WO1996038296A1 - Procede et dispositif de fabrication de carton ondule - Google Patents
Procede et dispositif de fabrication de carton ondule Download PDFInfo
- Publication number
- WO1996038296A1 WO1996038296A1 PCT/US1996/007180 US9607180W WO9638296A1 WO 1996038296 A1 WO1996038296 A1 WO 1996038296A1 US 9607180 W US9607180 W US 9607180W WO 9638296 A1 WO9638296 A1 WO 9638296A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- medium
- board
- coating
- corrugated
- exterior
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims description 45
- 238000004519 manufacturing process Methods 0.000 title claims description 24
- 238000000576 coating method Methods 0.000 claims abstract description 133
- 239000011248 coating agent Substances 0.000 claims abstract description 110
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 73
- 239000001993 wax Substances 0.000 claims abstract description 64
- 239000003292 glue Substances 0.000 claims abstract description 58
- 229920003048 styrene butadiene rubber Polymers 0.000 claims abstract description 44
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims abstract description 34
- 239000000945 filler Substances 0.000 claims abstract description 31
- -1 polyethylene Polymers 0.000 claims abstract description 29
- TZCXTZWJZNENPQ-UHFFFAOYSA-L barium sulfate Chemical compound [Ba+2].[O-]S([O-])(=O)=O TZCXTZWJZNENPQ-UHFFFAOYSA-L 0.000 claims abstract description 28
- 239000000839 emulsion Substances 0.000 claims abstract description 23
- 239000002245 particle Substances 0.000 claims abstract description 20
- 239000004698 Polyethylene Substances 0.000 claims abstract description 11
- 229920000573 polyethylene Polymers 0.000 claims abstract description 11
- 239000004203 carnauba wax Substances 0.000 claims abstract description 10
- 235000013869 carnauba wax Nutrition 0.000 claims abstract description 10
- 239000000203 mixture Substances 0.000 claims description 49
- 229920001577 copolymer Polymers 0.000 claims description 45
- 239000007864 aqueous solution Substances 0.000 claims description 34
- 239000002174 Styrene-butadiene Substances 0.000 claims description 30
- MTAZNLWOLGHBHU-UHFFFAOYSA-N butadiene-styrene rubber Chemical compound C=CC=C.C=CC1=CC=CC=C1 MTAZNLWOLGHBHU-UHFFFAOYSA-N 0.000 claims description 30
- 235000013305 food Nutrition 0.000 claims description 30
- 239000011115 styrene butadiene Substances 0.000 claims description 30
- 239000004971 Cross linker Substances 0.000 claims description 20
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 claims description 20
- 239000004202 carbamide Substances 0.000 claims description 20
- XTXRWKRVRITETP-UHFFFAOYSA-N Vinyl acetate Chemical compound CC(=O)OC=C XTXRWKRVRITETP-UHFFFAOYSA-N 0.000 claims description 19
- 238000010438 heat treatment Methods 0.000 claims description 18
- IVJISJACKSSFGE-UHFFFAOYSA-N formaldehyde;1,3,5-triazine-2,4,6-triamine Chemical compound O=C.NC1=NC(N)=NC(N)=N1 IVJISJACKSSFGE-UHFFFAOYSA-N 0.000 claims description 16
- PEDCQBHIVMGVHV-UHFFFAOYSA-N Glycerine Chemical compound OCC(O)CO PEDCQBHIVMGVHV-UHFFFAOYSA-N 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 14
- NJVOHKFLBKQLIZ-UHFFFAOYSA-N (2-ethenylphenyl) prop-2-enoate Chemical compound C=CC(=O)OC1=CC=CC=C1C=C NJVOHKFLBKQLIZ-UHFFFAOYSA-N 0.000 claims description 12
- 229910052783 alkali metal Inorganic materials 0.000 claims description 12
- 229940072056 alginate Drugs 0.000 claims description 11
- 235000010443 alginic acid Nutrition 0.000 claims description 11
- 229920000615 alginic acid Polymers 0.000 claims description 11
- 239000004593 Epoxy Substances 0.000 claims description 10
- 239000004642 Polyimide Substances 0.000 claims description 10
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 claims description 10
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 claims description 10
- 229920000728 polyester Polymers 0.000 claims description 10
- 229920001721 polyimide Polymers 0.000 claims description 10
- 239000004408 titanium dioxide Substances 0.000 claims description 9
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 claims description 8
- 239000005977 Ethylene Substances 0.000 claims description 8
- 238000010025 steaming Methods 0.000 claims description 8
- 239000000758 substrate Substances 0.000 claims description 8
- IXPNQXFRVYWDDI-UHFFFAOYSA-N 1-methyl-2,4-dioxo-1,3-diazinane-5-carboximidamide Chemical group CN1CC(C(N)=N)C(=O)NC1=O IXPNQXFRVYWDDI-UHFFFAOYSA-N 0.000 claims description 7
- 235000011187 glycerol Nutrition 0.000 claims description 7
- 235000010413 sodium alginate Nutrition 0.000 claims description 7
- 239000000661 sodium alginate Substances 0.000 claims description 7
- 229940005550 sodium alginate Drugs 0.000 claims description 7
- 241000196324 Embryophyta Species 0.000 claims description 6
- 229920000098 polyolefin Polymers 0.000 claims description 6
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 claims description 5
- 229920003192 poly(bis maleimide) Polymers 0.000 claims description 5
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 claims description 4
- 150000003673 urethanes Chemical class 0.000 claims 6
- 238000004132 cross linking Methods 0.000 claims 3
- 230000000977 initiatory effect Effects 0.000 claims 3
- 239000002609 medium Substances 0.000 description 62
- 239000000853 adhesive Substances 0.000 description 25
- 230000001070 adhesive effect Effects 0.000 description 25
- 239000008199 coating composition Substances 0.000 description 20
- 239000000047 product Substances 0.000 description 16
- 238000004026 adhesive bonding Methods 0.000 description 15
- 229920000591 gum Polymers 0.000 description 11
- 239000007787 solid Substances 0.000 description 11
- 229920002472 Starch Polymers 0.000 description 10
- 239000004615 ingredient Substances 0.000 description 10
- 239000008107 starch Substances 0.000 description 10
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- 239000000463 material Substances 0.000 description 7
- 238000004806 packaging method and process Methods 0.000 description 7
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 6
- 239000008280 blood Substances 0.000 description 6
- 210000004369 blood Anatomy 0.000 description 6
- 239000011436 cob Substances 0.000 description 6
- 239000004519 grease Substances 0.000 description 6
- 239000003921 oil Substances 0.000 description 6
- 239000011148 porous material Substances 0.000 description 6
- 238000011282 treatment Methods 0.000 description 6
- 229920001730 Moisture cure polyurethane Polymers 0.000 description 5
- 230000033228 biological regulation Effects 0.000 description 5
- 230000005540 biological transmission Effects 0.000 description 5
- 238000001816 cooling Methods 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 229920001038 ethylene copolymer Polymers 0.000 description 4
- 229920000877 Melamine resin Polymers 0.000 description 3
- CNCOEDDPFOAUMB-UHFFFAOYSA-N N-Methylolacrylamide Chemical compound OCNC(=O)C=C CNCOEDDPFOAUMB-UHFFFAOYSA-N 0.000 description 3
- 150000003926 acrylamides Chemical class 0.000 description 3
- 230000009471 action Effects 0.000 description 3
- 239000003431 cross linking reagent Substances 0.000 description 3
- 229940079593 drug Drugs 0.000 description 3
- 239000003814 drug Substances 0.000 description 3
- HDERJYVLTPVNRI-UHFFFAOYSA-N ethene;ethenyl acetate Chemical group C=C.CC(=O)OC=C HDERJYVLTPVNRI-UHFFFAOYSA-N 0.000 description 3
- 239000012467 final product Substances 0.000 description 3
- 230000006872 improvement Effects 0.000 description 3
- 238000005304 joining Methods 0.000 description 3
- 239000002655 kraft paper Substances 0.000 description 3
- 239000007788 liquid Substances 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 238000004064 recycling Methods 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 229920000084 Gum arabic Polymers 0.000 description 2
- 235000010489 acacia gum Nutrition 0.000 description 2
- 239000000205 acacia gum Substances 0.000 description 2
- 239000002313 adhesive film Substances 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
- 235000013372 meat Nutrition 0.000 description 2
- 239000000123 paper Substances 0.000 description 2
- 239000012188 paraffin wax Substances 0.000 description 2
- 238000007639 printing Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 238000010998 test method Methods 0.000 description 2
- LWIHDJKSTIGBAC-UHFFFAOYSA-K tripotassium phosphate Chemical compound [K+].[K+].[K+].[O-]P([O-])([O-])=O LWIHDJKSTIGBAC-UHFFFAOYSA-K 0.000 description 2
- BNCADMBVWNPPIZ-UHFFFAOYSA-N 2-n,2-n,4-n,4-n,6-n,6-n-hexakis(methoxymethyl)-1,3,5-triazine-2,4,6-triamine Chemical compound COCN(COC)C1=NC(N(COC)COC)=NC(N(COC)COC)=N1 BNCADMBVWNPPIZ-UHFFFAOYSA-N 0.000 description 1
- 244000215068 Acacia senegal Species 0.000 description 1
- 244000106483 Anogeissus latifolia Species 0.000 description 1
- 235000011514 Anogeissus latifolia Nutrition 0.000 description 1
- 241000416162 Astragalus gummifer Species 0.000 description 1
- 229920002134 Carboxymethyl cellulose Polymers 0.000 description 1
- 229920003270 Cymel® Polymers 0.000 description 1
- 241000282326 Felis catus Species 0.000 description 1
- 229920002907 Guar gum Polymers 0.000 description 1
- 239000001922 Gum ghatti Substances 0.000 description 1
- 229920000569 Gum karaya Polymers 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- 229920000161 Locust bean gum Polymers 0.000 description 1
- CERQOIWHTDAKMF-UHFFFAOYSA-N Methacrylic acid Chemical compound CC(=C)C(O)=O CERQOIWHTDAKMF-UHFFFAOYSA-N 0.000 description 1
- 241000203482 Polyscias Species 0.000 description 1
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 1
- 240000004584 Tamarindus indica Species 0.000 description 1
- 235000004298 Tamarindus indica Nutrition 0.000 description 1
- 229920001615 Tragacanth Polymers 0.000 description 1
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- 239000012736 aqueous medium Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 239000002585 base Substances 0.000 description 1
- CJZGTCYPCWQAJB-UHFFFAOYSA-L calcium stearate Chemical compound [Ca+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O CJZGTCYPCWQAJB-UHFFFAOYSA-L 0.000 description 1
- 235000013539 calcium stearate Nutrition 0.000 description 1
- 239000008116 calcium stearate Substances 0.000 description 1
- 150000001732 carboxylic acid derivatives Chemical class 0.000 description 1
- 235000010418 carrageenan Nutrition 0.000 description 1
- 239000000679 carrageenan Substances 0.000 description 1
- 229920001525 carrageenan Polymers 0.000 description 1
- 229940113118 carrageenan Drugs 0.000 description 1
- 239000000969 carrier Substances 0.000 description 1
- 235000013339 cereals Nutrition 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
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- 230000006735 deficit Effects 0.000 description 1
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- 239000003599 detergent Substances 0.000 description 1
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- 239000000665 guar gum Substances 0.000 description 1
- 229960002154 guar gum Drugs 0.000 description 1
- 235000019314 gum ghatti Nutrition 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 239000013071 indirect material Substances 0.000 description 1
- 235000010494 karaya gum Nutrition 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 235000010420 locust bean gum Nutrition 0.000 description 1
- 239000000711 locust bean gum Substances 0.000 description 1
- JDSHMPZPIAZGSV-UHFFFAOYSA-N melamine Chemical group NC1=NC(N)=NC(N)=N1 JDSHMPZPIAZGSV-UHFFFAOYSA-N 0.000 description 1
- 239000000155 melt Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 235000019809 paraffin wax Nutrition 0.000 description 1
- 229920001277 pectin Polymers 0.000 description 1
- 239000001814 pectin Substances 0.000 description 1
- 235000010987 pectin Nutrition 0.000 description 1
- 235000019271 petrolatum Nutrition 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 229920002689 polyvinyl acetate Polymers 0.000 description 1
- 239000011118 polyvinyl acetate Substances 0.000 description 1
- 229910052700 potassium Inorganic materials 0.000 description 1
- 239000011591 potassium Substances 0.000 description 1
- 229910000160 potassium phosphate Inorganic materials 0.000 description 1
- 235000011009 potassium phosphates Nutrition 0.000 description 1
- 244000144977 poultry Species 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000010926 purge Methods 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 235000014102 seafood Nutrition 0.000 description 1
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- 239000002562 thickening agent Substances 0.000 description 1
- 238000004078 waterproofing Methods 0.000 description 1
- 230000004584 weight gain Effects 0.000 description 1
- 235000019786 weight gain Nutrition 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 229920001285 xanthan gum Polymers 0.000 description 1
- 235000010493 xanthan gum Nutrition 0.000 description 1
- 239000000230 xanthan gum Substances 0.000 description 1
- 229940082509 xanthan gum Drugs 0.000 description 1
- UHVMMEOXYDMDKI-JKYCWFKZSA-L zinc;1-(5-cyanopyridin-2-yl)-3-[(1s,2s)-2-(6-fluoro-2-hydroxy-3-propanoylphenyl)cyclopropyl]urea;diacetate Chemical compound [Zn+2].CC([O-])=O.CC([O-])=O.CCC(=O)C1=CC=C(F)C([C@H]2[C@H](C2)NC(=O)NC=2N=CC(=CC=2)C#N)=C1O UHVMMEOXYDMDKI-JKYCWFKZSA-L 0.000 description 1
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
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/08—Corrugated 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
- B32B29/00—Layered products comprising a layer of paper or cardboard
- B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B29/005—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to another layer of paper or cardboard layer
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
- B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
- B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
-
- 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
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/04—Interconnection of layers
- B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
-
- 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
- B32B2310/00—Treatment by energy or chemical effects
- B32B2310/04—Treatment by energy or chemical effects using liquids, gas or steam
-
- 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
- B32B2317/00—Animal or vegetable based
- B32B2317/12—Paper, e.g. cardboard
- B32B2317/127—Corrugated 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
- B32B2553/00—Packaging equipment or accessories not otherwise provided for
-
- 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
- D21H19/18—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising waxes
-
- 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
- D21H19/20—Coatings without pigments applied in a form other than the aqueous solution defined in group D21H19/12 comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
-
- 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
Definitions
- This invention relates to a water and moisture resistant corrugated board. More particularly, this invention relates to a water and moisture resistant corrugated board that can be repulped and recycled. Additionally, this invention relates to improvements in the manufacturing techniques for corrugated board.
- Corrugated fiberboard (“board”) containers are used in many high humidity bulk packaging applications, such as in the packaging of fresh produce items.
- To overcome the known impairment in the strength of corrugated board in high humidity service it is known to treat such containers, or the corrugated board sheets or blanks from which the containers are formed, by impregnating them with a wax or wax-based material.
- wax treated containers cannot be repulped and recycled, and this requires that such containers be disposed of after use in an environmentally objectionable way, such as by incineration or disposition in a landfill.
- Such a method of disposition is also economically disadvantageous, since used corrugated containers that are suitable for repulping and recycling, such as those without wax treatment, have a significant resale value.
- wax treated corrugated board In addition to wax treated corrugated board not being repulpable or recyclable, these containers suffer from several other significant shortcomings. These wax treated products have a low strength to weight ratio as compared to the corrugated board of the present invention. This increases the manufacturing costs and distribution costs of these wax treated corrugated boards and the transportation costs of the finished products. Also with other water resistant corrugated boards, particularly those having wax based coatings, the corrugated board is not heat resistant, chemical resistant, blood resistant or grease and oil resistant. Further, wax based corrugated boards are not easily printable or gluable.
- Wax based corrugated boards are not elastic and frequently crack when scores are made.
- a corrugated board produced in accordance with the present invention can be readily scored and otherwise fabricated to permit it to be formed into containers and other useful products. In that regard, it inherently solves a problem that was previously solved at substantial complexity and expense by the construction of U.S. Patent 3,523,058 (Shick) , the disclosure of which is hereby incorporated by reference.
- Known corrugated boards are manufactured by a technique which includes hot set gluing. As compared with the method of the present invention which utilizes cold set gluing, hot set gluing results in higher equipment costs, higher operating costs, and a lower quality product due to warping which is a frequent result of hot set gluing.
- Corrugated board products on the market have flute lines which inhibit printing on one or both sides of the corrugated board.
- Treated corrugated board containers are a practical and cost effective way to ship produce, meats, seafood and other items.
- disposal of the treated corrugated board products, particularly wax coated corrugated board containers, by grocery stores and other end users has been a financial and environmental concern to the industry. It is desirable not only from an environmental standpoint, but also as a source of fiber for recycled paper, corrugated board and other products, to develop a corrugated board which may be repulped and recycled using standard, current mill technology.
- corrugated board that is water and moisture resistant and yet, can be easily made, repulped and recycled in contrast to boards waterproofed by wax.
- a corrugated board which can be manufactured by cold set gluing techniques.
- a repulpable and recyclable corrugated board with satisfactory water and moisture resistance for use in high humidity packaging applications, such as in the packaging of fresh produce items.
- the corrugated board of the present invention utilizes a cold set glue, rather than conventional starch adhesives, to bond the interior and exterior liner boards to the flutes of a corrugated medium that is positioned therebetween.
- the liner boards of the corrugated board are coated, as by rod coating prior to processing on a corrugator, with FDA approved coatings.
- the corrugated medium used in such corrugated board is coated, as by rod coating prior to processing on a corrugator, with an FDA approved coating.
- the present invention provides a double-faced liner board, i.e., corrugated board, comprising an exterior liner board, a medium corrugated layer and an interior liner board, the exterior liner board having a coating comprising (A) an aqueous solution of a styrene-butadiene copolymer, and (B) a filler such as Ti0 2 or barium sulfate; the medium having an aqueous coating composition comprising:
- a mixture of a styrene-acrylate copolymer with a crosslinker (2) a mixture of a styrene-acrylate copolymer with a crosslinker; and the interior liner board having a coating comprising (A) an aqueous solution of a styrene-butadiene copolymer, (B) an aqueous solution of a natural food gum and (C) a non-paraffinic wax, such as carnauba wax or polyethylene.
- FIGURE 1 is a cross sectional view of a sheet of corrugated board according to the preferred embodiment of the present invention.
- FIGURE 2 is a schematic representation of a corrugator which shows the equipment reductions which may be achieved with the inventive cold set gluing.
- a section of a sheet of corrugated board is indicated generally by reference numeral 10 in the drawing, and the corrugated board 10 is made up of an interior, product containing sheet of liner board 12, an exterior sheet of liner board 14, and a corrugated sheet of corrugating medium 16 that is between and adhesively joined to the sheets of liner board 12, 14 at the tips of flutes 16a of the corrugated medium by an glue 18, whose composition will be hereinafter described in more detail.
- the interior sheet of liner board 12 is coated on its interior, product contacting surface with a layer 20 of a coating composition that imparts moisture resistance to the liner board 12 and the corrugated board 10 incorporating the liner board 12.
- the exterior sheet of liner board 14 is coated with a layer 22 of a composition that imparts moisture resistance to the liner board 14 and to the corrugated board 10 that incorporates the liner board 14.
- the coatings 20, 22 may be applied to the liner board sheets 12, 14 prior to the delivery to a commercial corrugator of the rolls from which such liner board sheets 12, 14 are taken, for example, by rod coating, or the coatings 20, 22 may be applied to the liner board sheets 12, 14 on a corrugator as part of the corrugating operation, but prior to the bonding of the corrugating medium 16 thereto, if so desired.
- corrugated medium 16 is also provided with a coating of a moisture resistant composition which becomes impregnated into the corrugated medium as discussed below.
- the moisture resistant coating layer 20 must be in compliance with the Food and Drug Administration regulations for use in food contact surfaces, if the corrugated board 10 is to be used in a food packaging operation, and the coating layer 20 preferably must not inhibit the repulping or recycling of the corrugated board 10 to avoid the need to dispose of the corrugated board 10, after its useful life is completed, by incineration or disposition in a landfill. While the coating layer 22 on the exterior liner board sheet 14 is not expected to be in direct contact with contents packaged in a container formed from the corrugated board 10, and, thus, need not necessarily be subject to Food and Drug Administration regulations, nevertheless there are Food and Drug Administration requirements for indirect components of a food container, and it is important that the coating layer 22 meet such requirements.
- the coating layer 22 must not impede the repulping or recycling of the corrugated board 10.
- the coating layer 22 preferably has a white color, to permit appropriate graphics to be imparted thereto. It is also desirable that the coating layer 22 permit printing of the exterior liner board sheet or the gluing of labels thereon after the completion of the corrugating operation.
- the interior liner board coating composition is prepared by mixing the following ingredients in the approximate percents shown: Ingredients % by Weight
- compositions have a pH of about 8.5 to 9 and viscosity of about 12-13 (#3 Zahn) .
- the "natural food gum” may include any of the commonly known food gums, including alkali metal alginate, carrageenan, guar gum, gum arabic, gum ghatti, gum karaya, gum tragacanth, locust bean gum, pectin, xanthan gum, tamarind gum, acacia gum, agar gum, carboxymethylcellulose (CMC) , and cesapectin.
- alkali metal alginate including carrageenan, guar gum, gum arabic, gum ghatti, gum karaya, gum tragacanth, locust bean gum, pectin, xanthan gum, tamarind gum, acacia gum, agar gum, carboxymethylcellulose (CMC) , and cesapectin.
- CMC carboxymethylcellulose
- the natural food gum which is preferably an alkali metal alginate, serves as a thickener to thicken the water present and the overall coating composition.
- the alkali metal alginate solution is an aqueous solution which includes about 2 wt.% alkali metal alginate.
- the alkali metal alginate is preferably sodium alginate, although potassium and lithium can be used as the alkali metal.
- the percentage of the natural food gum, including sodium alginate is generally set by that amount of the gum which results in a viscosity range of about 20 sec. to about 40 sec. (#3 Zahn) , preferably about 30 sec. (#3 Zahn) .
- the coating is preferably applied in a 36-40% solids concentration at the approximate coating weight of 3 pounds per MSF (thousand square feet) , when applied to a 69 pound kraft liner by a smooth rod in a rod coating operation.
- a cellulosic material, such liner board or a corrugated board formed therefrom, with such a coating has good chemical, blood, grease and oil resistance, as well as good water vapor transmission rate (WVTR, see discussion below) , it has good flexibility at scores, thus permitting fabrication of containers from the corrugated board, and it exhibits good heat resistance when applied before corrugation.
- the corrugated board to which it is applied is fully repulpable and recyclable.
- the interior coating composition is easily applied to a substrate such as a liner board. The composition can be applied rapidly and the resultant coating formed merely by heating the composition to about 110°F to 180°F or above to form the waterproof coating.
- the thickness of the coating is generally about 0.2 to 30 mils and preferably about 1 to 5 mils.
- the styrene-butadiene copolymer is preferably utilized in an aqueous solution.
- the amounts of the aqueous copolymer in the interior coating composition is generally about 30 to 85 percent by weight, preferably about 65 to 75 percent by weight, and optimally, about 68 to 72 percent by weight.
- the amount of butadiene in the copolymer is generally about 25 to 40 percent by weight and preferably about 30 to 35 percent by weight. The optimum amount is generally about 32-33 percent by weight.
- a suitable pre-polymer of a styrene-butadiene copolymer for the interior coating composition is sold by BF Goodrich of Gastonia, NC (formerly sold by Rhone- Poulenc, Specialty Chemical Division) under the product name WRL 70631TM, which contains about 50% water.
- This copolymer may be cured or crosslinked with, for instance, crosslinking agents such as acrylamides including N- methanol acrylamide.
- the styrene-butadiene copolymer may be replaced, less preferably, with a carboxylated styrene-butadiene copolymer.
- the carboxylated pre-polymer can be cured or crosslinked with, for instance, crosslinking agents such as acrylamides including N-methanol acrylamide.
- a suitable carboxylated styrene-butadiene latex is sold by Reichhold Chemical, Research Triangle Park, N.C. as TYLAC® Resin Emulsion 97422-02.
- the carboxylated copolymer is made by reaction with an unsaturated carboxylic acid such as aleic acid or methacrylic acid.
- the non-paraffinic wax is preferably polyethylene or carnauba wax.
- the polyethylene is a liquid (non-solid) low molecular weight polyethylene having a molecular weight of about 1000 to about 2500.
- EMULSION 260TM (Chemical Corp. of America, Rutherford, N.J.) can be used.
- the liquid carnauba wax helps give the resultant coating body, and the wax is commercially available as AS35-3 (Chemical Corp. of America, Rutherford, N.J.).
- Other suitable non-paraffin waxes include other polyolefin based waxes and plant based waxes. Paraffinic waxes are to be avoided, as known coatings using paraffinic waxes either alone or in combination with polymers result in "greasy" surfaces which are generally unprintable and ungluable, i.e., for labels. The coating as described does not result in a "greasy" surface.
- Example 1 An aqueous coating composition was prepared by mixing the following ingredients in the approximate percents: Ingredients % by Weight
- the resulting composition had a pH of about 8.5 to 9 and viscosity of about 12-13 (#3 Zahn)
- the composition was applied to a liner board substrate to form, when heated, a waterproof coating.
- the coating was repulpable and recyclable.
- Example 2 A composition was made as in Example 1 except that a carboxylated styrene-butadiene (33% butadiene) copolymer was used instead of the styrene-butadiene copolymer. Substantially equivalent results were obtained.
- the coating 22 that is applied to the exterior liner board 14 comprises: about 40 wt.% to about 80 wt.% of an aqueous solution of a pre-copolymer of styrene-butadiene or carboxylated styrene-butadiene; and about 20 wt.% to about 60 wt.% of a filler selected from the group comprising titanium dioxide, barium sulfate, fillers which have a WVTR of less than about 1.1 times the WVTR of Ti0 2 at about the same weight percent filler, and combinations thereof;
- the coating is preferably applied in a 60-66% solids concentration at the approximate rate of 4 pounds per MSF to 69 pound liner board, is gluable and printable after application, and has very good weatherability for applications requiring outdoor storage. It has very good chemical, blood, oil and grease resistance, and it does not crack when scored, which enhances the moisture vapor transmission resistance properties of the final product container. Further, the corrugated board 10 is fully repulpable and recyclable when such a coating composition is used for the exterior coating layer 22. With the post-printability and the white coloration of the coating 22, a container fabricated from the corrugated board 10 can be readily printed on, in a single or in multiple colors, to meet the graphics needs or desires of customers.
- the exterior coating composition is easily applied to a substrate such as a liner board.
- the composition can be applied rapidly and the resultant coating formed merely by heating the composition to about 110°F to 180°F or above to form the waterproof coating.
- the exterior coating composition can be used advantageously as an exterior coating of a double faced liner board, the composition being waterproof and being recyclable in contrast to wax coatings.
- the thickness of the coating is generally about 0.2 to 30 mils and preferably about 1 to 5 mils.
- the coatings are measured for waterproof qualities by standard ASTM tests and TAPPI tests including the Cobb test. A lower Cobb value such as 10 to 30 is generally preferred.
- the styrene-butadiene copolymer is preferably utilized in an aqueous solution.
- the amounts of the copolymer in the exterior layer coating composition is generally about 40 to 80% by wt. , preferably about 50 to 70% by wt. , and optimally, about 56 to 62% by wt.
- the amount of butadiene in the copolymer is generally about 5 to 40 percent by weight and preferably about 30 to 35 percent by weight. The optimum amount is generally about 32 - 33 percent by weight.
- the fillers, Ti0 2 , barium sulfate, and other fillers which have a suitable WVTR are generally about 20 - 400 mesh and preferably 200 to 325 mesh in diameter.
- the amount of the filler in coating 22 is generally about 20 wt.% to about 60 wt.%, preferably about 30 wt% to about 50 wt.%, and optimally about 38 wt.% to about 42 wt.%.
- the water vapor transmission rate (WVTR) of a sheet material is the mass of water vapor transmitted from one face of a specimen to the other under given steady conditions.
- the standard unit is g/m 2 /day and for this method, the specimen has an atmosphere approaching 0% RH on one face and 90% RH on the other, at a temperature of 37.8°C (100°F) .
- the water vapor transmission rate may be calculated as follows:
- the quantities x and y can be derived conveniently from a plot of weight gain in grams vs. elapsed time in hours.
- This WVTR is a standard TAPPI test, TAPPI T 464 om- 90, "Gravimetric determination of water vapor transmission rate of sheet materials at high temperature and humidity", said test and testing procedure being incorporated by reference.
- Titanium dioxide and barium sulfate have been found to have acceptable WVTRs. With an exterior coating that has about 40 wt.% Ti0 2 , experiments on exterior liner boards show this coating composition has an acceptable WVTR of about 5 g/m 2 /day. Generally, the lower the wt.% Ti0 2 or barium sulfate, the lower the WVTR. With coatings having fillers other than Ti0 2 and barium sulfate, it is preferable to have a WVTR of less than about 1.1 times titanium dioxide's WVTR at about equal weight percentages of the fillers in their respective coatings.
- the fillers provide the exterior coating with heat resistance which may be desired from a manufacturing point, i.e., the desired ability to withstand high drying or glue setting temperatures, or an end-use point, i.e., the service the corrugated board container is used in.
- a manufacturing point i.e., the desired ability to withstand high drying or glue setting temperatures
- an end-use point i.e., the service the corrugated board container is used in.
- the more filler the more heat resistant the exterior coating is.
- Ti0 2 used as a filler provides a white, opaque exterior liner board appearance.
- Barium sulfate provides a clearer, duller white appearance.
- the exterior coating includes about 1 wt.% to about 12 wt.% glycerine. The higher percentages are less preferred as drying time is increased.
- the exterior coating includes about 1 wt.% to about 4 wt.% glycerine; optimally, about 2 wt.% glycerine.
- the exterior layer coating pre-polymer can be cured or crosslinked with crosslinking agents such as acrylamides including N-methanol acrylamide.
- a suitable pre-polymer of the styrene-butadiene copolymer is the same copolymer used in the interior coating composition, WRL 706S1TM, sold by BF Goodrich.
- Example 3 An aqueous composition was prepared by mixing the following ingredients in approximate percents by weight: Ingredients % bv Weight
- the viscosity of the composition was about 9.5 (No. 3 Zahn) and the pH was about 10.1.
- the composition was applied to a substrate to form, when heated, a waterproof coating. The coating was repulpable and recyclable. Subsequent testing showed that the presence of the additional water was less desired as it served to increase drying time.
- Example 4 A composition was made as set forth in Example 3 except that it included 1 to 20% by weight of additional ingredients including calcium stearate, a wetting agent, and potassium phosphate, a defoamer.
- the corrugated medium 16 is formed by a process comprising:
- the resulting medium When the wax particle emulsion is combined with the aqueous solution of a natural food gum, the resulting medium has improved moisture resistance with no appreciable stiffening or strengthening of the corrugated board.
- the coated medium With this combination coated on a medium, the coated medium is heated to at least about 135°F; the temperature generally correlating with the melt point of the particular wax chosen, taking into account the melting point influencing effects of the other ingredients present.
- the crosslinker may be any suitable crosslinker including epoxy, phenolic, bismaleimide, polyimide, melamine/formaldehyde, polyester, urethane, urea, urea/formaldehyde, and mixtures thereof.
- the preferred crosslinker is a melamine-formaldehyde pre-polymer.
- the crosslinker is initiated in any suitable way, preferably by heating to at least about 160°F.
- the styrene-acrylate and crosslinker is preferably used in combination with about 40 wt.% to about 98 wt.% of a wax particle emulsion.
- the styrene-acrylate and crosslinker impregnated fiber medium adds strength to the corrugated medium, resulting in a stronger, stiffer corrugated board.
- the additional strength provided by the styrene-acrylate and crosslinker impregnated flutes can advantageously be used to reduce the overall weight of a container as compared with a known container of the same strength or provide additional strength as compared with a known container of the same weight.
- the medium coating can be adjusted as desired to meet specific requirements. If just moisture resistance is desired, the wax particle emulsion and aqueous solution of a natural food gum carrier may be chosen. If additional strength is desired for a corrugated board, a styrene-acrylate copolymer and crosslinker may be chosen.
- the corrugated medium is preferably of 33 pound weight.
- the corrugating medium 16 is coated, either by rod coating prior to the delivery to the corrugator of a roll from which such corrugated medium 16 is to be formed or on the corrugator as part of the corrugating operation.
- the coating preferably is a 50- 60% solids concentration used in the approximate amount of 3 pounds per MSF.
- Corrugated medium materials and the corrugated board formed therefrom coated with such coatings have good water and heat resistance, they meet FDA requirements for indirect materials for use in food containers, they are gluable and they are repulpable and recyclable.
- the wax particles in the medium coating composition are generally about 0.1 to 150 microns and preferably 1 to 100 microns in diameter.
- the amount of wax is generally about 40 to 98 percent by weight of the composition and preferably about 50 to 75 percent by weight, the optimum amount for most applications being about 65 to 75 percent by weight.
- a suitable wax particle emulsion is AQUABEAD 325-ETM wax (65 percent total paraffin solids) from Micro Powders Inc., Tarrytown, N.Y.
- Suitable carriers for the medium coating are aqueous solutions of natural food gums, preferably, an aqueous solution of a alkali metal alginate (most preferably sodium alginate) and a mixture of a styrene-acrylate copolymer and crosslinker selected from the group comprising epoxy, phenolic, bismaleimide, polyimide, melamine/formaldehyde, polyester, urethane, urea, urea/formaldehyde, and mixtures thereof, preferably, a water-soluble melamine-formaldehyde prepolymer.
- the carrier is generally about 2 to 40 percent by weight, preferably 10 to 35 percent by weight; and more preferably 22 to 32 percent by weight of the composition.
- a suitable styrene-acrylate copolymer is P-158TM copolymer from Emulsion Systems Inc., Boca Raton, FL. P-158TM includes about 49% water.
- a suitable melamine/formaldehyde prepolymer is CYMEL 303TM, a hexamethoxymethylmelamine material, which may be purchased from Cytec Industries, Inc., Wallingford, CT.
- the melamine-formaldehyde prepolymer is present as about 1 wt.% to about 5 wt.% of the overall coating, preferably about 1 wt.% to about 2 wt.% of the overall composition.
- the viscosity of the medium coating composition at 78-82°F is about 13.5 to 15.5 sec (#3 Zahn) and the pH is about 8.9 to 9.2.
- the water resistance and other properties were measured by standard ASTM or TAPPI test methods including the Cobb test.
- the low Cobb values of 0.1 to 35 obtained are generally under 30 and preferably under 15.
- Example 5 A formulation providing a waterproof coating was prepared from a composition as follows:
- the composition formed a coating on a liner board that was waterproof.
- the composition was applied to a substrate to form a waterproof coating.
- the layers 12, 14, 16 are treated with moisture resistant coatings, as herein described, they generally cannot be readily bonded or adhered to one another by the use of conventional starch adhesives of the type widely used in manufacturing conventional corrugated board.
- the traditional starch based glues formerly used in corrugated board manufacturing have been found unsuitable for use with the coated liner boards of the present invention. It is believed that the starch based adhesives are unacceptable due to their high water content, of which the water cannot evaporate in the standard corrugated board manufacturing techniques due to the water and moisture resistant properties of the coated liner boards of the present invention and, due to the water resistant coatings, water does not carry the starch adhesive into the liner board fiber.
- an inventive cold set glue comprising: about 60 wt.% to about 95 wt.% of a copolymer of vinyl acetate and ethylene having less than about 0.5 wt.% vinyl acetate monomer, and about 5 wt.% to about 35 wt.% water; said glue having a viscosity of about 15 sec. to about 20 sec. as measured by #3 Zahn.
- the vinyl acetate-ethylene copolymer used as a cold set glue has significant advantages over known vinyl acetate adhesives whose use is known in fields other than corrugated board manufacturing.
- the vinyl acetate-ethylene copolymer cold set glue has significant advantages, including it provides improved set speed, wet tack, water resistance, and the dried adhesive is flexible while retaining good tensile strength.
- a cold set glue suitable for use in joining moisture treated corrugated medium to moisture resistant liners, as heretofore described, is a liquid adhesive sold by Sonoco Products Company of Hartsville, South Carolina under the designation CD 46-33.
- a water diluted version of this product is designated 9E 117-18.
- Such an adhesive is a white, water borne, resin based adhesive. This adhesive has good roll coating properties, and sets up quickly with minimum heat.
- a dried glue line with such an adhesive is somewhat flexible and as meets FDA regulation CFR 29, paragraph 175.105.
- Such an adhesive has a total solids composition of approximately 43.0%, a pH of 5.2, with good mechanical stability and fair water resistance.
- cold set glue is particularly applicable to the coated or treated liner boards as described herein, it is also useful in uncoated or untreated liner boards used in making untreated corrugated board.
- the use of cold set glue is advantageous as the current standard corrugation process utilizes a heating section normally employing hot plates which, after the joining of the interior liner board, the corrugated medium, and the exterior liner board, is heated to temperatures of about 350°F and above to set and dry the adhesive between the tips of the flute on the corrugated medium and the exterior liner board. This post-joining heating to cure this glued surface significantly increases the cost of the machinery required for producing corrugated board.
- this heating section is not required, dramatically reducing the cost of corrugated board manufacturing equipment which utilizes cold set glue.
- cold set gluing has the advantage of producing straight corrugated board as compared with the warped corrugated board which is often produced via traditional hot set gluing techniques using hot plates.
- cold set glue has the advantage of reducing flute lines, even with regard to larger sized flutes. It is known to produce smaller, closer spaced flutes to reduce the detrimental effects of flute lines. However, smaller, closer spaced flutes have the disadvantage of increasing the amount of medium used. Thus, the use of cold set glue reduces flute lines and reduces the amount of medium used in known techniques for reducing flute lines.
- Example 7 Various samples of 69 pound liner board, including untreated control samples and samples treated with the interior and exterior coatings were tested for various properties, with the following results:
- Example 8 A corrugated board was produced on a commercial corrugator at rates of 250 ft./minute and 280 ft./minute from a single facer 69 pound kraft liner board sheet precoated with the interior coating, a double facer 69 pound kraft liner board sheet precoated with the exterior coating and a 33 pound corrugated medium sheet precoated with the medium coating.
- the sheets were adhered together with the diluted Sonoco cold set adhesive 9E 117-18, after purging the starch adhesive previously used from the system.
- the corrugated board produced at 250 ft./minute had very good fibre pull adhesion, and it was observed as being better formed than conventional corrugated board with better adhesion than conventional, starch adhered corrugated board.
- the board showed signs of adhesive bond failure, due to the poor flow characteristics of the cold set adhesive at higher flow rates.
- the flute surface of the interior liner board and the exterior liner board may be advantageous to coat for water or moisture resistance (see coatings 30, 32) .
- Such a coating is desired when, there is a possibility that water or moisture could enter an open fluted end and thus absorb into the interior and exterior liner boards from the fluted side. It has been found that a mixture of about 4 wt.% Rhone Poulenc MANILOX X-196 and about 4 wt.% MANILOX X-197, with the remainder water provides a suitable water and moisture resistant coating for the flute surfaces of the interior and exterior liner board. This coating is preferably applied to the interior and exterior liner boards before the drying step at about 110°F to about 180°F, as discussed herein.
- a suitable lap glue for forming corners and sealed edges of the interior and exterior coated liner boards is Sonoco's water base adhesive containing poly(vinyl acetate) CD 47-91 (Sonoco Products Company, Hartsville, S.C.)
- the corrugated board of the present invention may be manufactured as follows. First, the interior and exterior coatings, as described above, are preferably coated on liner board and dried at about 110° F to about 180° F. Likewise, the medium coating, as described above, is coated on a sheet of uncorrugated medium and dried at about 110° F to about 180° F.
- These sheets may less preferably be coated just prior to the corrugation and/or adhesion steps.
- These sheets are supplied on rolls as is known in the art to a corrugator which may be a Langston, Mitsubishi or similar corrugator as known to those of skill in the art.
- FIGURE 2 a schematic representation of a corrugator having the following components: interior liner board roll 41, corrugating medium roll 42, exterior liner board roll 43, preheaters 44, pressure roll 45, corrugating rolls 46, roll applicators for applying glue 47, hot plates 48, cooling section 49, splitting and scoring section 50, cutoff section 51, single facer section 52, double facer section 53 and medium pre-conditioner 54.
- the medium sheet may be preheated to about 330°F which causes the medium coating to absorb or move via capillary action into the medium as described above and open pores on the medium surface for the cold set glue. While this preheating causes the coating on the flute sheet to absorb or move via capillary action into the medium, its primary purpose is tQ open the pores in the medium surface for the application of the glue (either hot set or cold set) .
- the glue either hot set or cold set
- the preheaters were required for the hot set glue which adhered the flutes to the interior liner board.
- this preheating step in pre-conditioner 54 is not required if an alternate means for opening pores in the medium surface is available. One such alternate means for opening the pores in the medium surface is to steam the medium sheet instead of heating it with preheaters.
- Steam opens the pores and is believed suitable with the inventive cold set glue of the present invention.
- "Steaming" i.e., contacting the medium sheet with steam, generally involves contacting the medium sheet with steam at, or slightly above atmospheric pressure.
- the steam temperature is at least about 240°F.
- a suitable apparatus to accomplish this steaming step is the GAYLORD SHOWER, available from Bell Packaging Corp., Dallas, Texas.
- the cold set glue of the present invention provides for a corrugated board manufacturing technique which does not require preheaters 45 or hot plates 48 (see discussion above) , and the corrugated board manufacturing technique may be completed at about ambient temperature. This significantly reduces equipment and operational cost.
- an applicator 47 is used to apply the cold set glue to the tips of the flutes for adhesion to the exterior liner board.
- This technique requires no further heating with hot plates 48 or cooling (see cooling section 49) as is currently done with known manufacturing techniques, and this equipment may be eliminated from a corrugated board manufacturing plant.
- the cold set glue of the present invention has a higher solids content (generally about 35 wt.% to about 60 wt.% solids) than the starch based adhesives previously used (generally about 20-25 wt.% solids). Due to this higher percent solids, it was determined that a thinner adhesive film performed better. With conventional starch based adhesives, an adhesive layer of about .012 in. was suitable. However, with the cold set glue of the present invention, an adhesive film of about .006 in. is desired. As such, an applicator roll having 25 cells/sq. in. is preferred over the currently known and generally used applicator rolls having 10 cells/sq. in.
- the method of manufacturing using the cold set glue of the present invention includes the vinyl acetate and ethylene co-polymer based adhesive as described above, a lower temperature, which not only saves equipment costs, but also provides a better adhesion, and a new applicator to optimally apply a thinner film of the inventive cold set glue, which is preferred due to the higher solids content of the inventive cold set glue.
- the interior coating, the exterior coating, the fluting treatment and the cold set adhesive are optimally designed to be used together to provide a water and moisture resistant, stiff and strong corrugated board for use in containers, these individual treatment steps and gluing procedures can be used individually, depending upon the needs of a particular corrugated board or container.
- the cold set glue and gluing process may be used in uncoated or untreated corrugated board.
- the fluting treatment may be used with or without the coatings and cold set glue to provide a stronger and stiffer corrugated board or a lower weight corrugated board of comparable strength to known corrugated board.
- the interior coating can be used without the other coating treatments and gluing procedures.
- the exterior coating may be used alone or in combination with any of the other coatings treatment or gluing procedures in applications where only exterior moisture protection is required.
- the interior and exterior coatings may be used on cellulosic fibrous substrates other than corrugated board to provide an inexpensive product with a high degree of waterproofing, including without limitation, water resistant paper, detergent boxes, cereal boxes, meat, poultry and/or produce packaging, mailboxes, cat boxes, dog houses, fibre drums, outdoor storage containers, cable wrap, concrete forms, rail box car liners, lumber wraps, casket liners, outdoor speaker backing, portable shelters, including ice fishing shanties, temporary restrooms and car and boat covers, and outdoor realtor signs.
- Such cellulosic fibrous substrate, non-corrugated board articles produced with the interior and exterior coatings will have the same advantages as the coated interior and exterior surfaces of corrugated board, including water and moisture resistance, improved crush strength, resistance to heat, chemicals, blood, grease and oil, scorable, and printable and gluable surfaces, while still being repulpable and recyclable.
- Corrugated boards made with the coatings and techniques disclosed herein solve the problems mentioned above, providing water and moisture resistant corrugated boards that can be repulped and recycled.
- the present invention provides corrugated boards which weighs less and/or have a higher strength than comparable known corrugated board, particularly for the inventive water resistant corrugated board in comparison with wax coated corrugated board. Also provided are water and moisture resistant corrugated boards which are also heat resistant, chemical resistant, blood resistant and grease and oil resistant.
- the present invention provides water and moisture resistant corrugated board which is elastic and does not crack during scoring which would inhibit the water resistant qualities of the final product.
- This invention provides a water and moisture resistant corrugated board which has printable and/or gluable surfaces, including surfaces without or with reduced flute lines.
- the present invention provides a water and moisture resistant corrugated board, the coatings on which are in compliance with FDA regulations for contact with food and other products.
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Abstract
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU59225/96A AU5922596A (en) | 1995-05-31 | 1996-05-29 | Corrugated board manufacturing system and method |
Applications Claiming Priority (13)
Application Number | Priority Date | Filing Date | Title |
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US08/455,130 US5658971A (en) | 1995-05-31 | 1995-05-31 | Coating composition |
US08/455,045 | 1995-05-31 | ||
US08/455,044 | 1995-05-31 | ||
US08/454,863 | 1995-05-31 | ||
US08/455,045 US5869192A (en) | 1995-05-31 | 1995-05-31 | Aqueous coating compositions |
US08/455,044 US5681621A (en) | 1995-05-31 | 1995-05-31 | Aqueous median treating composition |
US08/455,130 | 1995-05-31 | ||
US08/473,725 | 1995-06-07 | ||
US08/473,725 US5698295A (en) | 1995-06-07 | 1995-06-07 | Repulpable, moisture resistant corrugated board |
US54298395A | 1995-10-13 | 1995-10-13 | |
US54263695A | 1995-10-13 | 1995-10-13 | |
US08/542,983 | 1995-10-13 | ||
US08/542,636 | 1995-10-13 |
Publications (1)
Publication Number | Publication Date |
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WO1996038296A1 true WO1996038296A1 (fr) | 1996-12-05 |
Family
ID=27560014
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/007180 WO1996038296A1 (fr) | 1995-05-31 | 1996-05-29 | Procede et dispositif de fabrication de carton ondule |
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WO (1) | WO1996038296A1 (fr) |
Cited By (18)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2000029673A1 (fr) * | 1998-11-12 | 2000-05-25 | Paper Technology Foundation, Inc. | Materiaux lignocellulosiques partiellement impregnes |
EP1262311A1 (fr) * | 1999-12-27 | 2002-12-04 | Oji Paper Company Limited | Feuille de carton-fibre ondul e, recyclable et tanche |
AT409876B (de) * | 1998-05-29 | 2002-12-27 | Abel Kartonagen Roland Abel | Schalbauteil |
EP1616581A1 (fr) * | 2004-06-18 | 2006-01-18 | Nippon Shokubai Co., Ltd. | Composition de résine absorbant l'eau et procédé de laquelle |
CN103523374A (zh) * | 2013-10-29 | 2014-01-22 | 昆山市亚宙纸业有限公司 | 复合瓦楞纸板及其制造方法 |
WO2014052359A1 (fr) * | 2012-09-27 | 2014-04-03 | Eastman Chemical Company | Stratifiés auto-ondulés et leurs procédés de réalisation |
CN103866622A (zh) * | 2014-02-25 | 2014-06-18 | 苏州恒康新材料有限公司 | 一种双马来酰亚胺树脂施胶剂及其制备方法 |
US8952116B2 (en) | 2009-09-29 | 2015-02-10 | Nippon Shokubai Co., Ltd. | Particulate water absorbent and process for production thereof |
US9062140B2 (en) | 2005-04-07 | 2015-06-23 | Nippon Shokubai Co., Ltd. | Polyacrylic acid (salt) water-absorbent resin, production process thereof, and acrylic acid used in polymerization for production of water-absorbent resin |
US9064994B2 (en) | 2013-04-26 | 2015-06-23 | Eastman Chemical Company | Self-corrugating laminates useful in the manufacture of thermoelectric devices and corrugated structures therefrom |
US9090718B2 (en) | 2006-03-24 | 2015-07-28 | Nippon Shokubai Co., Ltd. | Water-absorbing resin and method for manufacturing the same |
CH712249A1 (de) * | 2016-03-11 | 2017-09-15 | Ziegler Papier Ag | Silikon- und fluorfreies Trennpapier. |
US9926449B2 (en) | 2005-12-22 | 2018-03-27 | Nippon Shokubai Co., Ltd. | Water-absorbent resin composition, method of manufacturing the same, and absorbent article |
KR101850343B1 (ko) | 2016-08-31 | 2018-04-19 | 권태영 | 골판지 함침액 함침장치 |
WO2019121733A1 (fr) * | 2017-12-22 | 2019-06-27 | Mitsubishi Hitec Paper Europe Gmbh | Papier barrière recyclable |
CN110228262A (zh) * | 2019-06-22 | 2019-09-13 | 叶庆奇 | 一种低变形率的瓦楞纸板 |
CN110861356A (zh) * | 2019-12-16 | 2020-03-06 | 上海定隆纸业有限公司 | 一种瓦楞纸板及瓦楞纸箱的生产工艺 |
CN112693160A (zh) * | 2020-12-29 | 2021-04-23 | 重庆卓兴实业发展有限公司 | 一种增强型纸箱的制作方法 |
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Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AT409876B (de) * | 1998-05-29 | 2002-12-27 | Abel Kartonagen Roland Abel | Schalbauteil |
WO2000029673A1 (fr) * | 1998-11-12 | 2000-05-25 | Paper Technology Foundation, Inc. | Materiaux lignocellulosiques partiellement impregnes |
EP1262311A1 (fr) * | 1999-12-27 | 2002-12-04 | Oji Paper Company Limited | Feuille de carton-fibre ondul e, recyclable et tanche |
EP1262311A4 (fr) * | 1999-12-27 | 2003-03-26 | Oji Paper Co | Feuille de carton-fibre ondul e, recyclable et tanche |
US6794016B2 (en) | 1999-12-27 | 2004-09-21 | Oji Paper Co., Ltd. | Recyclable water-resistant corrugated fiberboard sheet |
EP1616581A1 (fr) * | 2004-06-18 | 2006-01-18 | Nippon Shokubai Co., Ltd. | Composition de résine absorbant l'eau et procédé de laquelle |
US9062140B2 (en) | 2005-04-07 | 2015-06-23 | Nippon Shokubai Co., Ltd. | Polyacrylic acid (salt) water-absorbent resin, production process thereof, and acrylic acid used in polymerization for production of water-absorbent resin |
US10358558B2 (en) | 2005-12-22 | 2019-07-23 | Nippon Shokubai Co., Ltd. | Water-absorbent resin composition, method of manufacturing the same, and absorbent article |
US9926449B2 (en) | 2005-12-22 | 2018-03-27 | Nippon Shokubai Co., Ltd. | Water-absorbent resin composition, method of manufacturing the same, and absorbent article |
US9090718B2 (en) | 2006-03-24 | 2015-07-28 | Nippon Shokubai Co., Ltd. | Water-absorbing resin and method for manufacturing the same |
US9775927B2 (en) | 2009-09-29 | 2017-10-03 | Nippon Shokubai Co., Ltd. | Particulate water absorbent and process for production thereof |
US8952116B2 (en) | 2009-09-29 | 2015-02-10 | Nippon Shokubai Co., Ltd. | Particulate water absorbent and process for production thereof |
WO2014052359A1 (fr) * | 2012-09-27 | 2014-04-03 | Eastman Chemical Company | Stratifiés auto-ondulés et leurs procédés de réalisation |
US9064994B2 (en) | 2013-04-26 | 2015-06-23 | Eastman Chemical Company | Self-corrugating laminates useful in the manufacture of thermoelectric devices and corrugated structures therefrom |
CN103523374A (zh) * | 2013-10-29 | 2014-01-22 | 昆山市亚宙纸业有限公司 | 复合瓦楞纸板及其制造方法 |
CN103866622A (zh) * | 2014-02-25 | 2014-06-18 | 苏州恒康新材料有限公司 | 一种双马来酰亚胺树脂施胶剂及其制备方法 |
CH712249A1 (de) * | 2016-03-11 | 2017-09-15 | Ziegler Papier Ag | Silikon- und fluorfreies Trennpapier. |
KR101850343B1 (ko) | 2016-08-31 | 2018-04-19 | 권태영 | 골판지 함침액 함침장치 |
WO2019121733A1 (fr) * | 2017-12-22 | 2019-06-27 | Mitsubishi Hitec Paper Europe Gmbh | Papier barrière recyclable |
CN111511987A (zh) * | 2017-12-22 | 2020-08-07 | 三菱高新技术纸业欧洲有限公司 | 可回收的阻隔纸 |
CN110228262A (zh) * | 2019-06-22 | 2019-09-13 | 叶庆奇 | 一种低变形率的瓦楞纸板 |
CN110861356A (zh) * | 2019-12-16 | 2020-03-06 | 上海定隆纸业有限公司 | 一种瓦楞纸板及瓦楞纸箱的生产工艺 |
CN110861356B (zh) * | 2019-12-16 | 2021-04-06 | 上海定隆纸业有限公司 | 一种瓦楞纸板及瓦楞纸箱的生产工艺 |
CN112693160A (zh) * | 2020-12-29 | 2021-04-23 | 重庆卓兴实业发展有限公司 | 一种增强型纸箱的制作方法 |
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