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WO2025133896A1 - Carton ondulé comprenant un revêtement revêtu de polymère - Google Patents

Carton ondulé comprenant un revêtement revêtu de polymère Download PDF

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Publication number
WO2025133896A1
WO2025133896A1 PCT/IB2024/062746 IB2024062746W WO2025133896A1 WO 2025133896 A1 WO2025133896 A1 WO 2025133896A1 IB 2024062746 W IB2024062746 W IB 2024062746W WO 2025133896 A1 WO2025133896 A1 WO 2025133896A1
Authority
WO
WIPO (PCT)
Prior art keywords
liner
corrugated board
fdca
corrugated
coating layer
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.)
Pending
Application number
PCT/IB2024/062746
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English (en)
Inventor
Ville RIBU
Kaj Backfolk
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stora Enso Oyj
Original Assignee
Stora Enso Oyj
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Stora Enso Oyj filed Critical Stora Enso Oyj
Publication of WO2025133896A1 publication Critical patent/WO2025133896A1/fr
Pending legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/28—Layered products comprising a layer of synthetic resin comprising synthetic resins not wholly covered by any one of the sub-groups B32B27/30 - B32B27/42
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/06—Layered products comprising a layer of paper or cardboard specially treated, e.g. surfaced, parchmentised
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/08—Corrugated paper or cardboard
    • C—CHEMISTRY; METALLURGY
    • C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09D—COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR
    • C09D167/00—Coating compositions based on polyesters obtained by reactions forming a carboxylic ester link in the main chain; Coating compositions based on derivatives of such polymers
    • C09D167/02—Polyesters derived from dicarboxylic acids and dihydroxy compounds
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H17/00—Non-fibrous material added to the pulp, characterised by its constitution; Paper-impregnating material characterised by its constitution
    • D21H17/03—Non-macromolecular organic compounds
    • D21H17/05—Non-macromolecular organic compounds containing elements other than carbon and hydrogen only
    • D21H17/14—Carboxylic acids; Derivatives thereof
    • D21H17/15—Polycarboxylic acids, e.g. maleic acid
    • 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
    • D21H19/10—Coatings without pigments
    • D21H19/14—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12
    • D21H19/24—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
    • D21H19/28—Polyesters
    • 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
    • D21H19/80—Paper comprising more than one coating
    • D21H19/82—Paper comprising more than one coating superposed
    • 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
    • D21H19/80—Paper comprising more than one coating
    • D21H19/84—Paper comprising more than one coating on both sides of the substrate
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
    • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
    • D21H27/30—Multi-ply
    • D21H27/40—Multi-ply at least one of the sheets being non-planar, e.g. crêped
    • D—TEXTILES; PAPER
    • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
    • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
    • D21J1/00—Fibreboard
    • D21J1/08—Impregnated or coated fibreboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/26—Polymeric coating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/538—Roughness
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/704—Crystalline
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/718—Weight, e.g. weight per square meter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7244—Oxygen barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/724—Permeability to gases, adsorption
    • B32B2307/7242—Non-permeable
    • B32B2307/7246—Water vapor barrier
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles
    • B32B2439/70—Food packaging
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08G—MACROMOLECULAR COMPOUNDS OBTAINED OTHERWISE THAN BY REACTIONS ONLY INVOLVING UNSATURATED CARBON-TO-CARBON BONDS
    • C08G63/00—Macromolecular compounds obtained by reactions forming a carboxylic ester link in the main chain of the macromolecule
    • C08G63/02—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds
    • C08G63/12—Polyesters derived from hydroxycarboxylic acids or from polycarboxylic acids and polyhydroxy compounds derived from polycarboxylic acids and polyhydroxy compounds
    • C08G63/16—Dicarboxylic acids and dihydroxy compounds
    • C08G63/18—Dicarboxylic acids and dihydroxy compounds the acids or hydroxy compounds containing carbocyclic rings
    • C08G63/181—Acids containing aromatic rings

Definitions

  • Corrugated medium is formed from paper or paperboard which has been corrugated using heat, moisture and pressure using a corrugator.
  • Another solution is to provide a barrier layer on the liner to reduce the penetration of oil, fat,, grease, water and water vapor.
  • Barrier layers typically reduce the recyclability of the materials and it also make the material less sustainable.
  • Extrusion coating is a process by which a molten polymer material is applied to a substrate, such as paper or paperboard to form a very thin, smooth and uniform coating layer.
  • the coating can be formed by the extruded polymer itself, or the molten polymer can be used as an adhesive to laminate a solid polymer film onto the substrate.
  • Common polymer resins used in extrusion coating include polyethylene (PE), polypropylene (PP), and polyethylene terephthalate (PET).
  • PE polyethylene
  • PP polypropylene
  • PET polyethylene terephthalate
  • a big disadvantage with these polymers, such as PE and PET is that they are fossilbased polymers and their production and disposal have negative environmental impacts. There is therefore a need to find more sustainable polymers when making polymer coated paper or paperboard. Also, many of these polymer materials does not withstand too high temperatures.
  • PET Polyethylene terephthalate
  • Furandicarboxylic acid (FDCA) based polymers are a more sustainable polymer options since these are derived from renewable sources, such as vegetable or plant-based feedstocks like wood, sugarcane, sugar beet, or other agricultural crops or residues. These are then converted to saccharides such as fructose or glucose and then to intermediates before obtaining the FDCA. This bio-based origin of FDCA based polymers makes it more environmentally friendly.
  • FDCA based polymers such as polyethylene furanoate (PEF)
  • PEF polyethylene furanoate
  • a corrugated board comprising at least one liner and at least one corrugated medium, wherein said at least one liner comprises a first polymer coating layer formed by extrusion coating of a furandicarboxylic acid (FDCA) based resin onto at least one surface of the liner wherein the FDCA based resin comprises at least 50 % by weight of a FDCA based polymer.
  • FDCA furandicarboxylic acid
  • corrugated board has been found that by coating a liner with a FDCA based resin it is possible to provide a corrugated board with improved barrier properties and that is more sustainable.
  • the coated corrugated can also be produced at a lower grammage and with improved mechanical properties.
  • the corrugated board has been found to be able to package many grease and fat products, such as pizza, bakery products, fresh food products, including fish and berries as well as frozen food products.
  • the FDCA based resin comprises at least 70 % by weight, preferably at least 90 % by weight, of the FDCA based polymer.
  • the FDCA based resin of the invention may also consist, or substantially consist, of the FDCA based polymer.
  • it is preferred that the FDCA resin consists, or substantially consists, of the same FDCA polymer since such mono-material coating is easier to recycle.
  • the FDCA based polymer preferably has a melting temperature above 170 °C, preferably above 190 °C, the melting temperature is preferably between 170-270 °C and even more preferred between 190-255 °C, preferably between 200-225 °C.
  • the melting temperature is determined by differential scanning calorimetry according to standard ASTM D3418-21 .
  • it needs to be able to withstand heat treatment, for example if pre-heating and condition of the liner prior to attachment of the corrugated medium, and afterwards when attaching the corrugated medium which has a high temperature after being conducted through the corrugator.
  • the process might further include additional drying or curing steps, including steam treatment.
  • the FDCA based polymer preferably has an intrinsic viscosity of less than 0.9 dl/g, preferably between 0.5-0.9 dl/g, as determined according to ISO 1628. It has been found that the use of a FDCA based polymer with the mentioned intrinsic viscosity will improve the bonding of the FDCA based resin to the liner and the runnability of the polymer in the extruder. It is also believed that the FDCA based polymer with the lower intrinsic viscosity would be less prone to degradation compared other polymers such as PET.
  • the FDCA based polymer preferably has a crystallinity of between 5-40%, preferably between 10-35% and even more preferred between 15-25%. Crystallinity is measured according to ASTM E794-06 (2016). Low crystallinity is preferred since it will improve heat or ultrasonic sealability properties and adhesion of the FDCA based polymer. Also, the stability, stretchability and barrier properties has also been found to improve for FDCA based polymers having a lower crystallinity.
  • the FDCA based resin also comprises a FDCA based polymer having an intrinsic viscosity of 0.9 dl/g or higher, as determined according to ISO 1628.
  • the FDCA based resin comprises 1-50 % by weight of a FDCA based polymer having an intrinsic viscosity 0.9-1 .2 dl/g, as determined according to ISO 1628. It can be an advantage to use a mixture of FDCA based polymers having different intrinsic viscosity. FDCA based polymers with a higher intrinsic viscosity will contribute to improved mechanical and barrier properties of the polymer coating.
  • the formulation of a resin used for coating may vary greatly depending on the intended use of the coated linerboard.
  • the FDCA based resin may include a wide range of ingredients in varying quantities to improve the end performance of the product or processing of the coating.
  • the FDCA based resin can also comprise other polymeric or non-polymeric coating components.
  • the FDCA based resin can be a blend of the FDCA based polymer and another polymer.
  • the FDCA based resin preferably comprises at least one additional component selected from the group consisting of a polymer other than a FDCA based polymer, a colorant, (e.g. Titanium dioxide or carbon black), a dye, a filler or a pigment (e.g. CaCOs or talc).
  • the FDCA based resin my also comprise other additives such as lubricants, slip agents, plasticizers, antioxidants and/or UV stabilizers.
  • the term coating refers to an operation in which the surface of a substrate is covered with a composition to impart a desired properties, finish or texture to the substrate.
  • the coating can be applied to one side or both sides of the liner. It is preferred that the coating is only applied to one side of the liner.
  • the coating may be added by extrusion coating or lamination.
  • the first coating layer is the only coating layer applied to the liner.
  • the first coating layer is a single coating layer.
  • the first coating layer is a multiply coating layer.
  • the first coating layer is preferably located on the inside and/or outside of the corrugated board
  • the liner may also comprise at least one second coating layer disposed on top of the first coating layer. It may be preferred to add more than one coating layer on the liner to form a multilayer coating.
  • the second coating layer can have the same composition as the first coating layer.
  • the FDCA based coating layer provides good stability of the film formation and adhesion of the FDCA based resin to the liner, it may preferably be used as the first (or innermost) coating layer applied directly onto the liner surface.
  • the extrusion coated FDCA based coating layer may serve to promote adhesion of subsequently applied or coextruded polymeric coating layers.
  • the extrusion coated FDCA based coating layer may serve as an adhesive for a polymeric film in an extrusion film lamination process.
  • the liner extrusion coated with the FDCA based resin further comprises at least one additional polymeric coating layer disposed on top of the extrusion coated FDCA based resin, wherein the additional polymeric coating layer has a composition different from the extrusion coated FDCA based resin.
  • the second coating layer has a different composition than the first coating layer.
  • the second coating layer preferably comprises a FDCA based polymer, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP) and/or polylactic acid (PLA).
  • the at least one additional coating layer comprises polyethylene furanoate (PEF).
  • the at least one additional coating layer is formed by extrusion coating or by extrusion film lamination.
  • the first and eventual second coating layer/s are preferably applied to the liner at a combined grammage of less than 60 gsm, preferably less than 50 gsm, more preferably less than 40 gsm, measured according to ISO 536. It may be preferred that the first and eventual second coating layer/s is applied in an amount of 10-60 gsm, preferably between 15-50 gsm and even more preferred between 20-40 gsm, measured according to ISO 536. It has been found that it is possible to add small amount of coating layer/s and still be able to achieve sufficient adhesion and stability of the film.
  • the FDCA based polymer is preferably polyethylene furanoate (PEF), polybutylene furanoate (PBF), polytrimethylene furandicarboxylate (PTF), polypentamehylene furanoate (PPeF), polyheamethylene furanoate (PHF) or polypropylene furanotate (PPF). It is preferred that the FDCA based polymer is polyethylene furanoate (PEF).
  • the corrugated board preferably has a grammage between 60-500 gsm, measured according to ISO 536, even more preferred between 150-350 gsm, preferably between 150-250 gsm.
  • the the liner and/or corrugated medium preferably has a grammage between 20-250 gsm, preferably between 50-200 gsm and even more preferred between 80 and 150 gsm, measured according to ISO 536. It has been found that it is possible to reduce the grammage of the corrugated board and still be able to stable corrugated board having very good barrier properties.
  • the corrugated board preferably has a water vapor transmission rate (WVTR) below 50 g/m2/day at 23 C/50% RH measured according to ASTM D1249-20, preferably below 20 g/m2/day at 23 C/50% RH.
  • WVTR water vapor transmission rate
  • the coated side of the corrugated board preferably has less than 5 pinholes/m 2 , preferably less than 3 pinholes/m 2 , and more preferably less than 1 pinhole/m 2 , as determined according to EN13676:2001 . It is important that the FDCA based coating layer has very low amount of pinholes in order be able to provide a good barrier, especially good water, oil, fat or grease barrier.
  • the corrugated board preferably has a KIT value above 11 , preferably above 12, measured according to TAPPI T559.
  • KIT is a value of grease resistance. It is important that the corrugated board has improved grease resistance.
  • the corrugated board preferably also has a fat resistance above 48 hours, preferably above 56 hours, according to the modified ASTM F119-82 method evaluated at 60 °C and 0% RH. It is important that the corrugated board has a very high fat resistance which makes it suitable for packaging greasy products, such as pizza, bakery products, fresh food products, including fish and berries as well as frozen food products.
  • the liner can be a kraftliner, testliner or a white top liner.
  • the liner may have a primer layer located between the liner and the first coating layer.
  • the primer layer preferably has a grammage of 1-12 gsm, preferably 2-10 gsm.
  • the primer layer will improve the adhesion of the first coating layer to the liner. It is preferred that the primer layer also is stable after heat treatment.
  • the primer layer may comprise starch, carboxymethyl cellulose (CMC), m icrofibrillated cellulose, polyvinyl alcohol (PVOH), polyvinyl amine (PVAm), polyethylene imine (PEI), organosilanes, polyurethane, melamine, epoxy-based primers and/or acrylic co-polymers. It is also possible to add pigment into the primer layer to improve the light barrier properties.
  • the corrugated board according to the present invention comprises at least one liner and at least one corrugated medium. It may be preferred that the corrugated board comprises at least two liners and at least one corrugated medium. It is preferred that the corrugated medium is located between the at least two liners. It is preferred that only one of the at least two liners is coated with the first polymer coating layer. It is preferred that the first polymer coating layer is located on the outer side of the liner, i.e. the side not in contact with the corrugated medium.
  • the other of the at least two liners may comprise at least one additional coating layer added to the side of the liner that is not in contact with the corrugated medium.
  • the additional coating layer is preferably located on the outside on a package formed from the coated corrugated board.
  • the additional coating layer may comprise a FDCA based polymer, polyethylene terephthalate (PET), polyethylene (PE), polypropylene (PP) and/or polylactic acid (PLA).
  • a method for manufacturing a corrugated board comprising the steps of: providing a containerboard substrate, subjecting the containerboard substrate through a corrugator to form a corrugated medium, providing at least one liner, providing a FDCA based resin, applying the FDCA based resin onto the at least one liner by extrusion coating to form a first coating layer, applying an adhesive to at least one surface of the corrugated medium, attaching said corrugated medium to said liner in such way that the adhesive is located between the corrugated medium and the liner to form the corrugated board, wherein the FDCA based resin comprises at least 50 % by weight of a FDCA based polymer.
  • the containerboard substrate used to form the corrugated medium and the liner can be a single or multiply structure being manufactured in a paper or paperboard machine adapted for manufacturing of multiply containerboard.
  • the containerboard substrate and/or liner can be a multiply structure.
  • Paper or paperboard machines for making containerboard are well known in the art.
  • the machine layout comprises a stock handling section, a wet end section, a pressing and drying section and optionally a calendaring and/or coating section.
  • the ply or plies may be formed individually, using different headboxes and laminated in a wet state, or formed together in a multiply headbox. If formed individually, the plies are typically laminated before the press and drying section of the paper machine.
  • the method may further comprise the step of pre-heating the liner to a temperature of at least 100 °C, or more preferably at least 120 °C, and more preferably at least 140 °C, before the liner is attached to the corrugated medium.
  • the pre-heating is preferably done by steam and/or heat.
  • the liner is coated with the FDCA based coating before pre-heating and formation of the corrugated board. It is therefore crucial for the FDCA based polymer to be able to withstand high temperatures and to be thermally stable. It has been found that the FDCA based coating according to the invention is thermally stable and would provide the liner and thus the corrugated board with good barrier properties, especially moisture and grease resistance, also after being subjected to the formation of the corrugated board.
  • the FDCA based resin may also be applied to the liner after the corrugated board is formed.
  • the method may also comprise the step of cooling the first coating layer in a chill roll at a temperature of between 5-60 °C for a time of at least 0.15 s, preferably between 0.15-10 seconds after extrusion coating. It may be possible to use more than one chill roll placed subsequent of each other during the cooling step. It is important to cool the extruded FDCA resin for a sufficient time, especially when extruding a FDCA based polymer, in order to achieve sufficient adhesion to the liner.
  • the corrugator is preferably operated at a temperature above 125°C, preferably between 125-190 °C.
  • the high temperature is needed in order to be able to corrugate the containerboard substrate. Since the process for making corrugated board is done at a high temperature it has been found that the use of a FDCA based resin is especially suitable as a coating in corrugated board since it is stable at high temperatures and also after being subjected to high temperatures.
  • the FDCA based coated liner is normally not treated in the corrugator. However, the attachment of the liner to the formed corrugated medium is normally done in-line close to the corrugator which means that the corrugated medium still has a high temperature when the liner is attached.
  • the method may further comprise the step of drying the liner to a moisture content of between 5-14 % by weight before application of the FDCA based coating, preferably between 8-11 % by weight.
  • the moisture content is measured according to ISO 287.
  • the corrugated medium and liner(s) are attached to each other by arranging an adhesive between the corrugated medium and liner(s).
  • the liner is attached to at least one surface of the corrugated medium by the adhesive.
  • the adhesive is preferably applied on a least one surface of the fluted corrugated medium and the liner is thereafter attached to said surface. Any conventional adhesives in the area may be used.
  • the adhesive may for example be a glue that is based on starch that can be extracted from a wide variety of plants. Some of the most common plants are maize, wheat, barley, rice, potato, tapioca and peas.
  • the starch is preferably native, i.e. no modification of the starch has been done.
  • the adhesive may also comprise water, sodium hydroxide and cross-linker such as MFC or boric acid.
  • Other additives such as additives to improve the wet strength or adhesive bond strength may also be added.
  • other functional chemicals in order to improve e.g. moisture resistance or gelling behavior can be added, e.g. borax, glyoxal or mixtures thereof.
  • the adhesive is preferably a starch-based adhesive.
  • the corrugated medium and/or liner comprises cellulosic pulp.
  • the cellulosic pulp may be hardwood pulp or softwood pulp, or a mixture thereof.
  • the hardwood may for example be aspen, alder, poplar, eucalyptus, birch, acacia, or beech.
  • Softwood pulp may for example be spruce or pine.
  • the cellulosic pulp may be chemical pulp, mechanical pulp, thermomechanical pulp or chemi-thermomechanical pulp (CTMP).
  • CMP chemi-thermomechanical pulp
  • the cellulosic pulp may preferably be neutral sulfite semi chemical (NSSC) pulp.
  • the cellulosic pulp may be bleach or unbleached pulp.
  • the cellulosic pulp may comprise virgin and/or recycled fibers.
  • the corrugated medium and/or liner(s) may comprise an internal sizing agent.
  • the internal sizing agent is preferably a hydrophobizing sizing agent.
  • the internal sizing agent is selected form the group consisting of alkyl ketene dimer (AKD), alkenyl succinic anhydride (ASA), rosin sizes, and mixtures thereof.
  • the unit “% by weight” mentioned in the present disclosure refers to % by weight of the total dry weight of the relevant layer, composition, resin or the like.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Organic Chemistry (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un carton ondulé comprenant au moins un revêtement et au moins un support ondulé, le ou les revêtements comprenant une première couche de revêtement polymère formée par revêtement par extrusion d'une résine à base d'acide furandicarboxylique (FDCA) sur au moins une surface du revêtement, caractérisé en ce que la résine à base de FDCA comprend au moins 50 % en poids d'un polymère à base de FDCA. La présente invention concerne également un procédé permettant de fabriquer ledit carton ondulé.
PCT/IB2024/062746 2023-12-21 2024-12-17 Carton ondulé comprenant un revêtement revêtu de polymère Pending WO2025133896A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2330599A SE2330599A1 (en) 2023-12-21 2023-12-21 Corrugated board comprising a polymer coated liner
SE2330599-8 2023-12-21

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WO2025133896A1 true WO2025133896A1 (fr) 2025-06-26

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EP3501816A1 (fr) * 2017-12-22 2019-06-26 Tetra Laval Holdings & Finance S.A. Film de barrière et matériau d'emballage stratifié comprenant le film et récipient d'emballage réalisé à partir de ceux-ci
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