Product and method for producing same

Abstract

A product is disclosed. The product may include a layer formed at least in part from a mixture including a reinforcing component and at least 10% (w / w) of cellulosic fibers having surface sealing properties.

Description

Technical Field

[0001] The present disclosure relates to a product and a method for producing the same. Background Art

[0002] The demand for packaging materials is growing significantly. Renewable, recyclable and biodegradable packaging solutions are needed.

[0003] Cellulose, for example in the form of cellulose fibers or pulp, is a renewable and biodegradable material that is very suitable for packaging solutions. However, plastic materials or other less environmentally friendly materials, such as fluorinated compounds, for example as a coating, may often be required to impart barrier properties to packaging materials formed primarily from cellulose. Such packaging materials are not fully biodegradable and their recycling can be complicated. Summary of the invention

[0004] A product is disclosed. The product may include a layer formed at least in part from a mixture including a reinforcing component and at least 10% (w / w) of cellulosic fibers having surface blocking properties. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] The accompanying drawings are included to provide a further understanding of the embodiments and constitute a part of this specification, and illustrate various embodiments. In the drawings:

[0006] Figure 1A One embodiment of the product is shown in cross-sectional view;

[0007] Figure 1B Another embodiment of the product is described;

[0008] Figure 1C Another embodiment of the product is described;

[0009] Figure 2A One embodiment of the product is shown in cross-sectional view;

[0010] Figure 2B Another embodiment of the product is described;

[0011] Figure 2C Another embodiment of the product is described;

[0012] Figure 2D yet another embodiment of the product is described;

[0013] Figure 2E yet another embodiment of the product is described;

[0014] Figure 3A The oxygen permeability of cellulose membranes is shown;

[0015] Figure 3B The oil permeability of cellulose membranes is shown;

[0016] Figure 4 shows a packaging material produced by compression molding a fiber body having a cellulose film layer;

[0017] Figure 5 shows a packaging material produced by calendering a fiber body with a cellulose film layer;

[0018] Fig. 6A Apparent bulk density values ​​for specific fiber blends are shown;

[0019] Figure 6B The tensile index values ​​for specific fiber blends are shown;

[0020] Figure 6C shows the strain-at-break values ​​for a particular fiber blend; and

[0021] Figure 7 Air permeability measurements of the multilayer structures are shown. DETAILED DESCRIPTION

[0022] A product is disclosed.

[0023] The product may comprise a layer formed at least in part from a mixture comprising a reinforcing component and at least 10% (w / w) of cellulosic fibres having surface blocking properties.

[0024] Cellulose fibers with surface-blocking properties are moldable materials, and when a mixture comprising cellulose fibers with surface-blocking properties is densified, for example by compression, a layer with low porosity can be obtained. For example, by calendering, a very dense structure can be obtained from the mixture. Such a layer can have barrier properties. For example, it can have the properties of a gas (oxygen) barrier and / or a grease barrier (e.g. an oil barrier).

[0025] Reinforcing components, such as cellulose fibers, can provide mechanical strength to the product.

[0026] A reinforcing component layer (e.g., a cellulose fiber layer, such as chemical pulp) has good strength but a porous structure; a cellulose fiber layer with surface closure properties, such as hydrolyzed cellulose fibers, can provide a denser, smoother structure, but less strength. A mixture comprising a reinforcing component and at least 10% (w / w) of cellulose fibers with surface closure properties can provide a balance between strength and density and provide a smooth surface finish.

[0027] The relative proportions of the reinforcing component and the cellulosic fibers having surface blocking properties can be selected so that the strength and density of the layer can be optimized as desired. The composition of the mixture can also be selected to obtain the desired barrier properties.

[0028] Such products do not necessarily require, for example, plastic coatings or other non-cellulose based layers or coatings. For example, barrier properties have traditionally been achieved using fluorinated compounds, which are, for example, harmful to the environment and may be phased out in the future. Avoiding or reducing the need to use additional surface chemicals, layers or coatings to achieve barrier properties may be very useful, for example for environmental reasons. Products according to one or more embodiments described in this specification can be biodegradable and relatively easily recycled using existing processes. For example, up to 50% of the cellulose fibers in the product can be recovered in a recycling process. The product can be composted. The product can be burned, and can burn relatively cleanly.

[0029] The CED viscosity of the cellulose fiber having surface blocking properties may range from 50 to 500 ml / g, or from 50 to 400 ml / g, or from 120 to 300 ml / g, or from 140 to 200 ml / g.

[0030] The cellulose fiber with surface blocking properties can be a modified cellulose fiber. The modified cellulose fiber can include, for example, hydrolyzed cellulose fiber; nanocellulose; microfibril cellulose; or any mixture or combination thereof; or the modified cellulose fiber can be, for example, hydrolyzed cellulose fiber; nanocellulose; microfibril cellulose; or any mixture or combination thereof.

[0031] The cellulosic fibers having surface blocking properties may include or may be hydrolyzed cellulosic fibers. Hydrolyzed cellulosic fibers are readily available and have properties that are well suited for inclusion in the blend.

[0032] In the context of the present disclosure, the term "hydrolyzed cellulose fibers" may be understood to refer to cellulose fibers that have been treated, and the treatment has at least partially hydrolyzed the cellulose chains of the cellulose fibers, for example compared to comparable unhydrolyzed cellulose fibers. Hydrolysis may be obtained by alkaline hydrolysis, autohydrolysis or other types of hydrolysis. Therefore, the average length of the cellulose chains of the hydrolyzed cellulose fibers may be less than the average length of the cellulose chains of comparable unhydrolyzed cellulose fibers. Certain properties of cellulose fibers, such as CED viscosity, may be affected by hydrolysis. Hydrolyzed cellulose fibers (may) be obtained by, for example, enzymatic hydrolysis of cellulose fibers for 2-3 hours using cellulolytic enzymes and / or by acid or alkaline hydrolysis. Hydrolyzed cellulose fibers may be, for example, hydrolyzed pulp or include, for example, hydrolyzed pulp. In this article, the pulp of the hydrolyzed pulp may be any pulp described in this specification.

[0033] Cellulosic fibres with surface blocking properties, such as modified cellulose fibres, are for example obtainable by hydrolysis or electron beam technology, optionally followed by further hydrolysis, such as alkaline hydrolysis.

[0034] The CED viscosity of the hydrolyzed cellulose fibers may range from 50 to 500 ml / g. In some embodiments, the CED viscosity of the hydrolyzed cellulose fibers may range from 50 to 400 ml / g, or range from 120 to 300 ml / g, or range from 140-200 ml / g.

[0035] The term "CED viscosity" may be understood to mean the limiting viscosity number in copper ethylenediamine (CED) solution. The CED viscosity may be measured, for example, according to the ISO 5351:2010 standard.

[0036] The degree of polymerization (DP) of the hydrolyzed cellulose fibers may range from about 100 to 700, or from about 120 to 300. The degree of polymerization may be measured, for example, using standard ISO 5351:2010 (en). The degree of polymerization (DP) may be estimated from the CED viscosity value obtained according to the standard as follows:

[0037] DP=0.75[μ] 1 / 0.905 , where [μ] is the CED viscosity value.

[0038] In some embodiments, the cellulose fibers with surface blocking properties may be obtained by pretreatment or modification, such as surface modification, cellulose ester saponification or phosphorylation. The cellulose fibers with surface blocking properties may have traces of processes that result in, for example, surface chemical changes.

[0039] A proportion of at least 10% (w / w) of cellulose fibers having surface-blocking properties is understood to be the dry weight of cellulose fibers having surface-blocking properties based on the total dry weight of the mixture and / or of the layer at least partly formed from the mixture.

[0040] The mixture can contain, for example, at least 20% (w / w), or at least 30% (w / w), or at least 40% (w / w), or at least 50% (w / w), or at least 60% (w / w), or at least 70% (w / w), or at least 80% (w / w), or 100% (w / w) of cellulose fibers having surface-blocking properties.

[0041] The properties (such as degree of polymerization and / or CED viscosity) of the cellulose fiber and reinforcing component (such as cellulose fiber) with surface closure performance can be different from each other. The ratio of cellulose fiber and reinforcing component and optional other components can be selected so that the properties of the layer at least partially formed by the mixture meet the requirements. For example, increasing the ratio of cellulose fiber with surface closure performance can increase the density of the layer at least partially formed by the mixture, which can reduce the permeability to, for example, grease and / or oxygen. Therefore, the ratio of cellulose fiber with surface closure performance can be selected to achieve required density, required barrier properties and / or required smoothness. Reinforcing component can be provided in a desired ratio, for example, to provide required intensity and / or other properties for the layer at least partially formed by the mixture.

[0042] The CED viscosity of the reinforcing component (e.g., cellulose fiber) may be greater than 500 ml / g, for example, in the range of about 500 to 3000 ml / g. In some embodiments, the CED viscosity of the reinforcing component (e.g., cellulose fiber) may be, for example, in the range of 800 to 1200 ml / g, or in the range of 900 to 1100 ml / g.

[0043] In the embodiment where the reinforcing component includes cellulose fibers or is cellulose fibers, the cellulose fibers of the reinforcing component may be other cellulose fibers, ie, cellulose fibers other than cellulose fibers having surface blocking properties.

[0044] The reinforcing component, such as cellulosic fibers, can include, for example, unmodified and / or non-hydrolyzed cellulosic fibers, or be, for example, unmodified and / or non-hydrolyzed cellulosic fibers.

[0045] The fiber of cellulose fiber (including cellulose fiber of reinforcing component and / or cellulose fiber with surface closure performance, such as hydrolysis or non-hydrolysis cellulose fiber) can be natural fiber, such as lignocellulose fiber, cellulose fiber, cellulose fiber derivative, wood derivative or any combination or mixture thereof. The fiber in cellulose fiber can be natural source fiber, such as modified natural source fiber, and / or cellulose-based fiber. The fiber in cellulose fiber can be virgin, regenerated or secondary natural fiber, or any mixture or combination thereof. Cellulose fiber can be, for example, short fiber. Cellulose fiber can be the fiber derived from, for example, cotton or cotton linter. Cellulose fiber can include, for example, pulp or, for example, pulp. Pulp can include, for example, wood pulp (such as hardwood and / or softwood pulp), non-wood pulp and / or agricultural pulp (agropulp), or, for example, wood pulp (such as hardwood and / or softwood pulp), non-wood pulp and / or agricultural pulp (agropulp). Pulp can be chemical pulp, such as kraft pulp, soda pulp, sulfate pulp or organic solvent pulp. The pulp may be mechanical and thermal pulp (TMP), mechanical pulp (ground wood (GW), pressure ground wood (PGW), refined mechanical pulp (RMP)) and / or chemithermomechanical pulp (CTMP). Additionally or alternatively, the pulp may be an undried pulp, such as an undried kraft pulp. The cellulose fibers or pulp may include or may be recycled fibers. The fibers in the cellulose fibers may include at least one of wood pulp, non-wood pulp, short fibers, recycled fibers, or any mixture or combination thereof, or may be at least one of wood pulp, non-wood pulp, short fibers, recycled fibers, or any mixture or combination thereof. In some embodiments, the fibers in the cellulose fibers may not contain man-made fibers and / or oil-based fibers. Short fibers having a desired length may be combined with other types of reinforcing components, such as other types of cellulose fibers.

[0046] The reinforcing component, such as cellulose fibers, may include or may be natural and / or man-made cellulose fibers having a CED viscosity in the range of 500-3000 ml / g. Man-made cellulose fibers may have a lower CED viscosity, at least in some embodiments.

[0047] In the context of the present specification, the term "unmodified cellulose fibers" may refer to cellulose fibers that have not been intentionally subjected to substantial chemical modification. Unmodified cellulose fibers may, for example, be unhydrolyzed. However, unmodified cellulose fibers may, for example, be chemical pulps, such as kraft pulps, and may, for example, be bleached during the production of chemical pulps. Although, for example, the kraft pulping process may result in slight hydrolysis of the cellulose fibers, chemical pulps may still be considered to be or contain unmodified cellulose fibers.

[0048] The reinforcing component, such as cellulosic fibers, may be or include chemical pulp, such as kraft pulp, sulfate pulp, and / or organosolv pulp; and / or staple fibers.

[0049] The mixture may include about 10 to 90% (w / w) of the cellulose fibers having surface blocking properties and about 10 to 90% (w / w) of the reinforcing cellulose fibers.

[0050] The mixture may contain about 20 to 50% (w / w) of cellulose fibers having surface blocking properties and about 50 to 80% (w / w) of a reinforcing component, such as cellulose fibers.

[0051] The mixture may contain about 20 to 40% (w / w) of cellulose fibers having surface blocking properties and about 60 to 80% (w / w) of a reinforcing component, such as cellulose fibers.

[0052] The weight ratio of the cellulose fiber having surface blocking properties to the reinforcing component (eg, cellulose fiber) may be in the range of about 10:90 to about 50:50, or in the range of about 20:80 to about 40:60.

[0053] The product may be a moldable product or a molded product.

[0054] The moldable product can be, for example, a sheet or a flat structure. Such a moldable product can be molded into a final form having a desired shape. Various methods can be used to mold the product.

[0055] The molded product may be, for example, a container or a receptacle, such as a cup or a plate. However, the shape of the molded product is not particularly limited.

[0056] The product can be flexible, or a flexible product. The product can also be rigid, or a rigid product.

[0057] The product may be, for example, a packaging material, a wrapping paper, a wrapping paper, a protective paper, a packaging board, a packaging 3D material, a decorative paper, an envelope, a container or a release liner.

[0058] The product may be formed primarily from cellulose based materials.

[0059] In some embodiments, the product may be formed substantially from or entirely from cellulose-based materials.

[0060] However, in such products, the presence of small amounts of non-cellulose-based materials is not necessarily excluded. For example, a product mainly or substantially formed of cellulose-based materials may contain, for example, non-cellulose-based binders, such as glue, additives, pigments or inks.

[0061] In the context of this specification, the term "mainly formed of cellulose-based materials" may refer to a product in which at least 85% (w / w), or at least 95% (w / w), or at least 98% (w / w), or at least 99% (w / w) or 100% (w / w) of the material is cellulose-based material.

[0062] The product may be biodegradable. The product may be biodegradable as determined by OECD Chemical Testing Standard 301F.

[0063] In at least some embodiments, the term "biodegradable" may refer to readily biodegradable products measured according to OECD chemical testing standard 301F (manometric respiratory test). A readily biodegradable product may be a product that reaches at least 60% biodegradation within 28 days measured according to OECD chemical testing standard 301F.

[0064] Products may be recyclable.

[0065] The product may comprise or consist of a single layer at least partially formed from a mixture comprising a reinforcing component, such as cellulose fibers, and at least 10% (w / w) of cellulose fibers having surface blocking properties. The product may comprise a single layer mixture. In other words, the product may be a single layer product. However, in some embodiments, the product may comprise two or more layers, such as at least partially formed from a mixture. In such embodiments, the product may therefore be formed by adding two or more layers formed from a mixture, thereby effectively forming a single layer. The product may consist of one or more layers formed from a mixture.

[0066] In other embodiments, the product may include one or more layers, such as two or more layers. At least one layer of the product may be a layer formed at least in part from a mixture comprising a reinforcing component, such as cellulose fibers, and at least 10% (w / w) cellulose fibers having surface blocking properties.

[0067] In the context of this specification, unless otherwise specified, the term "layer" is understood to mean a layer at least partially formed of a mixture comprising a reinforcing component, such as cellulose fibers, and at least 10% (w / w) cellulose fibers having surface-blocking properties.

[0068] The product may include an additional layer, or one or more additional layers. In other words, in some embodiments, the product may be a multilayer product. For example, the product may include an additional base layer. Such a base layer may have a composition different from the composition of the layer formed at least in part by the mixture. Such a base layer may be formed at least in part by, for example, a reinforcing component, such as cellulose fibers. The reinforcing component of the base layer, such as cellulose fibers, may be, for example, any reinforcing component described in this specification. The product may include one or more base layers, such as one or two base layers.

[0069] The product may also include additional layers. For example, the product may include an intermediate layer (or at least one intermediate layer) between the base layer and the layer at least partially formed by the mixture. Such an intermediate layer may also be based on cellulose fibers. However, its composition may be different from the base layer and / or the layer at least partially formed by the mixture.

[0070] The product may comprise a base layer and two layers formed at least in part of the mixture, the layers formed at least in part of the mixture being arranged on opposite sides of the base layer.

[0071] The product may comprise a layer formed at least in part by the mixture and two base layers, the base layers being arranged on opposite sides of the layer formed at least in part by the mixture.

[0072] The layer formed at least in part from the mixture may be a densified and / or compressed layer. In other words, the layer formed at least in part from the mixture may be a densified and / or compressed layer.

[0073] The base layer may be dense and / or compressed. In other words, the base layer may be a dense and / or compressed layer.

[0074] The layer formed at least in part from the mixture and the base layer (or any or all such layers) may be densified and / or compressed.

[0075] Densification can be performed, for example, by wet calendering or dry calendering. Wet calendering can further improve densification.

[0076] However, compression or densification may not always be necessary to achieve the desired barrier properties. For example, a layer formed at least in part of the mixture can be formed by spraying the material of the layer onto the base layer (or, in some embodiments, onto another additional layer). As another example, the layer formed at least in part of the mixture and the base layer (and any additional layers, if present) can be formed, for example, in a double-layer or multi-layer headbox of a paper or board machine.

[0077] Densification and / or compression can provide, for example, a certain oxygen permeability to the layer and / or product. Densification and / or compression can provide, for example, a certain smoothness to the layer and / or product.

[0078] The weight of the layer at least partly formed from the mixture may be in the range of 20 to 1000 gsm (grams per square meter). However, the weight (grammage) of the layer may depend, for example, on whether the product comprises any other layers.

[0079] In at least some embodiments, the thickness of the layer formed at least in part from the mixture may be 300 μm or less, or in the range of 1-200 μm, or in the range of 10-100 μm, or in the range of 10-40 μm. However, the thickness of the layer may depend, for example, on whether the product includes any other layers. Products in single-layer form (e.g., molded cups or trays) may be very thick. In products that include other layers (e.g., reinforcing base layers), the layer formed at least in part from the mixture may be relatively thin.

[0080] The base layer may be formed from a densified mixture of cellulose fibers.

[0081] The weight of the base layer may be, for example, at least 20 gsm, or in the range of 20 - 800 gsm, or in the range of 40-800 gsm (grams per square meter).

[0082] In some embodiments, the product does not contain any plastic or metal. In some embodiments, the product may not contain inorganic materials, such as pigments.

[0083] The product may also include a surface chemical for providing barrier properties, which is applied to the layer at least partially formed by the mixture. Such a surface chemical may include or may be a starch, a wax, a fatty acid, an alkyl ketene dimer, an alkyl succinic anhydride, a thermoplastic component or any combination or mixture thereof. The surface chemical may or may not chemically react with the cellulose of the cellulose fibers; this may depend on its chemical nature. The surface chemical may be covalently or non-covalently attached to the cellulose. The surface chemical may be physically attached to the cellulose. It may, for example, impregnate the layer at least partially formed by the mixture and / or the base layer and / or any other additional layers and provide the desired physical properties to the product.

[0084] The product may also comprise a coating covering the layer at least partly formed from the mixture and / or the base layer or any other layer.

[0085] A coating can be the outermost layer of a product.

[0086] The coating can be, for example, a hot melt coating, a dip coating, or a carton coating, or can be applied as, for example, a hot melt coating, a dip coating, or a carton coating. Such coatings, such as hot melt coatings, can improve the heat sealing properties of the product.

[0087] The product may also include a cellulose film layer. In other words, the product may also include a coating, which is a cellulose film layer. The cellulose film layer may be formed by solidifying an alkaline cellulose concentrate. The cellulose film layer may cover a layer and / or a base layer, or any other layer (if present), at least partially formed by a mixture. The cellulose film layer may cover a layer and / or a base layer, or any other layer (if present), at least partially formed by a mixture, so that the cellulose film layer may be the outermost layer of the product. The cellulose film layer may improve the oxygen and / or grease barrier properties of the product. However, this embodiment is not necessarily moldable. When the product is already molded, a cellulose film layer may be added. When the coating is a cellulose film layer, it may also be biodegradable. Therefore, in contrast to products such as those comprising a plastic coating, the entire product (of the present invention) may be cellulose-based and optionally biodegradable.

[0088] In the context of this specification, the term "alkali cellulose dope" can be understood as a solution comprising cellulose dissolved in an alkaline solution (usually in a cold alkaline dope). For example, the alkali cellulose dope can be a cellulose spinning solution (i.e., an alkali cellulose spinning solution) or a cellulose solution (i.e., an alkali cellulose solution) for extrusion, spinning, electrostatic spinning, molding, casting, film formation, film extrusion, cellulose bead production, coating, spraying and / or 3D printing. In other words, it can refer to a cellulose material in an alkaline solution suitable for, for example, spinning filaments, staple fibers, film manufacturing, cellulose bead production and various other uses. The alkali cellulose dope can be condensed into solid cellulose under suitable conditions, for example, condensed into type II cellulose.

[0089] Providing a cold alkaline solution may typically include mixing and / or dissolving an alkaline agent such as NaOH and an optional solvent or stabilizer such as a zinc compound (e.g. ZnO) with water. They may be mixed under conditions suitable for dissolving the components in water, such as at an elevated temperature, such that an alkaline agent such as NaOH is added at a concentration of at least 40% (w / w). The elevated temperature may be, for example, a temperature of at least 60° C. The resulting alkaline solution may then be diluted. The alkaline agent in the (cold) alkaline solution may include or may be, for example, NaOH, LiOH, KOH and / or any mixture or combination thereof.

[0090] The cellulose film layer can be applied by, for example, calendering. This can be achieved by, for example, extruding and coagulating an alkaline cellulose dope to prepare the cellulose film and preparing the product separately. The product and the cellulose film can be combined and calendered so that the cellulose film is attached to the product and forms a cellulose film layer.

[0091] Alternatively, the cellulose film layer may be formed by surface treatment. The product may be surface treated, for example, by a hydroxide (e.g., NaOH) such that the cellulose fibers on the surface of the product are at least partially dissolved and subsequently coagulated, thereby forming a cellulose film layer. The cellulose film layer formed by surface treatment may be similar to a cellulose film layer prepared, for example, by coagulating an alkaline cellulose concentrate.

[0092] The product may also include an adhesive layer between a layer and an additional layer (e.g., base layer) formed at least in part by the mixture. The product (e.g., multilayer product) may include an adhesive layer (or another adhesive layer) between one or more other layers. The adhesive layer may connect a layer and a base layer and / or any other layer (depending on the presence and arrangement of the embodiment and layer) formed at least in part by the mixture to each other. Adhesive may be, for example, a bio-based and / or biodegradable adhesive, such as a bio-based and / or biodegradable glue.

[0093] The product may also include an ink and / or paint layer. The ink and / or paint layer may be formed, for example, by printing ink or painting on the surface of the product.

[0094] The product, especially when it does not contain a cellulose film layer, can have an oxygen transmission rate of 1000 cm 3 / (m 2 ·day) or lower, or 100cm 3 / (m 2 ·day) or lower, or 20cm 3 / (m 2 In other embodiments, the product, particularly when it comprises a cellulose film layer, may have an oxygen permeability of 20 cm 3 / (m 2 ·day) or less, or 5cm 3 / (m 2 ·day) or less, or 1cm 3 / (m 2 · days) or less.

[0095] Oxygen permeability can be measured at 23°C and 50% relative humidity. Oxygen permeability can be measured using a MOCON OX-TRAN@ instrument. The instrument design and operation can comply with the ASTM D 3985 standard. In some embodiments, the oxygen permeability can be measured using a Mocon Ox-Tran 2 / 21MH instrument according to one of the standards ASTM D3985, ASTM F1927, or ISO 15105-2. In one embodiment, the oxygen permeability is measured at 23°C and 0% relative humidity, 100% O2 using a MOCON OX-TRAN instrument according to the ASTM D 3985 standard.

[0096] The product, particularly when it does not contain a cellulose film layer, may have an oxygen transmission rate of 1000 cm2 at 23°C and 0% relative humidity, 100% O2. 3 / (m 2 ·day) or lower, or 100cm 3 / (m 2 ·day) or lower, or 20cm 3 / (m 2 In other embodiments, the product, particularly when it comprises a cellulose film layer, may have an oxygen transmission rate of 20 cm2 at 23°C and 0% relative humidity and 100% O2. 3 / (m 2 ·day) or less, or 5cm 3 / (m 2 ·day) or less, or 1cm 3 / (m 2 · days) or less.

[0097] The composition of the product, such as the presence or absence of a cellulose film layer or surface chemicals, or densification and / or compression, may have a significant impact on water vapor permeability and oil permeability (e.g., as measured by heptane vapor transmission rate.) Therefore, the values ​​of such parameters may vary significantly for products according to various embodiments described herein.

[0098] The water vapor permeability of the product, in particular the product comprising a cellulose film layer, may be, for example, 300 g / (m 2 ·day) or less, or 100g / (m 2 ·day) or less, or 30g / (m 2 Water vapor permeability can be measured at 23°C and 50% relative humidity.

[0099] The water vapor permeability of the product, in particular a product comprising a cellulose film layer and a surface chemistry (such as any of the surface chemistry described in this specification) and / or densification (such as by calendering) may be, for example, 100 g / (m 2 ·day) or lower, or 50g / (m 2 ·day) or lower, or 20g / (m 2 Water vapor permeability can be measured at 23°C and 50% relative humidity.

[0100] The product, in particular a product comprising a cellulose film layer, may have a density of, for example, 100 g / (m 2 ·day) or less, or 50g / (m 2 ·day) or lower, or 5g / (m 2·day) or less. The heptane vapor transmission rate can be measured at 23°C and 50% relative humidity.

[0101] The product may be semi-transparent and / or translucent. This may depend, for example, on the composition of the layer at least partially formed by the mixture and any other additional layers. The layer at least partially formed by the mixture and, for example, the base layer may be densified to the extent of being semi-transparent and / or translucent.

[0102] The light transmittance of the product may be in the range of 0 to 70%, or in the range of 1 to 70% or 20 to 70%. The light transmittance may be understood to refer to visible light transmittance. The light transmittance may be measured, for example, using an optical profilometer.

[0103] A method of producing a product according to one or more embodiments described in this specification is disclosed. The method may include forming a layer from a mixture comprising a reinforcing component (eg, cellulose fibers) and cellulose fibers having surface blocking properties.

[0104] The method may comprise providing a mixture comprising a reinforcing component, such as cellulose fibers, and cellulose fibers having surface blocking properties; and forming a layer. A product may be obtained thereby. For example, a single-layer product may be obtained thereby.

[0105] The method may include providing a mixture comprising a reinforcing component (e.g., cellulose fibers) and cellulose fibers having surface-blocking properties; providing a base material; forming a layer from the mixture comprising a reinforcing component (e.g., cellulose fibers) and cellulose fibers having surface-blocking properties; forming the base; and forming a product therefrom.

[0106] The material and composition of the layers and, for example, the base layer (if present) may be in accordance with one or more embodiments described in this specification.

[0107] The mixture comprising reinforcing cellulose fibers and cellulose fibers having surface closure properties can be formed into a web, and the web can be calendered to form a layer formed at least in part of the mixture. Densification can be performed by, for example, wet calendering or dry calendering. Wet calendering can further improve densification. The web can be calendered using, for example, a nip pressure of 3 to 350 kN / m.

[0108] The method may further comprise moulding the product. The product may be moulded from a dry web or from a suspension.

[0109] The cellulose film layer can be applied by calendering. This can be achieved by, for example, preparing the cellulose film by extruding and coagulating an alkaline cellulose concentrate and preparing the product separately. The product and the cellulose film can be combined and calendered so that the cellulose film is attached to the product and forms a cellulose film layer.

[0110] The method may further comprise forming a cellulose film layer on the product by surface treatment. The product may be surface treated, for example, by a hydroxide (e.g., NaOH) such that cellulose fibers on the surface of the product are at least partially dissolved and subsequently coagulated, thereby forming a cellulose film layer. The cellulose film layer formed by surface treatment may be similar to a cellulose film layer prepared, for example, by coagulating an alkaline cellulose dope.

[0111] Example

[0112] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings.

[0113] The following description discloses some embodiments in detail so that those skilled in the art can utilize these embodiments based on the present disclosure. Not all steps or features of the embodiments are discussed in detail because many steps or features are obvious to those skilled in the art based on the present description.

[0114] Figure 1A An embodiment of product 1 is described in cross-sectional view. Product 1 is a single-layer product, comprising a layer 2 formed of a mixture comprising cellulose fibers as a reinforcing component and at least 10% (w / w) of cellulose fibers having surface-blocking properties. The composition of the mixture forming layer 2 can be any composition of the mixture described in this specification. Product 1 in this exemplary embodiment is flat or sheet-like and can be molded into a desired shape.

[0115] Figure 1B Another embodiment of the product 1 is described. The product 1 and Figure 1A The product 1 is similar to the product shown in , except that the product 1 further comprises a coating 3. The coating can be, for example, a plastic coating. In some embodiments, the coating 3 can be, for example, a cellulose film layer. The coating 3 is arranged on the layer 2 formed by the mixture. It at least partially covers the layer 2, or as Figure 1B The complete covering layer 2 is shown.

[0116] Figure 1C Another embodiment of the product 1 is depicted in cross-sectional view. Figure 1A The product shown in is similar to that shown in , except that it is a molded product, such as a cup or tray. As will be appreciated by those skilled in the art, various other shapes may be envisioned.

[0117] Figure 2AAn embodiment of a product 1 is depicted in a cross-sectional view. In this exemplary embodiment, the product 1 is a multi-layer product. The multi-layer product 1 comprises a layer 2 formed of a mixture, wherein the mixture comprises cellulose fibers as a reinforcing component and at least 10% (w / w) of cellulose fibers having surface-blocking properties, and a base layer 4 formed of, for example, the reinforcing component (e.g., cellulose fibers). The layer 2 at least partially covers the base layer 4, or Figure 2A As shown, the base layer 4 is completely covered.

[0118] Figure 2B Another embodiment of a multilayer product 1 is described. The multilayer product 1 is similar to Figure 2A The product shown in FIG. 1 is different in that the multilayer product 1 further includes a coating 3. The coating may be similar to Figure 1B In some embodiments, the coating 3 may be, for example, a cellulose film layer. The coating 3 is disposed on the layer 2 formed by the mixture. It at least partially covers the layer 2, or Figure 2B As shown, the coating 3 completely covers the layer 2. However, as will be appreciated by those skilled in the art, the coating 3 may be disposed on the base layer 4 as an alternative or in addition. It will also be appreciated by those skilled in the art that the coating 3 may also include FIG. 2C to FIG. 2E In any of the embodiments shown.

[0119] Figure 2C Another embodiment of a multilayer product 1 is described. The multilayer product 1 is similar to Figure 2A The product shown in , differs in that the multilayer product 1 comprises three layers: a base layer 4 and two layers 2 and 2 'formed from a mixture. The layers 2 and 2 'are arranged on opposite sides of the base layer 4.

[0120] Figure 2D A further embodiment of a multilayer product 1 is described. The multilayer product 1 is similar to Figure 2C The product shown in , differs in that the multilayer product 1 comprises three layers: two base layers 4 and 4 ′ and a layer 2 formed of a mixture. The base layers 4 and 4 ′ are arranged on opposite sides of the layer 2 .

[0121] Figure 2E A further embodiment of a multilayer product 1 is described. The multilayer product 1 is similar to Figure 2A The product shown in , except that the multilayer product 1 further comprises an adhesive layer 5 located between the base layer 4 and the layer 2 at least partially formed by the mixture. The adhesive layer 5 extends between the base layer 4 and the layer 2, and can attach the base layer 4 and the layer 2 to each other. The adhesive in the adhesive layer 5 can be, for example, any adhesive described in this specification.

[0122] Figures 2A to 2EThe exemplary embodiments shown are flat or sheet-like and may be moldable or molded into a desired shape.

[0123] Example 1

[0124] The oxygen transmission rate (OTR) and fat permeability of cellulose films were measured. Cellulose films were prepared by regenerating an alkaline cellulose concentrate in citric acid with or without the addition of a plasticizer and then drying the prepared films at 180°C and 410 kPa for 3 minutes. The oxygen transmission rate and fat permeability of the films were measured.

[0125] Figure 3A The oxygen transmission rate of cellulose membrane at 23°C and 50% relative humidity is shown. Figure 3B Shown is the grease permeability at 40°C.

[0126] Example 2

[0127] The fiber composition (fiber body, i.e., substrate) coated with a cellulose film layer was evaluated. The cellulose film layer was directly applied by sandwiching the structure in a compression molding process. The fiber body and film layer were first conditioned in an appropriate humidity chamber and compression molded at 80°C with a pressure of 410 kp for 20 minutes, or at 95°C with a pressure of 650 kp for 20 minutes. The preconditioning of the fiber body and film as well as the applied pressure and temperature can be adjusted as required.

[0128] Figure 4 A packaging material produced by compression molding of a fiber body and a cellulose film layer is shown.

[0129] Example 3

[0130] Cellulose film-coated fiber compositions (fiber bodies, i.e., substrates) applied by a calendering process were evaluated. First, the fiber bodies and / or films were conditioned in an appropriate humidity chamber and calendered at 80°C and 500 kp pressure or at 100°C and 6000 kp pressure. The preconditioning of the fiber bodies and films, as well as the applied pressure and temperature, can be adjusted as desired.

[0131] Figure 5 Shown is a packaging material produced by calendering a fiber body with a cellulose film.

[0132] Example 4

[0133] The physical and mechanical properties of mixtures containing kraft softwood pulp fibers and hydrolyzed kraft softwood pulp fibers with different CED viscosities were evaluated. Pulp 1 refers to hydrolyzed kraft softwood pulp fibers with a CED viscosity of 166 ml / g, and pulp 2 refers to hydrolyzed kraft softwood pulp fibers with a CED viscosity of 200 ml / g. Formulation x:y represents the dry weight fiber mixture with kraft softwood pulp fibers: pulp 1 or pulp 2. For example, 60:40 represents a formulation with 60% kraft softwood pulp fibers and 40% pulp 1 or pulp 2. The physical and mechanical properties of the formulations are as follows: Fig. 6A , 6B and 6C.

[0134] Fig. 6A Apparent bulk density values ​​are shown for specific fiber blends.

[0135] Figure 6B The tensile index values ​​for specific fiber blends are shown.

[0136] Figure 6C The strain-at-break values ​​for specific fiber blends are shown.

[0137] Example 5

[0138] Multilayer sheets of two or three layer combinations were produced by combining the softwood base layer with pulp 1 (hydrolyzed kraft softwood pulp fibers with a CED viscosity of 166 ml / g) in different combinations. For example, a two-layer sheet was produced by stacking the softwood base layer with a pulp 1 layer. For three layers, the pulp 1 layer was sandwiched between two softwood layers. The air permeability of the resulting multilayer structure was measured according to ISO 5636-3, as Figure 7 shown.

[0139] It is obvious to a person skilled in the art that, as technology develops, the basic idea can be implemented in various ways. Therefore, the implementations are not limited to the above-described embodiments; instead, they may vary within the scope of the claims.

[0140] The embodiments described above can be used in any combination with each other. Several embodiments can be combined to form further embodiments. The methods, products or uses disclosed herein may include at least one embodiment described above. It is understood that the above benefits and advantages may relate to one embodiment, or may relate to several embodiments. The embodiments of the present invention are not limited to embodiments that can solve any or all of the problems described, nor are they limited to embodiments that have any or all of the benefits and advantages described. It should be further understood that the "one" item mentioned refers to one or more items therein. The term "comprising" used in this specification includes the features or behaviors thereafter, without excluding the presence of one or more other features or behaviors.

Claims

1. A product comprising a layer formed at least in part from a mixture comprising a reinforcing component and at least 10% (w / w) of cellulose fibers having surface-blocking properties.

2. The product according to claim 1, wherein The product is formed predominantly from a cellulose-based material and / or wherein the reinforcing component comprises cellulose fibers or the reinforcing component is a cellulose fiber.

3. The product according to claim 1 or 2, wherein: The product is a packaging material, a packaging paper, a wrapping paper, a protective paper, a packaging board, a packaging 3D material, a decorative paper, an envelope, a container or a release liner.

4. The product according to any one of claims 1 to 3, wherein The product is a moldable product or a molded product.

5. The product according to any one of claims 1 to 4, wherein The product is determined to be biodegradable according to OECD Chemical Substance Testing Standard 301F.

6. The product according to any one of claims 1 to 5, wherein The cellulose fibers having surface blocking properties include modified cellulose fibers, or the cellulose fibers having surface blocking properties are modified cellulose fibers, such as hydrolyzed cellulose fibers.

7. The product according to any one of claims 1 to 6, wherein The CED viscosity of the cellulose fiber having surface blocking properties ranges from 50 to 500 ml / g, or from 50 to 400 ml / g, or from 120 to 300 ml / g, or from 140 to 200 ml / g.

8. The product according to any one of claims 1 to 7, wherein The reinforcing component comprises or is a chemical pulp, such as kraft pulp, sulfate pulp and / or organosolv pulp; and / or short fibers.

9. The product according to any one of claims 1 to 8, wherein The product further comprises a surface chemical applied to the layer for providing barrier properties, such as starch, wax, fatty acid, alkyl ketene dimer, alkyl succinic anhydride, thermoplastic component, or any combination or mixture thereof.

10. The product according to any one of claims 1 to 9, wherein The layers are densified and / or compressed.

11. The product according to any one of claims 1 to 10, wherein The weight of the layer is in the range of 20 gsm to 1000 gsm.

12. The product according to any one of claims 1 to 11, wherein The product described does not contain any plastic or metal.

13. The product according to any one of claims 1 to 12, wherein The product further comprises a cellulose film layer (4) optionally formed by coagulating an alkaline cellulose dope.

14. The product according to any one of claims 1 to 12, wherein The oxygen permeability of the product is 1000cm 3 / (m 2 ·day) or lower, 100cm 3 / (m 2 ·day) or lower, or 20cm 3 / (m 2 · days) or less; or the product according to claim 13, wherein the oxygen permeability of the product is 20cm 3 / (m 2 ·day) or lower, or 5cm 3 / (m 2 ·day) or less, or 1cm 3 / (m 2 · days) or lower.

15. The product according to any one of claims 1 to 14, wherein The product is translucent and / or translucent.

16. A method of producing a product as claimed in any one of claims 1 to 15, the method comprising forming the layer from a mixture comprising a reinforcing component and cellulosic fibres having surface blocking properties.

17. The method of claim 16, wherein: A mixture comprising a reinforcing component, such as cellulose fibers, and cellulose fibers having surface blocking properties is formed into a web, and the web is then calendered to form the layer.

18. The method according to claim 16 or 17, wherein: The method further comprises molding the product, optionally from a dry web or a suspension.

Images