 to 19.5 g/m 2 (5 to 12 lbs per 3000 ft 2 ).
  • FIG.1 and FIG 2 illustrate an exemplary on-paper machine method for coating a paperboard web with one or more layers of aqueous coating.
  • a forming wire 110 in the form of an endless belt passes over a breast roll 115 that rotates proximate to a headbox 120.
  • the headbox provides a fiber slurry in water with a fairly low consistency (for example, about 0.5% solids) that passes onto the moving forming wire 110.
  • a first distance 230 water drains from the slurry and through the forming wire 110, forming a web 300 of wet fibers.
  • the slurry during distance 130 may yet have a wet appearance as there is free water on its surface. At some point as drainage continues the free water may disappear from the surface, and over distance 231, water may continue to drain although the surface appears free from water.
  • the web is carried by a transfer felt or press felt through one or more pressing devices such as press rolls 130 that help to further dewatering the web, usually with the application of pressure, vacuum, and sometimes heat.
  • the still relatively wet web 300 is dried, for example using dryer or drying sections 401, 402 to produce a dry web ("raw stock") 310 which may then be run through a size press 510 that applies a surface sizing to produce a sized "base stock” 320 which may then be run through additional dryer sections 403 and (on FIG. 2 ) smoothing steps such as calendar 520.
  • the base stock 320 may then be run through one or more coaters.
  • coater 530 may apply a first coat ("BC") to a first side ("C1") of the web, and the first coat may be dried in one or more dryer sections 404.
  • Coater 540 may apply a second coat ("TC") to the first side of the web, and the second coat may be dried in one or more dryer sections 405.
  • coater 550 may apply a first coat to the second side ("C2") of the web, and this coat may be dried in one or more dryer sections 406.
  • Coater 560 may apply a second coat to the second side of the web, and this coat may be dried in one or more dryer sections 407.
  • the order of coaters 540, 550 may be swapped, so that both sides C1 and C2 are first given a first coat, and then one side or both sides are given a second coat. In some instances, only one side will be coated as shown in FIG. 3 , or only a first coat may be applied. In some instances, a third coat may be applied to one side.
  • coating may be applied by an off-machine coater as shown in Fig. 4 .
  • the paperboard having been produced on the paper machine and wound onto reel 572 may then be transported (as a reel or as smaller rolls) to an off-machine coater 600, where the paperboard is unwound from reel 572, given a first coating by coater 610, dried in dryer(s) 601, given an optional second coating by coater 620, dried in dryer(s) 602, optionally given further treatment (such as gloss calendaring) and then wound onto reel 573.
  • An off-machine coater could instead apply a single coat to one side of the paperboard, or could apply a single coat to each side, or could apply more than one coat to either or both sides. Alternately some coating may be done on the paper machine, with additional coating done on an off-machine coater.
  • coaters illustrated in FIGs. 2 to 4 are devices where a coating is held in a pan, transferred by a roll to the lower surface of the web (which may be either the first side or the second side depending on the web path), and then the excess coating scraped off by a blade as the web wraps partially around a backing roll.
  • coater types including but not limited to curtain coater, air knife coater, rod coater, film coater, short-dwell coater, spray coater, and metering film size press.
  • the particular materials used in the coatings may be selected according to the desired properties of the finished paperboard.
  • one side e.g. C1 may be given coating(s) that provide desired printability, while the other side e.g. C2 may be given barrier coating(s) that provide oil and grease resistance (OGR).
  • the printability coating may be applied before the OGR coating, or, the OGR coating may be applied before the printability coating.
  • Typical aqueous barrier coatings often use specialty polymer(s), wax, and/or a higher polymer binder level (compared to conventional print coatings). These coatings can cause problems with repulpability of the coated paperboard because the coatings are usually difficult to breakdown to acceptable size or tend to form 'stickies' in paperboard making with the recycled fibers. Due to the high content of synthetic polymer binder in the coating, it is extremely challenging for each of the individual organic components in the coating to meet the ⁇ 1% non-biodegradable composition requirement of the ASTM D6868-11 compostability standard.
  • barrier coatings give paperboard a tendency to 'block' (the layers stick together) either in the reel 570, 571, 572, 573 or after it is rewound into rolls.
  • the reel 570 there may be residual heat from the dryers, which may dissipate quite slowly because of the large mass of the reel. Higher temperatures may increase the tendency toward blocking.
  • paperboard coated with conventional printability coatings usually does not block, and usually is fully repulpable. It would be advantageous if non-blocking and fully repulpable coatings also provided at least some degree of barrier properties.
  • conventional printability coatings do not provide satisfactory barrier properties.
  • Their formulations have relatively low levels of binder so as to absorb rather than repel fluid (printing ink, for example).
  • Binder amounts in conventional printability coatings can range from 15-25 parts per 100 parts of pigment by weight for base coatings, and 10-20 parts per 100 parts pigment by weight for top coatings. Printing grades would tend to be in the lower half of these ranges. Limiting the binder amount in the top coating may allow printing inks or adhesives to absorb readily into the printability coating. Simply increasing the binder to improve barrier properties eventually interferes with printability and causes additional problems, including blocking and repulpability problems.
  • inventive coatings disclosed in the present application provide easy repulping, meet the composition requirement for the ASTM compostability standard, do not block at elevated temperature and pressure, and show good barrier properties, while using conventional pigments and synthetic and natural binders that are low-cost and readily available as coating materials for the paper or paperboard industry.
  • pigments are used in the present invention and may include, but are not limited to, kaolin clay, calcium carbonate, etc. Pigments used in the examples herein are given the following 'shorthand' designations:
  • Synthetic polymer binders may include, but are not limited to, styrene acrylate copolymer (SA), polyvinyl acetate (PVAc), and styrene-butadiene copolymer (SB), etc.
  • Natural binders may include, but are not limited to, starch, alginate, protein, etc.
  • Coatings including control coatings in the present invention were prepared according to the formulations shown in Table 1, which provides a list of major constituents in dry parts of the aqueous coating (C - Control, CF - Compostable Formulation) formulations used to achieve the oil and grease resistance, and to meet the composition requirement for the ASTM compostability standard, without blocking or repulpability problems.
  • Table 1 provides a list of major constituents in dry parts of the aqueous coating (C - Control, CF - Compostable Formulation) formulations used to achieve the oil and grease resistance, and to meet the composition requirement for the ASTM compostability standard, without blocking or repulpability problems.
  • Tables 3 and 4 The test results are shown in Tables 3 and 4.
  • substantially no fluorochemical was used in the coatings.
  • substantially no fluorochemical is meant that fluorochemicals were not deliberately utilized, and that any amount present would have been at most trace amounts. Although fluorochemicals can be excluded in lab experiments, trace amounts of such materials might be present in some paper machine systems due to making various grades of product, or might be introduced into a papermaking system through recycling processes. Likewise, substantially no wax was used in the coatings.
  • the total binder to pigment ratio (parts of binder, by weight, to 100 parts of pigment) of the formulations shown in Table 1 ranges from 30 to 35. This is more than the binder to pigment ratio for typical printability coatings (where rapid absorption of ink is desired) and less than the binder to pigment ratio of typical barrier coatings. Thus, it appears that an effective binder to pigment ratio may be from about 25 to about 40 parts binder per 100 parts pigment (by weight), or from 30 to 35 parts binder per 100 parts pigment. However, perhaps acceptable results (good 3M kit test, no blocking, and good repulpability) might be achieved with a slightly greater range.
  • Blending starch (such as Pen-cote@ D), a natural biodegradable material, into the formulation helps meet the ⁇ 1% non-biodegradable composition requirement for the ASTM compostability standard while maintaining the barrier performance.
  • the Pen-cote ® D starch was added at up to 5 parts in the final formulations.
  • Paperboard samples were made using solid bleached sulphate (SBS) substrate with a caliper of 457 ⁇ m (18 pt. (0.018”)). The samples were coated on one side (herein termed the "barrier side") using a pilot blade coater with a one-layer coating. The pilot results are expected to be representative of results that might be achieved on a production paper machine or a production off-machine coater.
  • SBS solid bleached sulphate
  • the oil and grease resistance (OGR) of the samples was measured on the 'barrier 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). The results here gave 3M kit levels between 1 to 6 (see Table 3). The higher values were obtained with the higher coat weights for each specific formulation.
  • Basonal@ binder itself (C2 formulation) performs better on 3M kit level than SA binder (C1 formulation) at comparable coat weights (see Table 3); furthermore, blending Pen-cote@ D starch with Basonal@ (CF1-3) maintains the performance on 3M kit level as using Basonal@ itself at comparable or slightly higher coat weight, while meeting the ⁇ 1% non-biodegradable composition requirement for the ASTM compostability standard. Especially, a 3M kit level of 4 to 5 (suitable for most food service packages) is achieved while meeting the compostability standard.
  • oil absorptiveness was used to quantify and compare the OGR performance (oil and grease resistance), which measures the mass of oil absorbed in a specific time, e.g., 30 minutes, by 1 square meter of coated paperboard.
  • OGR performance oil and grease resistance
  • the sample was cut to provide two pieces each 6 inch ⁇ 6 inch square.
  • Each square sample was weighed just before the test. Then a 4 inch ⁇ 4 inch (area of 16 square inches or 0.0103 square meters) square of blotting paper saturated with peanut oil was put on the center of the test specimen (barrier side) and pressed gently to make sure the full area of oily blotting paper was contacting the coated surface.
  • Moisture resistance of the coatings was evaluated by WVTR (water vapor transmission rate at 38°C and 90% relative humidity; TAPPI Standard T464 OM-12) and water Cobb (TAPPI Standard T441 om-04). All the formulations (CF1-4, Table 3) containing Basonal@ and Pen cote ® D starch showed similar water Cobb and WVTR values compared to both control formulations (C1 or C2), while all of them met the ASTM compostability standard.
  • the blocking behaviour 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. 5 .
  • the paperboard was cut into 5cm ⁇ 5cm (2" ⁇ 2") square samples.
  • Several duplicates were tested for each condition, with each duplicate evaluating the blocking between a pair of samples 752, 754. (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 752 contacting the uncoated side of the other piece 754.
  • the pairs were placed into a stack 750 with a spacer 756 between adjacent pairs, the spacer being foil, release paper, or even copy paper.
  • the entire sample stack was placed into the test device 700 illustrated in FIG. 5 .
  • the test device 700 includes a frame 710. An adjustment knob 712 is attached to a screw 714 which is threaded through the frame top 716. The lower end of screw 714 is attached to a plate 718 which bears upon a heavy coil spring 720. The lower end of the spring 720 bears upon a plate 722 whose lower surface 724 has an area of one square inch. A scale 726 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 724).
  • the stack 750 of samples is placed between lower surface 724 and the frame bottom 728.
  • the knob 712 is tightened until the scale 726 reads the desired force of 100 lbf (100 psi applied to the samples).
  • the entire device 700 including samples is then placed in an oven at 50°C for 24 hours.
  • the device 700 is then removed from the test environment and cooled to room temperature. The pressure is then released and the samples removed from the device.
  • Blocking damage is visible as fiber tear, which if present usually occurs with fibers pulling up from the non-barrier surface of samples 754. If the non-barrier surface was coated with a print coating, then blocking might also be evinced by damage to the print coating.
  • samples 752(0)/754(0) might be representative of a "0" blocking (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 752(3)/754(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 754(3).
  • Samples 752(4)/754(4) might be representative of a "4" blocking rating with more than 25% fiber tear, particularly in the uncoated surface of sample 754(4).
  • the depictions in FIG. 5 are only meant to approximately suggest the percent damage to such test samples, rather than showing a realistic appearance of the samples.
  • Repulpability was tested using an AMC Maelstom repulper. 110 grams of coated paperboard, cut into 2.5cm ⁇ 2.5cm (1" ⁇ 1") 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 (0.15mm (0.006”) 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.
  • SBS paperboard coated with low density polyethylene (LDPE) at a coat weight of 11.3 to 17.8 g.m 2 (7-11 lbs per 3000ft 2 ) was tested and gave fiber accepts in a range of 91 to 97%. (A fiber accepts percentage close to 100% is desired). Paperboard coated with polyethylene not easily repulpable and recyclable.
  • LDPE low density polyethylene
  • paperboard CF1, CF2, CF3, CF4 are for coatings blending the Basonal@ binder with Pen-cote@ D, a modified starch made by Ingredion Incorporated. These paperboards all meet the compostability definition.
  • Gloss was measured on a Technidyne Model T 480A Glossmeter according to TAPPI standard T480.
  • GE Brightness was measured on a Technidyne Brightimeter Micro S-5 according to TAPPI standard T452.
  • CIE Whiteness was measured the Technidyne Brightimeter Micro S-5 according to TAPPI standard T562.
  • Basonal@ binder or a blend of Basonal@ binder with Pen-cote@ D starch showed similar or slightly higher gloss of the coating than using SA binder, but with slightly lower brightness and whiteness and slightly higher b-color value.
  • Barrier properties are the focus of the inventive coatings, however, if there is a need to adjust the color or shade, food contact compliant dyes can be used in the formulations.
  • the Basonal ® X 400 AL binder made by BASF Corporation contains about 30% natural polymer component.
  • a natural polymer component refers to one grown and found in nature, which for example, can be any protein or polysaccharide or their derivatives.
  • the idea of using the Basonal@ X 400 AL binder along with some additional natural polymer (such as starch) in the present invention was that the natural component in the Basonal@ binder would promote the compatibility of the additional starch with the Basonal@ binder. Compatibility of the different ingredients is important for a barrier coating.
  • Tables 3 and 4 thus show that the combined use of Pen-cote@ D specialized starch with Basonal ® binder provides improved barrier performance, especially, achieving a 3M kit level of 5+, while meeting the compostability standard, being fully repulpable, and not having blocking problems.
  • FIG. 6 shows 3M kit level vs. coat weight. The kit value generally increases (improves) as coat weight increases. None of the control samples (using SA binder) were compostable in the coat weight range of 9.7 to 19.5 g/m 2 (6-12 lbs / 3msf).
  • FIG. 7 shows oil Cobb vs. coat weight for the selected samples as in FIG. 6 .
  • the oil Cob generally decreases (improves) as coat weight increases.
  • the compostability (or lack thereof) has already been described.
  • the test samples using (combined) Basonal@ and Pen-cote@ D gave oil Cobb tests equal or better (lower) than the test samples using styrene-acrylate binder.
  • the results show that compostable paperboard with full repulpability and moderate grease resistance is achieved by replacing standard binders (such as styrene acrylate) with a binder such as Basonal@ X400AL in combination with small amounts of Pen-cote@ D specialized starch.
  • the paperboard product meets the composition requirements of the ASTM compostability standard, at least for paperboards of caliper 305 ⁇ m (12 pt.) and higher.
  • the compostability standard involves calculations of how much of each non-biodegradable organic constituent is used in the product. It is hypothesized that by adjusting the coating, or the paperboard basis weight, compostability according to the ASTM standard might be achieved with somewhat lower calipers, such as 254 ⁇ m (10 pt. (0.010”)).

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Claims (15)

  1. Carton couché, comprenant :
    un substrat en carton ;
    un revêtement en contact avec le substrat en carton, le revêtement comprenant un liant et un pigment, le pigment comprenant au moins un parmi de l'argile et du carbonate de calcium, le revêtement ne contenant sensiblement pas de composé fluoré ni de paraffine ;
    dans lequel le liant comprend des liants synthétiques et naturels ;
    dans lequel le rapport liant sur pigment dans le revêtement est entre 25 et 40 parties de liant pour 100 parties de pigment, en poids ;
    dans lequel le carton couché présente une épaisseur d'au moins 254 µm (0,010") ;
    dans lequel le carton couché fournit des propriétés de barrière contre au moins une parmi l'huile, la graisse et l'humidité ; et
    dans lequel le carton couché est compostable selon la norme ASTM D6868-11 pour la compostabilité.
  2. Carton couché selon la revendication 1, dans lequel le rapport liant sur pigment dans le revêtement est entre 30 et 35 parties de liant pour 100 parties de pigment, en poids.
  3. Carton couché selon la revendication 1 ou la revendication 2, dans lequel le liant comprend un polymère synthétique incluant (i) un constituant non biodégradable et (ii) un constituant biodégradable naturel.
  4. Carton couché selon la revendication 3, dans lequel le liant comprend en outre (iii) un constituant biodégradable naturel supplémentaire.
  5. Carton couché selon la revendication 4, dans lequel le constituant biodégradable supplémentaire (iii) est au moins un parmi un polysaccharide et une protéine.
  6. Carton couché selon la revendication 4 ou 5, dans lequel le constituant biodégradable supplémentaire (iii) comprend entre 1 et 7 parties d'amidon pour 100 parties de pigment, en poids.
  7. Carton couché selon l'une quelconque des revendications 1 à 6, dans lequel la valeur de test de kit 3M est d'au moins 3.
  8. Carton couché selon l'une quelconque des revendications 1 à 7, dans lequel le carton couché présente un essai de Cobb à l'huile de 30 minutes d'au maximum 20 grammes par mètre carré.
  9. Carton couché selon l'une quelconque des revendications 1 à 8, dans lequel le carton couché est repulpable dans la mesure où, après le repulpage, le taux d'acceptation est d'au moins 99 %.
  10. Carton couché selon la revendication 9, dans lequel le taux d'acceptation est d'au moins 99,9 %.
  11. Carton couché selon l'une quelconque des revendications 1 à 10, ne présentant aucune tendance au collage, définie comme un indice de collage de « 0 », déterminé en évaluant l'adhérence entre la face barrière couchée et l'autre face non couchée d'échantillons du carton couché en utilisant un dispositif de test (700) (illustré sur la FIG. 5) et en maintenant lesdits échantillons pendant 24 heures à 50 °C à une pression de 689,5 kPa (100 psi).
  12. Procédé de traitement du carton, le procédé comprenant :
    la fourniture d'un substrat en carton ;
    l'application sur le substrat en carton d'un revêtement comprenant un liant et un pigment, le pigment comprenant au moins un parmi de l'argile et du carbonate de calcium, et le revêtement ne contenant sensiblement pas de composé fluoré ni de paraffine ;
    dans lequel le liant comprend des liants synthétiques et naturels ;
    dans lequel le rapport liant sur pigment dans le revêtement est entre 25 et 40 parties de liant pour 100 parties de pigment, en poids ;
    dans lequel le carton couché présente une épaisseur d'au moins 254 µm (0,010") ;
    dans lequel le carton couché est compostable selon la norme ASTM D6868-11 pour la compostabilité.
  13. Procédé selon la revendication 12, dans lequel le liant naturel est de l'amidon.
  14. Procédé selon la revendication 12 ou la revendication 13, dans lequel le revêtement sur le substrat en carton présente un poids de revêtement, sur une base sèche, de 8,1 g/m2 à 19,5 g/m2 (5 à 12 lb pour 3 000 pi2).
  15. Procédé selon la revendication 14, dans lequel le revêtement appliqué sur le substrat en carton est appliqué en deux passages pour un poids de revêtement total de revêtement sur le substrat en carton, sur une base sèche de 8,1 g/m2 à 19,5 g/m2 (5 à 12 lb pour 3 000 pi2).
EP17751962.6A 2016-08-08 2017-08-04 Carton compostable presentant une résistance à l'huile, à la graisse et à l'humidité Revoked EP3497282B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15/230,896 US9670621B2 (en) 2015-02-11 2016-08-08 Compostable paperboard with oil, grease, and moisture resistance
PCT/US2017/045412 WO2018031387A1 (fr) 2016-08-08 2017-08-04 Carton compostable presentant une résistance à l'huile, à la graisse et à l'humidité

Publications (3)

Publication Number Publication Date
EP3497282A1 EP3497282A1 (fr) 2019-06-19
EP3497282B1 true EP3497282B1 (fr) 2024-01-10
EP3497282C0 EP3497282C0 (fr) 2024-01-10

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EP17751962.6A Revoked EP3497282B1 (fr) 2016-08-08 2017-08-04 Carton compostable presentant une résistance à l'huile, à la graisse et à l'humidité

Country Status (5)

Country Link
EP (1) EP3497282B1 (fr)
CN (1) CN109790686B (fr)
BR (1) BR112019002654B1 (fr)
ES (1) ES2969258T3 (fr)
WO (1) WO2018031387A1 (fr)

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Publication number Priority date Publication date Assignee Title
US11549216B2 (en) 2020-11-11 2023-01-10 Sappi North America, Inc. Oil/grease resistant paper products

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Also Published As

Publication number Publication date
CN109790686A (zh) 2019-05-21
CN109790686B (zh) 2022-03-15
WO2018031387A1 (fr) 2018-02-15
EP3497282A1 (fr) 2019-06-19
ES2969258T3 (es) 2024-05-17
EP3497282C0 (fr) 2024-01-10
BR112019002654A2 (pt) 2019-05-28
BR112019002654B1 (pt) 2023-04-11

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