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Apparatus, systems and methods for making re-pulpable insulated paper products

a technology of re-pulpable insulated paper and apparatus, which is applied in the field of apparatus and systems for making insulated paper products, can solve the problems of increasing the downtime of the paper machine, and affecting the quality of the paper

Inactive Publication Date: 2020-09-10
TRIPLE POINT INNOVATIONS LLC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention is about machine configurations that can make insulated paper products that can keep food cold or hot without needing extra inserts. The paper products have multiple ways to introduce insulating materials, such as into the paper furnish or as adhesive between layers. The insulated paper products can be made fully recyclable, repulpable, and biodegradable. The method involves forming an insulated paper product with paper layers and insulating material, where the insulating material can be introduced into one or more layers of paper or formed in a non-uniform distribution throughout the paper.

Problems solved by technology

Expanded polystyrene (1) is persistent in the environment, contributing to ocean pollution and long term landfills, (2) is frequently litter that is unsightly and may cause obstruction in the guts of smaller animals when ingested, (3) is not recyclable in most municipalities, (4) has to be separated from the box prior to recycling, (5) has to be inserted inside the box, and (6) does not nest, meaning that it is expensive to ship, and bulky to store.
Introducing treatments, coatings, liners, and other materials into the cardboard box that cannot be fed directly back into the re-pulping process complicates the production process and risks increasing paper machine (FIG. 8) down-time if mistakes are made.
None of these materials can be used in a cardboard box manufacturing line because any scrap containing these synthetic polymers would have to be segregated from the regular pulp.
Furthermore, the insulating material has to be removed prior to recycling the box as many municipalities do not recycle plastic films or expanded polystyrene.
For similar reasons, some paper beverage cups are also difficult to recycle.
They are coated with a low molecular weight polyethylene, which causes problems when introduced into the pulp.

Method used

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  • Apparatus, systems and methods for making re-pulpable insulated paper products

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embodiment 32

33. The system of embodiment 32, wherein the particles having an average particle size of less than about 500 microns (μm).

34. The system of embodiment 32 or 33, wherein the particles having a multi-modal particle size distribution.

35. The system of any one of embodiments 32 to 34, wherein said particles consist of perlite, expanded perlite, perlite hollow microspheres, perlite microspheres, milled expanded perlite, perlite flakes, or any combination thereof.

36. A system for making insulated paper products 10 / 100 / 100′ with an uneven cross-sectional distribution of insulating material 12 therethrough, said system comprising:[0117](I) an apparatus comprising:[0118]a first paper forming wire 206 moving along a first papermaking path;[0119]a first headbox 204 positioned to deposit a first pulp slurry onto the first paper forming wire 206;[0120]a first formation plate 241 positioned below the first paper forming wire 206 proximate the first headbox 204;[0121]at least one first nozzle 229...

embodiment 52

53. The method of embodiment 52, wherein the insulating coating comprises one or more insulating materials comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, sericite, or any mixture or combination thereof.

54. The method of embodiment 52 or 53, wherein the insulating coating comprises one or more insulating materials comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof.

55. The method of any one of embodiments 52 to 54, wherein the insulating coating comprises from about 50.0 weight percent (wt %) to about 99.9 wt % of the one or more insulating materials and from about 50.0 wt % to about 0.1 wt % of the binder.

56. The method of any one of embodiments 52 to 55, wherein the insulating coating comprises from about 90.0 wt % to about 99.9 wt % of the one or more insulating materials and from about 10.0 wt % to about 0.1 wt % of the binder.

embodiment 56

57. The method of embodiment 56, wherein the binder comprises a latex binder.

58. The method of any one of embodiments 52 to 57, wherein each insulating coating independently comprises one or more coating layers with each coating layer comprising the insulating material and the binder.

59. The method of any one of embodiments 52 to 58, wherein at least one insulating coating comprises two or more coating layers with each coating layer comprising the insulating material and the binder.

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Abstract

Apparatus, systems, and methods for making insulated paper products are disclosed.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This patent application is a continuation-in-part of U.S. Utility patent application Ser. No. 16 / 590,224 entitled “RE-PULPABLE INSULATED PAPER PRODUCTS AND METHODS OF MAKING AND USING THE SAME,” and filed on Oct. 1, 2019, which claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62 / 739,735 filed on Oct. 1, 2018 entitled “RE-PULPABLE INSULATED PAPER PRODUCTS AND METHODS OF MAKING AND USING THE SAME,” the subject matter of both of which is hereby incorporated by reference in their entirety.FIELD OF THE INVENTION[0002]The present invention relates generally to apparatus and systems for making insulated paper products. The present invention further relates to methods of making insulated paper products.BACKGROUND OF THE INVENTION[0003]With the advent of on-line shopping, many goods are now delivered directly to the consumer's front door from distributors such as Amazon and others. Food and other temperature sensitive...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): D21F9/00D21F11/04D21F1/02D21F7/00D21H27/34
CPCD21F1/028D21F7/003D21F9/006D21F11/04D21H27/34D21H15/02D21H15/08D21H17/63D21H17/68D21H27/00D21H27/30
Inventor FLYNN, NIGEL J.LEIGH, TAYLOR KOPACKALYE, JASONLISS, RYAN D.PSCHIGODA, II, LON E.
Owner TRIPLE POINT INNOVATIONS LLC