Extensible high puncture-resistant recyclable paper-based packaging structures

A paper-based packaging structure with a specific anisotropy ratio and high paper fiber content, combined with polymer coatings, addresses the need for recyclable, puncture-resistant packaging that withstands high-weight products and provides thermal insulation.

US20260002322A1Pending Publication Date: 2026-01-01PROAMPAC HOLDINGS INC
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Patent Information

Application Number
US19/237681
Authority / Receiving Office
US · United States
Patent Type
Applications(United States)
Current Assignee / Owner
Priority Date
2024-06-26
Filing Date
2025-06-13
Publication Date
2026-01-01

AI Technical Summary

Technical Problem

Existing paper-based packaging structures lack sufficient elongation and puncture resistance while being recyclable, especially for high-weight products, and do not adequately address thermal insulation needs, particularly for frozen goods.

Method used

A paper-based packaging structure with a paper substrate layer and a polymer extrusion or coextrusion coating layer, featuring an anisotropy ratio of 0.67 to 1.5 and a paper fiber content of 60% to 99%, providing superior elongation, puncture resistance, and optional moisture and oxygen barrier properties, ensuring recyclability through curbside programs.

Benefits of technology

The structure achieves enhanced mechanical strength, including puncture resistance greater than 3 lbf, and maintains integrity for high-weight products, while being recyclable and offering thermal insulation, thus reducing waste and meeting robustness requirements.

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Abstract

Recyclable, paper-based packaging structures and articles comprise extensible or semi-extensible paper layer with an anisotropy ratio in the range of 0.67 to 1.5 and a polymer extrusion coating layer. Methods for forming same are also provided. The structures and articles have a puncture resistance of 3 lbf or greater. Recyclable, paper-based packaging structures and articles and methods are formed using a polymer extrusion coating layer disposed on one side of an extensible or semi-extensible paper layer having an anisotropy ratio in the range of 0.67 to 1.5. A second polymer extrusion coating layer is disposed on a second side of the paper substrate layer. Advantageously, the paper substrates have a puncture resistance in the range of 3 lbf to 13.5 lbf.
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