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WO2020152671A1 - Matériau d'emballage compostable - Google Patents

Matériau d'emballage compostable Download PDF

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Publication number
WO2020152671A1
WO2020152671A1 PCT/IL2020/050053 IL2020050053W WO2020152671A1 WO 2020152671 A1 WO2020152671 A1 WO 2020152671A1 IL 2020050053 W IL2020050053 W IL 2020050053W WO 2020152671 A1 WO2020152671 A1 WO 2020152671A1
Authority
WO
WIPO (PCT)
Prior art keywords
laminate
layer
container
astm
compostable
Prior art date
Application number
PCT/IL2020/050053
Other languages
English (en)
Inventor
Itzhak Yoffe
Original Assignee
Miba Star Ltd
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 Miba Star Ltd filed Critical Miba Star Ltd
Publication of WO2020152671A1 publication Critical patent/WO2020152671A1/fr

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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
    • B32B1/00—Layered products having a non-planar shape
    • 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
    • B32B23/00—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose
    • B32B23/04—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B23/06—Layered products comprising a layer of cellulosic plastic substances, i.e. substances obtained by chemical modification of cellulose, e.g. cellulose ethers, cellulose esters, viscose comprising such cellulosic plastic substance 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
    • 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
    • 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
    • B32B2250/02—2 layers
    • 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
    • B32B2250/03—3 layers
    • 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
    • B32B2250/00—Layers arrangement
    • B32B2250/42—Alternating layers, e.g. ABAB(C), AABBAABB(C)
    • 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
    • B32B2255/12—Coating on the layer surface on paper 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
    • 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
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
    • 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
    • B32B2307/726—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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/738—Thermoformability
    • 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
    • B32B2439/02—Open containers
    • 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
    • B32B2439/00—Containers; Receptacles
    • B32B2439/80—Medical packaging

Definitions

  • the present invention in some embodiments thereof, relates to a fully compostable packaging material, and more particularly, but not exclusively, to a thermoformable and airtight compostable blank suitable for food packaging and the like.
  • biodegradability has been the starting point for most environmentally-aware manufacturers of plastics, however, biodegradable plastic waste still leaves much to be desired, as biodegradable plastic may have the ability to break down into small bits so that microorganisms can consume it, given enough time, but plastic take much longer.
  • biodegradable plastic may have the ability to break down into small bits so that microorganisms can consume it, given enough time, but plastic take much longer.
  • plastic since the production of plastic, there has been no evidence that plastic completely disappears back into our soil or waters.
  • breaking up to small bits is why many animals ingest small biodegradable plastic pieces.
  • Compostable materials given composting conditions, will leave essentially no discemable trace in the soil, and their non-gaseous breakdown products can serve as plant/bacteria/fungi food, without toxication. While some compostable materials have been used for food packaging, the mechanical and physical demands of modern packaging techniques pose a difficult challenges, stemming from the limited strength and thermoformability, and high moisture and oxygen permeability of compostable materials.
  • U.S. Patent Application Publication No. 2016/0288978 provides a package and a method of producing the package adapted to be sealed, comprising arranging a sheet of stretchable paper on a cavity; applying a pressure to the sheet such that a nip is obtained at the rim of the cavity; applying a force to the sheet such that the sheet partly slides into the cavity and partly extends within the cavity to form a package having a body portion and a rim portion formed at the nip; and coating a surface of the rim portion to form a surface for gas-tight sealing.
  • U.S. Patent No. 10,086,585 provides paper laminate comprising a first stretchable paper layer, a second stretchable paper layer and an intermediate paper layer arranged between the first and the second stretchable paper layer, characterized in that the stretchability (ISO 1924/3) of the first and the second stretchable paper layer is at least 5% in both the machine direction (MD) and the cross direction (CD) and the stretchability (ISO 1924/3) of the intermediate paper layer is less than 4% in the MD and/or the CD.
  • MD machine direction
  • CD cross direction
  • Regenerated cellulose film as disclosed in U.S. Patent Nos. 1,961,316 and 2,451,768, has been known and used in the food industry for decades.
  • U.S. Patent No. 9,539,794 teaches a coated film comprising a substantially biodegradable substrate having a biodegradable coating thereon at a coat weight of not more than 12 g/m 2 , as well as useful articles sealed inside a package at least partly comprising such a film, and also a process for producing a coated film comprising providing a substantially biodegradable film substrate and applying a biodegradable coating to the substrate at a coat weight of less than 12 g/m 2 by means of a hot melt coating step.
  • Additional background art includes EP2963178, EP3211135, U.S. Patent Nos. 4,681,797, 4,847,148, 5,972,447, 6,177,159, 6,503,588, 6,998,157 and 10,065,779, and U.S. Patent Application Publication Nos. 2010/0003457 and 2016/0340069, and WO 2016/001028.
  • aspects of the present invention are drawn to compostable and thermoformable laminate, comprising stretchable paper and regenerated cellulose film, and fully compostable packaging material and products made therefrom.
  • a laminate that includes at least a first layer and a second layer, wherein the first layer includes a stretchable cellulosic pulp sheet (e.g., stretchable paper), the second layer includes a regenerated cellulose film (e.g., cellophane); at least one of the layers is coated on at least one side thereof with an substantially impermeable coating, wherein the coating is substantially impermeable to water and oxygen; wherein the laminate is characterized by a thermoforming coefficient of at least 0.15, whereas the thermoforming coefficient being a ratio of a deepest depth to a shortest width of a curved depression made in the laminate without rendering the laminate permeable to water and oxygen; and the laminate is compostable according to at least one of EN 13432 and ASTM D6400.
  • the first layer includes a stretchable cellulosic pulp sheet (e.g., stretchable paper)
  • the second layer includes a regenerated cellulose film (e.g., cellophane)
  • at least one of the layers is coated on
  • the laminate further includes a third layer, the third layer includes a stretchable cellulosic pulp sheet, and the second layer is interposed between the first and the third layer.
  • the laminate further includes a fourth layer, the fourth layer includes a regenerated cellulose film, and positioned over the third layer. In some embodiments, any one of the third layer and the fourth layer is coated on at least one side thereof with the substantially impermeable coating.
  • the laminate further includes a lamination adhesive between each two adjacent layers.
  • the grammage of the lamination adhesive ranges 1-5 g/m 2 .
  • the stretchable cellulosic pulp sheet (e.g., stretchable paper) is characterized by a stretchability (ISO 1924/3) of at least 5 % in both the machine direction (MD) and the cross direction (CD).
  • the grammage of the first layer and the third layer if present each independently ranges 50-300 g/m 2 .
  • the grammage of the second layer and the fourth layer if present each independently ranges 20-80 g/m 2 .
  • the grammage of the substantially impermeable coating ranges 0.5-10 g/m 2 .
  • a container formed from the laminate presented herein.
  • the container is formed by a thermoforming process.
  • the container exhibits a flanged rim and further includes a removable (e.g., peelable) cover, the cover is affixed to the flanged rim and seals the container by heat or adhesion.
  • a removable (e.g., peelable) cover the cover is affixed to the flanged rim and seals the container by heat or adhesion.
  • removable cover is coated on at least the inner surface thereof with a substantially impermeable coating.
  • the removable cover is compostable according to at least one of EN 13432 and ASTM D6400.
  • the removable cover includes regenerated cellulose film.
  • the container further includes a single or a plurality of objects packaged therein.
  • the object is selected from the group consisting of a foodstuff and a drug.
  • the container further includes a modified atmosphere enclosed therein.
  • the roll further includes a core cylinder.
  • the core cylinder is compostable according to at least one of EN 13432 and ASTM D6400.
  • the roll is wrapped in a sheath.
  • the sheath is compostable according to at least one of EN 13432 and ASTM D6400.
  • FIGs. 1A-D present schematic illustrations of a side-view (side-cut) of the laminate, according to some embodiments of the present invention, wherein FIG. 1A shows laminate 10 having first layer 11 made of STP, second layer 12 made of RCF placed on top of layer 11, and optional lamination adhesive 13 affixing the layers to one another, FIG. IB shows laminate 10 having first and third layers 11 made of STP, second layer 12 made of RCF interposed between first and third layers 11, and optional lamination adhesive 13 affixing the layers to one another, FIG. 1C shows laminate 10 having first and third layers 11 made of STP, second and fourth layers 12 made of RCF interposed between first and third layers 11 and on top of third layer 11, and optional lamination adhesive 13 affixing the layers to one another, and FIG.
  • FIG. 1A shows laminate 10 having first layer 11 made of STP, second layer 12 made of RCF placed on top of layer 11, and optional lamination adhesive 13 affixing the layers to one another
  • FIG. IB shows laminate 10 having first and third layers 11 made
  • FIG. 1C shows laminate 10 as in FIG. 1C, with an additional lacquer coating, whereas at least one of each of the layers further includes a substantially impermeable coating on at least one face thereof (not shown in FIGs 1A-D);
  • FIG. 2 presents a schematic illustration of a packaging tray made from the laminate in a standard thermoforming operation, according to some embodiments of the present invention, wherein tray 20 is show in a top-view on the left, and a side-view on the right, noting packaging depth 21, length of shortest side of the packaging 22, and flanged rim 23, whereas the thermoforming coefficient is a ratio between packaging depth 21 and length of shortest side of the packaging 22;
  • FIG. 3 presents a schematic illustration of roll 30, wherein laminate 31, corresponding to the laminate presented herein, is wound around core 32 (protective sheath not shown);
  • FIG. 4 presents a schematic illustration of an individual sealable container 40, according to some embodiments of the present invention, which is manufactured by conventional packaging operations, having peelable heat sealed cover 41 with pull tab 42, heat-sealable on flanged rim 43 that formed a part of tray 44.
  • the present invention in some embodiments thereof, relates to a fully compostable packaging material, and more particularly, but not exclusively, to a thermoformable and airtight compostable blank suitable for food packaging and the like.
  • Biodegradable refers to a material breaking down with the help of microorganisms. To be labelled a biodegradable plastic, there is no time limit set on when the product breaks down and whether these plastics leave toxic residue behind.
  • the term“compostable” is distinguished from the term“biodegradable” and refers to a material capable of breaking down, at the same rate as cellulose, into carbon dioxide, water, and biomass, given compost conditions. Compostable material is characterized in that it disintegrates and becomes indistinguishable in compost and leave no toxic material behind.
  • a compostable material is such that conforms to the internationally acceptable standards, such as the EN 13432 and ASTM D6400 standards for compostability.
  • thermoformable laminates a sheet of material made by bonding two or more sheets or layers
  • thermoformable and thus useful for packaging are known to comprise non- compostable elements; even laminates that are based on compostable paper include plastic plies, added to confer thermoformability, mechanical strength, impermeability and seal.
  • non-compostable plastic content such as PE or PET
  • these known laminates do not conform to any of the internationally acceptable standards for compostable materials, and are therefore considered as non-compostable materials.
  • the inventor has contemplated a thermoformable laminate that would conform to the internationally acceptable standards, and still be thermoformable, namely mechanically suitable and safe for use for food packaging.
  • thermoformable laminate While reducing the present invention to practice, the present inventor has surprisingly found that interposing a ply of a regenerated cellulose film, also known in its generic name as cellophane or as a line of products under the trademarked name CellophaneTM, between two layers of stretchable and thermoformable paper, affords a fully compostable and yet also thermoformable laminate, which can be used to manufacture containers for food and other products.
  • a regenerated cellulose film also known in its generic name as cellophane or as a line of products under the trademarked name CellophaneTM
  • thermoformable laminates which are also non-compostable materials, such as polyethylene (PE) or polyethylene terephthalate (PET), while CellophaneTM, or regenerated cellulose film, is known to be thermoset and not thermoplastic, thus it is not thermoformable.
  • PE polyethylene
  • PET polyethylene terephthalate
  • CellophaneTM or regenerated cellulose film
  • the first layer is made substantially from a stretchable paper, as this type of material is described hereinbelow, and referred to as“STP”;
  • the second layer is made substantially from a regenerated cellulose film, referred to herein as“RCF”, as this type of material is described hereinbelow;
  • At least one of the layers is coated on at least one side thereof with a substantially impermeable coating, the coating is substantially impermeable to water and oxygen, as this property of the material is described hereinbelow;
  • the laminate is compostable in the sense of at least one of EN 13432 and ASTM D6400, which are the most internationally acceptable standards for compostability.
  • thermoformable refers to the capacity of the laminate to undergo industrial shape forming processes, which include any process that is known in the art for turning a two dimensional laminate (sheet; blank) into a three dimensional object, as these are known in the art, without limitation, as thermoforming, thermo-and-stamp forming, deep draw, press form and vacuum forming. Some of these processes are known by other names and may be construed as equivalent and encompassed under the term“thermoformable” to describe the input material for any of these processes.
  • the laminate further includes a third layer, which is also made substantially from the stretchable paper.
  • the second layer of RCF is interposed between the first layer (STP) and the third layer (STP).
  • the laminate further includes a fourth layer, which is also made substantially from RCF, and positioned over the third layer (STP).
  • a fourth layer which is also made substantially from RCF, and positioned over the third layer (STP).
  • any one of the third layer and fourth layer may be coated on at least one side thereof with the substantially impermeable coating.
  • the laminate may further include a lamination adhesive between each of the layers.
  • FIGs. 1A-D present schematic illustrations of a side-view (side-cut) of the laminate, according to some embodiments of the present invention, wherein FIG. 1A shows laminate 10 having first layer 11 made of STP, second layer 12 made of RCF placed on top of layer 11, and optional lamination adhesive 13 affixing the layers to one another, FIG. IB shows laminate 10 having first and third layers 11 made of STP, second layer 12 made of RCF interposed between first and third layers 11, and optional lamination adhesive 13 affixing the layers to one another, FIG. 1C shows laminate 10 having first and third layers 11 made of STP, second and fourth layers 12 made of RCF interposed between first and third layers 11 and on top of third layer 11, and optional lamination adhesive 13 affixing the layers to one another, and FIG. 1C shows laminate 10 as in FIG. 1C, with an additional lacquer coating, whereas at least one of each of the layers further includes a substantially impermeable coating on at least one face thereof (not shown in FIGs 1A-D).
  • the laminates presented herein and products, such as containers produced therefrom are essentially devoid of a non-compostable materials, namely contains less than 10 % non-compostable materials, less than 5 %, less than 2 %, less than 1 %, or less than 0.5 % non-compostable materials by weight of the total weight of the laminate or a product produced therefrom.
  • the laminates presented herein and products, such as containers produced therefrom are essentially devoid of PE and/or PET.
  • the thermoformable and compostable laminate comprises at least two layers (plies) of a stretchable sheet made of a cellulosic pulp.
  • the term“cellulosic pulp sheet” is referred to herein as “paper”, and the two terms are used interchangeably.
  • This form of paper contributes to both the thermoformability and compostability of the laminate and any product prepared therefrom, and its physico-mechanical properties essentially determines the thermoformability and compostability of the laminate and a product prepared therefrom, while the other plies and coating present in the laminate contribute, and essentially determine other properties of the laminate and a product prepared therefrom, such as permeability.
  • Stretchable cellulosic pulp sheet has been introduced to the food packaging industry decades ago, in publications that include U.S. Patent Nos. 2,169,505, 2,245,014, 2,267,320, and 3,483,071. More recently, stretchable paper has been further developed to a level where it can be used as a thermoformable material (hence stretchable and thermoformable paper, or STP), as disclosed by the firm BillerudKorsnas AB of Sweden, in, for example, WO 2018/185216, WO 2013/135215, WO 2018/185213, WO 2018/178070, WO 2017/148921, WO 2016156454, WO 2016/130071, WO 2015/189130, WO 2015/117954, WO 2015/117954 and WO 2015/082268, and U.S. Patent No. 10,086,585, each of which is incorporated herein by reference.
  • the stretchable paper used for at least two layers (plies), separated by an airtight ply of RCF in the laminate provided herein is characterized by the ability to thermoform into 3D-shapes in a standard thermoforming process.
  • the ability to thermoform can be defined in physico-mechanical terms per given thickness of the material.
  • the stretchable paper that is used in the laminate provided herein confers the ability to process the laminate into 3D packaging products using machine feeders that feed the laminate into the thermoforming line fitted with pressure and heating plates, with or without an air pressure and/or vacuum fittings, while the machine settings depend on the forming die design and the laminate composition and thickness.
  • the stretchable and thermoformable paper essentially determines the formability of the laminate.
  • the STP is characterized by about 15 % elongation in the machine direction, and about 10 % elongation in the cross direction, whereas the size of the packaging being manufactured from a laminate that includes the STP determines the achievable depth, and the length on the shortest side of the packaging determines the maximal possible depth.
  • This thermoforming coefficient corresponds to the Draw Ratio discussed hereinbelow.
  • FIG. 2 presents a schematic illustration of a packaging tray made from the laminate in a standard thermoforming operation, according to some embodiments of the present invention, wherein tray 20 is show in a top-view on the left, and a side-view on the right, noting packaging depth 21, length of shortest side of the packaging 22, and flanged rim 23, whereas the thermoforming coefficient is a ratio between packaging depth 21 and length of shortest side of the packaging 22.
  • a stretchable paper is selected to exhibit a grammage of 50-300 g/m 2 according to ISO 536, or 50-140 g/m 2 , 70-140 g/m 2 , or 80- 140 g/m 2 , or 90-140 g/m 2 , or 70-130 g/m 2 , or 80-130 g/m 2 , or 90-130 g/m 2 , or 100-130 g/m 2 , 100-150 g/m 2 , 100-180 g/m 2 , 100-200 g/m 2 , or 100-200 g/m 2 ; wherein“grammage” is an art- recognized term that refers to the amount of a material coating a surface, as well as a correlation to the thickness of a substantially homogeneously thick sheet of a material.
  • the paper is also characterized by a stretchability (according to ISO 1924/3) in the machine direction (MD) of above 5 %, 6 %, 7 %, 8 %, 9 %, 10 %, 11 %, 12 %, or above 15 %.
  • the stretchability (according to ISO 1924/3) in the cross direction (CD) of the paper is typically above 5 %, 6 %, 7 %, 8 %, 9 % or above 10 %.
  • the tensile energy absorption (TEA) is often considered to be a paper property that best represents the relevant strength of the paper wall, whereas the tensile strength is the maximum force that a paper will withstand before breaking.
  • the TEA of the paper used in the laminate provided herein, according to ISO 1924/3 in the MD of the paper may be, for example at least 300 J/m 2 , such as at least 330 J/m 2 , such as at least 350 J/m 2 .
  • the TEA index according to ISO 1924/3 in the MD of the paper may be, for example at least 3.4 J/g, such as at least 3.5 J/g.
  • the TEA index according to ISO 1924/3 in the CD of the stretchable paper of the laminate aspect may be, for example, at least 2.4 J/g, such as at least 2.6 J/g.
  • the stretchable paper of the laminate aspect may be bleached, which means that its brightness may be least 78 % or at least 80 % according to ISO 2470-1; preferably, the brightness of a bleached stretchable paper of the laminate aspect is at least 83 %.
  • the stretchable paper is a paper as described in EP 3211135, the contents of which is incorporated herein by reference.
  • the laminate comprises at least one ply of regenerated cellulose film, which is known for being thermoset, and thus non-thermoformable
  • the stretchable and thermoformable paper, or STP surprisingly confers essentially the same thermoformability to the laminate prepared therewith, wherein said thermoformability is governed substantially by the total thickness of the laminate, the breadth and depth of the cavity that it is depressed into, the heat and/or pressure (direct die press or by vacuum) that the laminate is exposed thereto during the thermoforming process, and other machine related variable.
  • the stretchable paper is used in its pristine form, namely uncoated and not comprising any additional reinforcement elements, plies or structural additives, and is referred to as stretchable and thermoformable paper (STP).
  • STP stretchable and thermoformable paper
  • the term “regenerated cellulose film”, or RCF refers to a polymeric cellulose film made from the cellulose from wood, cotton, hemp, or other sources.
  • the raw material of choice is called dissolving pulp, or regenerated cellulose, which is white like cotton and contains about 92-98% cellulose.
  • the cellulose is dissolved in alkali in a process known as mercerization. It is aged several days, and treated with carbon disulfide to make an orange solution called viscose, or cellulose xanthate. The viscose solution is then extruded through a slit into a bath of dilute sulfuric acid and sodium sulfate to reconvert the viscose back into cellulose.
  • Typical RCF has a CAS number of 9005-81- 6.
  • RCF may further include a coat of another substance, such as PVDC, nitrocellulose or wax to make it impermeable to air and/or water vapor. It may also be coated with other materials to make it heat sealable for automated wrapping machines.
  • RCF Manufacturers and trademarks of RCF include Innovia, the owner of the trademark CellophaneTM, and the manufactures of cellulosic film for applications that include tapes and labels, photographic film, coatings for paper, glass, and plastic.
  • Several Innovia CellophaneTM products include CellophaneTM P00 - uncoated regenerated cellulose film (RCF) with no softeners incorporated; Cellophane P25 - uncoated RCF with high mechanical strength; CellophaneTM DM/DMS - RCF with one side coated with nitrocellulose by a solvent process; Cellophane LST - RCF with both sides coated with nitrocellulose by a solvent process; and CellophaneTM XSB - RCF with both sides coated with polyvinylidene chloride (PVDC) by a solvent process.
  • PVDC polyvinylidene chloride
  • RCF may be suitable for many packaging applications, it is not thermoplastic, but rather thermoset, and thus its use for thermoformable blanks and/or thermoformable laminates has not been implemented or considered hitherto. It is noted herein that the addition of an RCF ply to an already thermoformed product, or its use as a lid for a thermoformed product, is not considered as being part of a thermoformable laminate, at least in the context of embodiments of the present invention.
  • the RCF can be used as a RCF pristine ply, or as a pre-coated ply.
  • the coating may be for adding advantageous property to the thermoformed product made from the presently claimed laminate - for example, a coat selected to add oxygen impermeability, moisture impermeability, physico-mechanical strength, adhesion and tackiness, and glossy finish.
  • the RCF is a ply (layer) that is interposed between two plies of STP.
  • the interposed RCF layer comprises coated RCF.
  • the interposed coated RCF layer is coated on one side/face thereof, in some embodiments it is coated on both sides thereof, in some embodiments it is coated on both sides thereof by two different coating materials.
  • cellulose esters such as cellulose acetate (CAc), the co-esters cellulose acetate -propionate (CAP), and cellulose acetate-butyrate (CAB) are excluded from the scope of the RCF layer.
  • CAc cellulose acetate
  • CAP co-esters cellulose acetate -propionate
  • CAB cellulose acetate-butyrate
  • N nitrocellulose
  • the term“substantially impermeable” refers to a material characterized by the ability to substantially block the passage of another substance therethrough, as measured or determined by a widely-accepted standard.
  • the thermoformable and compostable laminate presented herein is substantially impermeable to oxygen and moisture (water vapor).
  • Such impermeability can be afforded by using a barrier coating, as described below.
  • the substantially impermeable coating is also referred to herein and in the industry as“barrier”, as in“oxygen barrier” and/or “water vapor barrier”.
  • oxygen transmission rate, or OTR of the presently provided laminate can be determined using the ASTM D3985-17 set of standards.
  • OTR is a widely used determinant of the packaging protection afforded by barrier materials. It is not, however, the sole determinant, and additional tests, based on experience, may also be used to correlate packaging performance with OTR. It is suitable as a referee method of testing, provided that the purchaser and the seller have agreed on sampling procedures, standardization procedures, test conditions, and acceptance criteria. This test method covers a procedure for determination of the steady-state rate of transmission of oxygen gas through plastics in the form of film, sheeting, laminates, coextrusions, or plastic-coated papers or fabrics.
  • OTR oxygen gas transmission rate
  • PO2 oxygen gas
  • R ⁇ 2 oxygen permeability coefficient
  • ASTM standards that are relevant in the context of gas permeability include D1434, a test method for determining gas permeability characteristics of plastic film and sheeting; D1898, practice for sampling of plastics; E691, practice for conducting an interlaboratory study to determine the precision of a test method; and ASTM F1927, a test method for determination of oxygen gas transmission rate, permeability and permeance at controlled relative humidity through barrier materials using a coulometric detector.
  • ASTM F3136-15 is a standard test method for oxygen gas transmission rate through plastic film and sheeting using a dynamic accumulation method. OTR is determined hereby as a determinant of packaging functionality afforded by packaging materials for a wide variety of packaged products including food, pharmaceuticals and medical devices. In some applications, sufficient oxygen must be allowed to permeate into the package, while in others, the oxygen ingress must be minimized to maintain product quality.
  • the substantially impermeable coating is substantially impermeable to oxygen according to ASTM D3985-17, and/or ASTM D1434, and/or ASTM D1898, and/or ASTM E691, and/or ASTM F1927, and/or ASTM, and/or ASTM F3136-15, and/or ASTM D3985, and/or ASTM F2622, and/or ASTM D3985, and/or ASTM E177, and/or ASTM E691, and/or ASTM F2714.
  • the water vapor transmission is not a linear function of film thickness, temperature or relative humidity. Values of water vapor transmission rate (WVT) and water vapor permeance (WVP) can be used in the relative rating of coatings only if the coatings are tested under the same closely controlled conditions of temperature and relative humidity, and if their thicknesses are equal.
  • Test Method A or the Dry Cup Method, is the preferred test method for obtaining values that relate to conventional dwellings where high relative humidity is not anticipated, while Test Method B, or the Wet Cup Method, is the preferred test method for obtaining values that relate to applications where high relative humidity is anticipated in the vicinity of the barrier material.
  • ASTM standards include: ASTM D823, practices for producing films of uniform thickness of paint, varnish, and related products on test panels; ASTM D1005, test method for measurement of dry-film thickness of organic coatings using micrometers; ASTM D1193, specification for reagent water; ASTM D4708, practice for preparation of uniform free films of organic coatings; ASTM E96, test methods for water vapor transmission of materials; and ASTM E104, practice for maintaining constant relative humidity by means of aqueous solutions.
  • the substantially impermeable coating is substantially impermeable to water vapor according to ASTM D1653-13, and/or ASTM E96, and/or ASTM D1653, and/or ASTM D823, and/or ASTM D1005, and/or ASTM D1193, and/or ASTM D4708, and/or ASTM E104.
  • the substantially impermeable coating is selected to be suitable for coming in contact with dry or moist food, and/or drugs, and/or any oxygen- and/or moisture- sensitive substance, as this coating is preferably the only element in the laminate presented herein, that comes in contact with the food, drug, sensitive substance, according to some embodiments of the invention.
  • at least one side of the laminate presented herein preferably the side that comes in contact with food, is coated with a substantially impermeable coating (barrier), and preferably, the substantially impermeable coating is selected from suitable food contact materials, and more preferably, selected from materials that comply with the framework Regulation No. 1935/2004(EC), and/or the Code of Federal Legislation (CFR): 21 CFR 174 - 21 CFR 190 (USA).
  • the present invention is directed at the impermeability property which is suitable and/or required from the product being produced from the presently provided laminate, as such suitability and/or requirement can be achieved by an appropriately selected coating material, and application thereof in the appropriate amount/thickness that affords the suitable and/or required impermeability level.
  • thermoformable and compostable laminate provided herein is characterized by an OTR that ranges from 1.0 to 200 cm 3 /m 2 in 24 hours at 0 % relative humidity, as determined by, e.g., the ASTM F1927 standard.
  • thermoformable and compostable laminate provided herein is characterized by a WVTR that ranges from 0 to 40 g/m 2 in 24 hours at 38 °C and 90 % relative humidity, as determined by, e.g., the ASTM E96 standard.
  • the laminate presented herein further includes an exterior substantially impermeable coating, referred to herein as“lacquer”, having a grammage that ranges 0.2-7 g/m 2 , particularly in the context of a container comprising the same.
  • lacquer exterior substantially impermeable coating
  • OTR and WVTR values are obtainable by using organic coatings in an amount and composition that would not diminish the composability of the laminate or products produced therefrom.
  • OTR and WVTR values are obtainable by using PVDC coating at a grammage (an amount) that ranges 0.1-5 g/m 2 .
  • oxygen impermeability typically encompasses water vapor impermeability; thus, in the context of embodiments of the present invention, the optional oxygen barrier materials are also considered as water vapor barrier materials.
  • Exemplary barrier materials may include non-compostable substances, however, their use in the presently disclosed compostable laminates is limited to such amounts that are well within the allowable margins of the standards acceptable in the art.
  • Alternative barrier materials include, without limitation, silica-coated PET, dry ethylene vinyl alcohol (EVOH), typical coextmsion EVOH, liquid crystal polymer, extruded or coated PVDC, dry MXD6 nylon, coextmsion of MXD6 nylon, polyacrylonitrile, polyethylene naphthalate (PEN) polyester, wet amorphous nylon, dry amorphous nylon, dry nylon 6 or 66, wet nylon 6 or 66, 25-45% crystallinity PET, and amorphous PET, provided that the non-compostable materials are present in the laminate in an amount that complies with the acceptable standards for compostability, as discussed herein.
  • EVOH dry ethylene vinyl alcohol
  • typical coextmsion EVOH liquid crystal polymer
  • polyacrylonitrile polyethylene naphthalate (PEN) polyester
  • PEN polyethylene naphthalate
  • wet amorphous nylon dry
  • barrier materials for packaging can be found in, for example, Lange, J. et al., Recent innovations in barrier technologies for plastic packaging - A Review: Packaging Technology and Science, 2003, 16(4), pp. 149-158, doi:10.1002/pts.621, which is incorporated herein by reference.
  • adhesion of the various lamella to each other can be achieved, optionally, by using a lamination adhesive.
  • Lamination adhesive can be classified by application type, namely solvent borne, solventless (100 % solids), aqueous-based, and radiation curable (100 % solids or combination with solvent).
  • Lamination adhesive can also be classified by performance level or chemistry, namely polyether urethane (aqueous, solvent, and solventless), polyester (solvent based), polyester urethane (aqueous, solvent, and solventless), and acrylic (aqueous or solvent).
  • performance level or chemistry namely polyether urethane (aqueous, solvent, and solventless), polyester (solvent based), polyester urethane (aqueous, solvent, and solventless), and acrylic (aqueous or solvent).
  • a liquid adhesive is coated on a substrate, dried with heat and air flow, and then laminated to a second substrate via a heated compression nip.
  • Suitable adhesive types include, without limitation, polyurethane solutions, dispersions and emulsions, acrylic solutions, dispersions and emulsions, water-based polyvinyl alcohol, ethylene vinyl acetate copolymers, and silicone-based solutions, dispersions and emulsions.
  • hot melt seal coating approach low viscosity hot melt adhesives are applied to substrate, and then laminated to a second substrate via a heated compression nip.
  • Suitable adhesive types include, without limitation, ethylene vinyl acetate, modified polyolefin, and polyesters solutions, dispersions and emulsions. In the cold seal approach, a liquid adhesive is applied, dried with heat and air, and then bonded only with slight pressure (formulated so that tack to non-cold seal surfaces is minimized).
  • Suitable adhesive types include, without limitation, synthetic rubber, acrylic and natural rubber.
  • lamination adhesives include, without limitation, SunLamTM NS- 2033A/HA-306, Herberts lk-LF 190 X#, and Mydrin k -LF-194.
  • the grammage of the lamination adhesive is present between two layers in an amount (grammage) that ranges 1-5 g/m 2 , or 2-4 g/m 2 , or 2-3 g/m 2 .
  • the amount of the lamination adhesive is typically determined by the manufacturer thereof and by the particular application and intended use of the laminate, as would be appreciated by any person of ordinary skills in the art.
  • a roll of laminate :
  • FIG. 3 presents a schematic illustration of roll 30, wherein laminate 31, corresponding to the laminate presented herein, is wound around core 32 (protective sheath not shown).
  • FIG. 4 presents a schematic illustration of an individual sealable container 40, according to some embodiments of the present invention, which is manufactured by conventional packaging operations, having peelable heat sealed cover 41 with pull tab 42, heat-sealable on flanged rim 43 that formed a part of tray 44.
  • Draw Ratio the surface area of the finished object / the footprint of the finished object. For example, for a tray of 10 cm x 12 cm x 2 cm deep, the Draw Ratio will be:
  • a common design solution is to use radii and/or a chamfers on the object, preventing the laminate from having to continue deeper into the comer, thus arresting the thinning that would normally occur.
  • the other advantage of radii and chamfers is that they distribute stress over a larger area than a sharp 90 degree comer.
  • a chamfer does not distribute the stress as well as a radius, but it gives the designer the option of sharp comers at the transition points of the chamfer.
  • a three-sided comer does occur, one large radius with a chamfer or smaller radius on the other edges is often sufficient to solve the thinning and strength problems that occur. As the draw ratio gets larger the radii will almost always have to be increased.
  • thermoforming techniques and mold designs used to help the laminate stretch as uniformly as possible.
  • a skilled and competent artisan of the field (a thermoformer) will be able to implement them in a project with any reasonable draw ratio.
  • Pressure forming is a process of applying compressed air (20-120 p.s.i.) to the heated laminate, thus forcing it to conform to the contour of the mold; evacuation of the air between the sheet and the mold is required. This process is typically used for containers and trays, and high appearance products.
  • Twin-sheet pressure forming is a process of injecting compressed air (20-120 p.s.i.) between two hot sheets, thus forcing it to conform to the contour of each of two molds mounted opposed to each other. Evacuation of the air between the sheet and the mold is required.
  • aspects of some embodiments of the present invention include a sealed container having packaged therein an article, a foodstuff, a drug, or any other single or plurality of objects, wherein the container is formed from the laminate provided herein. It is typical to form and fill the packaging, made from the laminate provided herein, at the same manufacturing process, namely the container is thermoformed, then the contents is placed therein, and thereafter the container is sealed with the cover, with or without modifying the atmosphere in the container.
  • aspects of some embodiments of the present invention include a sealed container having, e.g., a foodstuff, a drug or a substance, single or plurality of objects, that is/are sensitive to ambient atmosphere, contained therein, and further comprising a modified atmosphere enclosed therein; wherein the foodstuff is advantageously engulfed in the modified atmosphere for a time period that depends, inter alia, on the substantial impermeability of the cover seal and the container.
  • Modified atmosphere is the practice of modifying the composition of the internal atmosphere of a package (commonly food packages, drugs, etc.) in order to improve the shelf life. The need for this technology for food arises from the short shelf life of food products such as meat, fish, poultry, and dairy in the presence of oxygen.
  • Oxygen In food, oxygen is readily available for lipid oxidation reactions. Oxygen also helps maintain high respiration rates of fresh produce, which contribute to shortened shelf life. From a microbiological aspect, oxygen encourages the growth of aerobic spoilage microorganisms. Therefore, the reduction of oxygen and its replacement with other gases can reduce or delay oxidation reactions and microbiological spoilage. Oxygen scavengers may also be used to reduce browning due to lipid oxidation by halting the auto-oxidative chemical process. The modification process generally lowers the amount of oxygen (O2) in the headspace of the package. Oxygen can be replaced with nitrogen (N2), a comparatively inert gas, or carbon dioxide (CO2). A stable atmosphere of gases inside the packaging can be achieved using active techniques, such as gas flushing and compensated vacuum, or passively by designing“breathable” films, or selective semi-permeable barriers.
  • active techniques such as gas flushing and compensated vacuum, or passively by designing“breathable” films, or selective semi-permeable barriers.
  • the laminate provided herein is suitable for printing over its exposed surfaces before and/or after the packaging operation (thermoforming, filling and sealing), by selecting an exterior coating receptive to ink, or by selecting ink suitable for printing thereon.
  • aspects of some embodiments of the present invention include printable compostable and thermoformable laminates.
  • compostable and thermoformable laminate It is expected that during the life of a patent maturing from this application many relevant compostable and thermoformable laminates will be developed and the scope of the phrase “compostable and thermoformable laminate” is intended to include all such new technologies a priori.
  • compositions, method or structure may include additional ingredients, steps and/or parts, but only if the additional ingredients, steps and/or parts do not materially alter the basic and novel characteristics of the claimed composition, method or structure.
  • phrases “substantially devoid of” and/or “essentially devoid of” in the context of a certain substance refer to a composition that is totally devoid of this substance or includes less than about 5, 1, 0.5 or 0.1 percent of the substance by total weight or volume of the composition.
  • the phrases "substantially devoid of” and/or “essentially devoid of” in the context of a process, a method, a property or a characteristic refer to a process, a composition, a structure or an article that is totally devoid of a certain process/method step, or a certain property or a certain characteristic, or a process/method wherein the certain process/method step is effected at less than about 5, 1, 0.5 or 0.1 percent compared to a given standard process/method, or property or a characteristic characterized by less than about 5, 1, 0.5 or 0.1 percent of the property or characteristic, compared to a given standard.
  • a compound or “at least one compound” may include a plurality of compounds, including mixtures thereof.
  • a proof of concept of some embodiments of the present invention was carried out by preparing a four-layer laminate having alternating plies of STP and RCF, wherein the bottom layer of the laminate is seen as the outwards-facing side in the context of a container formed therefrom, and the top layer of the laminate is seen as the inwards-facing side in the context of the container.
  • PVDC-coated RCF 42 cm wide PVDC-coated cellophane
  • the lamination adhesive that was selected for affixing the lamella is a commonly used two-part solventless adhesive, used in an amount of about 4 g/m 2 .
  • the lacquer that was selected for sealing the out-facing side of the laminate is a commonly used PVDC-based lacquer, used in an amount of about 1 g/m 2 .
  • Machine for forming the laminate is a LAMIFLEXTM lamination machine by Soma Spol. S.R.O., Czech Republic.
  • the procedure for forming the 4-layers laminate was conducted sequentially, wherein the substrate for the first run is the first layer, the substrate for the second run was a laminate comprising the first layer and the second layer, and so on.
  • Example 1 The laminate described in Example 1 was used to form a lidded food packaging container in the shape of a tray.
  • the lid was cut from the same PVDC-coated RCF that was used for the interposed layer and the inwards-facing layer of the laminate.
  • the laminate was loaded as a 42 cm wide roll on a MultivacTM automatic tray sealer machine (Model R535) as well as a roll of impermeable barrier-coated RCF (about 30 g/m 2 ) to be used as a peelable heat sealed cover (lid) for the tray.

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Abstract

L'invention concerne un stratifié compostable et thermoformable, comprenant du papier étirable et un film de cellulose régénérée, et un matériau d'emballage entièrement compostable et des produits fabriqués à partir de celui-ci.
PCT/IL2020/050053 2019-01-24 2020-01-14 Matériau d'emballage compostable WO2020152671A1 (fr)

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WO2022048876A1 (fr) * 2020-09-04 2022-03-10 Société des Produits Nestlé S.A. Emballage alimentaire thermoformé à base de cellulose
WO2023079092A1 (fr) * 2021-11-08 2023-05-11 Futamura Chemical Uk Ltd Article biodégradable
WO2023180452A1 (fr) * 2022-03-23 2023-09-28 delsci GmbH Matériau d'emballage pour produits alimentaires comprenant une couche barrière intérieure
WO2024054210A1 (fr) * 2022-09-08 2024-03-14 Amcor Flexibles North America, Inc. Films d'emballage à base de papier à film barrière multicouche
WO2024079484A1 (fr) * 2022-10-13 2024-04-18 McCormick (UK) Limited Emballage et procédés de production de celui-ci
IT202200023127A1 (it) * 2022-11-09 2024-05-09 Pusterla 1880 S P A Elemento di confezione multistrato, confezione comprendente tale elemento e processo per realizzare tale elemento di confezione.
PL131308U1 (pl) * 2023-03-13 2024-09-16 Label-Pack Spółka Z Ograniczoną Odpowiedzialnością Naklejka adhezyjna ekologiczna
SE2350709A1 (en) * 2023-06-12 2024-12-13 Pulpac AB A method for producing a cellulose product and a cellulose product

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US20060275563A1 (en) * 2005-06-06 2006-12-07 Kevin Duffy Biodegradable and compostable material
US20100003431A1 (en) * 2008-07-02 2010-01-07 John Raybuck Composite materials

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US20100003431A1 (en) * 2008-07-02 2010-01-07 John Raybuck Composite materials

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2022048876A1 (fr) * 2020-09-04 2022-03-10 Société des Produits Nestlé S.A. Emballage alimentaire thermoformé à base de cellulose
WO2023079092A1 (fr) * 2021-11-08 2023-05-11 Futamura Chemical Uk Ltd Article biodégradable
WO2023180452A1 (fr) * 2022-03-23 2023-09-28 delsci GmbH Matériau d'emballage pour produits alimentaires comprenant une couche barrière intérieure
WO2024054210A1 (fr) * 2022-09-08 2024-03-14 Amcor Flexibles North America, Inc. Films d'emballage à base de papier à film barrière multicouche
WO2024079484A1 (fr) * 2022-10-13 2024-04-18 McCormick (UK) Limited Emballage et procédés de production de celui-ci
IT202200023127A1 (it) * 2022-11-09 2024-05-09 Pusterla 1880 S P A Elemento di confezione multistrato, confezione comprendente tale elemento e processo per realizzare tale elemento di confezione.
PL131308U1 (pl) * 2023-03-13 2024-09-16 Label-Pack Spółka Z Ograniczoną Odpowiedzialnością Naklejka adhezyjna ekologiczna
SE2350709A1 (en) * 2023-06-12 2024-12-13 Pulpac AB A method for producing a cellulose product and a cellulose product

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