Product and its manufacturing method

Abstract

Disclosed is an article of manufacture that may include a layer at least partially formed from a mixture that includes a reinforcing component and at least 10% (w / w) of cellulose fibers having surface closure properties.

Description

[Technical Field]

[0001] The present disclosure relates to products and methods for making the products. [Background technology]

[0002] The demand for packaging materials is increasing significantly. There is a need for packaging means that are renewable, recyclable and biodegradable.

[0003] Cellulose, for example in the form of cellulose fibers or pulp, is a renewable and biodegradable material well suited for packaging. However, in many cases, plastic materials or other less environmentally friendly materials, such as fluorinated compounds, may be required, for example as coatings to impart barrier properties to packaging materials formed primarily from cellulose. Such packaging materials are not completely biodegradable, and their recycling may be complicated. Summary of the Invention [Means for solving the problem]

[0004] Disclosed is an article of manufacture that may include a layer at least partially formed from a mixture that includes a reinforcing component and at least 10% (w / w) of cellulose fibers having surface closure properties. [Brief explanation of the drawings]

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

[0006] [Figure 1A] 1 illustrates an embodiment of a product in cross section. [Figure 1B] 1 illustrates another embodiment of the product. [Figure 1C] 1 illustrates another embodiment of the product. [Figure 2A] 1 illustrates an embodiment of a product in cross section. [Figure 2B]1 illustrates another embodiment of the product. [Figure 2C] 1 illustrates another embodiment of the product. [Figure 2D] 1 illustrates yet another embodiment of the product. [Figure 2E] 1 illustrates yet another embodiment of the product. [Figure 3A] The oxygen permeability of the cellulose film is shown. [Figure 3B] This shows the grease permeability of cellulose films. [Figure 4] 1 shows a packaging material produced by compression molding a fibrous body having a cellulose film layer. [Figure 5] 1 shows a packaging material produced by calendering a fibrous body having a cellulose film layer. [Figure 6A] The apparent bulk density values ​​of certain fiber blends are given. [Figure 6B] The tensile index values ​​for specific fiber blends are given. [Figure 6C] The strain at break values ​​for specific fiber blends are given. [Figure 7] 1 shows the measured air permeability of the multilayer structure. DETAILED DESCRIPTION OF THE INVENTION

[0007] A product is disclosed.

[0008] The article may include a layer at least partially formed from a mixture comprising a reinforcing component and at least 10% (w / w) of cellulosic fibers having surface-closing properties.

[0009] Cellulose fibers with surface-closing properties are moldable materials, and when a mixture containing cellulose fibers with surface-closing properties is densified, such as by compression, a layer with low porosity may be obtained. For example, a highly dense structure may be obtained from the mixture by calendaring. Such a layer may have barrier properties. For example, the layer may have the properties of a gas (oxygen) barrier and / or a grease barrier layer, such as an oil barrier layer.

[0010] Reinforcing components, such as cellulose fibers, may provide mechanical strength to the product.

[0011] A layer of a reinforcing component, such as a layer of cellulose fibers, e.g., chemical pulp, has good strength but a porous structure. A layer of cellulose fibers with surface-closing properties, such as hydrolyzed cellulose fibers, may provide a denser, smoother structure but little strength. A blend comprising a reinforcing component and at least 10% (w / w) cellulose fibers with surface-closing properties may provide a balance between strength and density, as well as a smooth surface finish.

[0012] The relative proportions of the reinforcing component and the cellulose fibers having surface-closing properties may be selected so that the strength and, on the other hand, the density of the layer may be optimized as desired. The composition of the mixture may also be selected to obtain the desired barrier properties.

[0013] 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 fluorochemicals, which are, for example, harmful to the environment and whose use may be phased out in the future. Eliminating 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 herein may be biodegradable and relatively easily recyclable using existing processes. For example, up to 50% of the cellulose fibers in the product may be recoverable in a recycling process. The product may also be compostable. The product may be burned, and may burn relatively cleanly.

[0014] The cellulose fibres having surface closure properties may have a CED viscosity in the range of 50 to 500 ml / g, or in the range of 50 to 400 ml / g, or in the range of 120 to 300 ml / g, or in the range of 140 to 200 ml / g.

[0015] The cellulose fibers having surface-closing properties may be modified cellulose fibers, which may include or be, for example, hydrolyzed cellulose fibers, nanocellulose, microfibril cellulose, or any mixture or combination thereof.

[0016] The cellulose fibers having surface-closing properties may include or be hydrolyzed cellulose fibers, which are readily available and have properties that make them well suited for inclusion in the mixture.

[0017] In the context of the present disclosure, the term "hydrolyzed cellulose fibers" may be understood to refer to cellulose fibers that have undergone a process to at least partially hydrolyze the cellulose chains of the cellulose fibers, for example, compared to comparable non-hydrolyzed cellulose fibers. The hydrolysis may be achieved by alkaline hydrolysis, autohydrolysis, or other types of hydrolysis. Accordingly, the average cellulose chain length of the hydrolyzed cellulose fibers may be less than the average cellulose chain length of comparable non-hydrolyzed cellulose fibers. Certain properties of the cellulose fibers, such as the CED viscosity, may be affected by the hydrolysis. Hydrolyzed cellulose fibers may be, or may be, obtained, for example, by enzymatic hydrolysis of cellulose fibers using cellulolytic enzymes for 2 to 3 hours, and / or by acid or alkaline hydrolysis. The hydrolyzed cellulose fibers may be, or may include, for example, hydrolyzed pulp. In this context, the pulp of the hydrolyzed pulp may be any pulp described herein.

[0018] Cellulose fibers with surface-closing properties, such as modified cellulose fibers, may be obtainable or may be obtained, for example, by hydrolysis or by electron beam techniques, optionally followed by further hydrolysis, such as alkaline hydrolysis.

[0019] The hydrolyzed cellulose fibers may have a CED viscosity in the range of 50 to 500 ml / g. In some embodiments, the hydrolyzed cellulose fibers may have a CED viscosity in the range of 50 to 400 ml / g, or in the range of 120 to 300 ml / g, or in the range of 140 to 200 ml / g.

[0020] The term "CED viscosity" may be understood to refer to the intrinsic viscosity in cupriethylenediamine (CED) solution. CED viscosity may be measured, for example, according to standard ISO 5351:2010.

[0021] The hydrolyzed cellulose fibers may have a degree of polymerization (DP) in the range of about 100 to 700, or in the range of 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 above standard according to the following formula: DP=0.75[μ] 1 / 0.905 In the formula, [μ] is the CED viscosity value.

[0022] Cellulose fibers with surface-closed properties may, in some embodiments, be obtainable by pretreatment or modification, for example, by surface modification, saponification of cellulose esters, or phosphorylation. Cellulose fibers with surface-closed properties may, for example, have signatures of processes that cause changes in the surface chemistry.

[0023] A proportion of at least 10% (w / w) of cellulose fibers having surface-closing properties may be understood as the dry weight of cellulose fibers having surface-closing properties based on the total dry weight of the mixture and / or the total dry weight of a layer at least partially formed from the mixture.

[0024] The mixture may, for example, comprise at least 20% (w / w), or at least 30% (w / w), or at least 40% (w / w), or at least 50% (w / w), 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 closure properties.

[0025] The cellulose fibers having surface-closing properties and the reinforcing component, such as the cellulose fibers, may differ in properties, such as degree of polymerization and / or CED viscosity. The proportions of the cellulose fibers having surface-closing properties and the reinforcing component, and optionally other components, may be selected to achieve desired properties of a layer at least partially formed from the mixture. For example, increasing the proportion of cellulose fibers having surface-closing properties may increase the density of a layer at least partially formed from the mixture, which may in turn reduce tolerance to, for example, grease and / or oxygen. Thus, the proportion of cellulose fibers having surface-closing properties may be selected to achieve a desired density, desired barrier properties, and / or desired smoothness. The reinforcing component may be provided in a desired proportion, for example, to provide desired strength and / or other properties to a layer at least partially formed from the mixture.

[0026] The CED viscosity of the reinforcing component, such as cellulose fibers, may be greater than 500 ml / g, for example, in the range of about 500-3000 ml / g. In some embodiments, the CED viscosity of the reinforcing component, such as cellulose fibers, may be, for example, in the range of 800-1200 ml / g, or in the range of 900-1100 ml / g.

[0027] In embodiments in which the reinforcing component includes or is cellulose fibers, the cellulose fibers of the reinforcing component may be other cellulose fibers, i.e., cellulose fibers other than those having surface-closing properties.

[0028] The reinforcing component, such as cellulose fibers, may include or be, for example, unmodified and / or unhydrolyzed cellulose fibers.

[0029] The cellulose fibers (including cellulose fibers having reinforcing components and / or surface-closing properties, e.g., hydrolyzed cellulose fibers or non-hydrolyzed cellulose fibers) may be natural fibers, such as lignocellulosic fibers, cellulose fibers, cellulose fiber derivatives, wood derivatives, or any combination or mixture thereof. The fibers in the cellulose fibers may be natural-origin fibers, such as modified natural-origin fibers, and / or cellulosic fibers. The fibers in the cellulose fibers may be virgin fibers, regenerated fibers, or secondary natural fibers, or any mixture or combination thereof. The cellulose fibers may be, for example, staple fibers. The cellulose fibers may be, for example, fibers derived from cotton or cotton linters. The cellulose fibers may include or be, for example, pulp. The pulp may include or be, for example, wood pulp (such as hardwood pulp and / or softwood pulp), non-wood pulp, and / or agropulp. The pulp may also be a chemical pulp, such as kraft pulp, soda pulp, sulfate pulp, or organosolv pulp. The pulp may be thermomechanical pulp (TMP), mechanical pulp (groundwood (GW), pressure groundwood (PGW), refined groundwood (RMP)), and / or chemi-thermomechanical pulp (CTMP). Additionally or alternatively, the pulp may be undried pulp, such as undried kraft pulp. The cellulosic fibers or pulp may include recycled fibers or may be recycled fibers. The fibers in the cellulosic fibers may include at least one of wood pulp, non-wood pulp, staple fiber, recycled fiber, or any mixture or combination thereof, or may be at least one of wood pulp, non-wood pulp, staple fiber, recycled fiber, or any mixture or combination thereof. In some embodiments, the fibers in the cellulosic fibers may be free of man-made fibers and / or petroleum-based fibers. Staple fibers having a desired length may be combined with other types of reinforcing components, such as other types of cellulosic fibers.

[0030] The reinforcing component, such as cellulose fibers, may include or be natural and / or man-made cellulose fibers having a CED viscosity in the range of 500 to 3000 ml / g. Man-made cellulose fibers may, at least in some embodiments, have a lower CED viscosity.

[0031] In the context of this specification, the term "unmodified cellulose fibers" may refer to cellulose fibers that have not been intentionally chemically modified to a significant extent. Unmodified cellulose fibers may, for example, not be hydrolyzed. However, unmodified cellulose fibers may also be chemical pulps, such as kraft pulp, which may, for example, be bleached during the chemical pulp manufacturing process. For example, the kraft pulping process may result in mild hydrolysis of the cellulose fibers, but the chemical pulp may still be considered to be or contain unmodified cellulose fibers.

[0032] The reinforcing component, such as cellulose fibers, may be or include chemical pulp, such as kraft pulp, sulfate pulp, and / or organosolv pulp, and / or staple fibers.

[0033] The mixture may comprise about 10-90% (w / w) of cellulose fibers having surface-closing properties and about 10-90% (w / w) of reinforcing cellulose fibers.

[0034] The mixture may comprise about 20-50% (w / w) of cellulose fibers having surface-closing properties and about 50-80% (w / w) of a reinforcing component such as cellulose fibers.

[0035] The mixture may comprise about 20-40% (w / w) of cellulose fibers having surface-closing properties and about 60-80% (w / w) of a reinforcing component such as cellulose fibers.

[0036] The weight ratio of the cellulose fibers having surface closure properties to the reinforcing component, such as cellulose fibers, 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.

[0037] The product may be a moldable product or a molded product.

[0038] The moldable product may be, for example, a sheet or a flat structure. Such moldable products may be formed into a final form having a desired shape. Various methods of forming the product may be available.

[0039] The molded product may be, for example, a container or receptacle, such as a cup or plate. However, the shape of the molded product is not particularly limited.

[0040] The product may be flexible or may be a flexible product, or the product may be rigid or may be a rigid product.

[0041] The product may be, for example, a packaging material, packaging paper, wrapping paper, protective paper, packaging board, 3D packaging material, decorative paper, envelope, container, or release liner.

[0042] The product may be formed primarily from cellulosic materials.

[0043] In some embodiments, the product may be formed essentially or entirely from cellulosic materials.

[0044] However, the presence of trace amounts of non-cellulosic materials is not necessarily excluded in such products. For example, products formed primarily or essentially from cellulosic materials may contain, for example, non-cellulosic adhesives, such as glues, additives, colorants, or inks.

[0045] In the context of this specification, the term "formed primarily from cellulosic material" 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 cellulosic.

[0046] The product may be biodegradable. The product may be biodegradable as determined by standard OECD 301F for the testing of chemical substances.

[0047] The term "biodegradable," at least in some embodiments, may refer to readily biodegradable (readily biodegradable) as determined by OECD 301F Standard for the Testing of Chemical Substances (manometric respirometry). A readily degradable product may be one that reaches at least 60% biodegradability within 28 days as determined by OECD 301F Standard for the Testing of Chemical Substances.

[0048] The product may be recyclable.

[0049] 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) cellulose fibers having surface closure properties. The product may comprise a single layer of the mixture. In other words, the product may be a single-layer product. However, in some embodiments, the product may comprise, for example, two or more layers at least partially formed from the mixture. In such embodiments, the product may thus be formed by adding two or more layers formed from the mixture so as to effectively create a single layer. The product may consist of one or more layers formed from the mixture.

[0050] In other embodiments, the product may include one or more layers, for example, two or more layers, at least one of the layers of the product may be a layer at least partially formed from a mixture comprising a reinforcing component, such as cellulose fibers, and at least 10% (w / w) cellulose fibers having surface closure properties.

[0051] In the context of this specification, unless otherwise stated, the term "layer" may be understood to refer to a 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 closure properties.

[0052] The product may include an additional layer, or one or more additional layers. In other words, in some embodiments, the product may be a multi-layer product. For example, the product may include an additional base layer. Such a base layer may have a composition that is different from the composition of the layer at least partially formed from the mixture. Such a base layer may be at least partially formed from a reinforcing component, such as, for example, cellulose fibers. The reinforcing component, such as, for example, cellulose fibers, of the base layer may be, for example, any of the reinforcing components described herein. The product may include one or more base layers, such as one or two base layers.

[0053] The product may further comprise additional layers. For example, the product may comprise an intermediate layer (or at least one intermediate layer) between the base layer and the layer at least partially formed from the mixture. Such an intermediate layer may also be based on cellulose fibers. However, its composition may differ from that of the base layer and / or the layer at least partially formed from the mixture.

[0054] The product may include a base layer and two layers at least partially formed from the mixture, the layers at least partially formed from the mixture being disposed on either side of the base layer.

[0055] The product may include a layer at least partially formed from the mixture and two base layers disposed on either side of the layer at least partially formed from the mixture.

[0056] A layer at least partially formed from the mixture may be densified and / or compressed, in other words, a layer at least partially formed from the mixture may be a densified and / or compressed layer.

[0057] The base layer may be densified and / or compressed, in other words, the base layer may be a densified and / or compressed layer.

[0058] Both the layer at least partially formed from the mixture and the base layer (ie, any or all such layers) may be densified and / or compressed.

[0059] Densification may be carried out, for example, by wet or dry calendering. Wet calendering may further improve densification.

[0060] However, compression or densification may not be necessary to achieve the desired barrier properties. For example, a layer at least partially formed from the mixture may be formed by spraying the material of that layer onto a base layer (or, in some embodiments, onto another additional layer). As another example, the layer at least partially formed from the mixture and the base layer (and any additional layers, if present) may be formed in, for example, a two-ply or multi-ply headbox of a paper or board machine.

[0061] Densification and / or compression may, for example, provide a particular oxygen permeability to the layer and / or product. Densification and / or compression may, for example, provide a particular smoothness to the layer and / or product.

[0062] A layer at least partially formed from the mixture may have a weight ranging from 20 to 1000 gsm (grams per square meter), although the weight (basis weight) of the layer may depend, for example, on whether the product includes any additional layers.

[0063] A layer at least partially formed from the mixture may, in at least some embodiments, have a thickness of 300 μm or less, or in the range of 1 to 200 μm, or in the range of 10 to 100 μm, or in the range of 10 to 40 μm. However, the thickness of the layer may depend, for example, on whether the product includes any additional layers. Products such as molded cups or trays in the form of a single layer may be quite thick. In products that include additional layers, such as a reinforcing base layer, the layer at least partially formed from the mixture may be relatively thin.

[0064] The base layer may be formed from a densified cellulosic fiber mixture.

[0065] The base layer may, for example, have a weight of at least 20 gsm, or in the range of 20 to 800 gsm, or in the range of 40 to 800 gsm (grams per square meter).

[0066] In some embodiments, the product does not contain any plastics or metals. The product may, in some embodiments, be free of inorganic materials such as pigments.

[0067] The product may further include a surface chemical to provide barrier properties, which is applied to the layer at least partially formed from the mixture. Such a surface chemical may include starch, wax, fatty acid, alkyl ketene dimer, alkyl succinic anhydride, thermoplastic component, or any combination or mixture thereof. The surface chemical may or may not chemically react with the cellulose of the cellulose fibers, depending on its chemical properties. The surface chemical may be covalently or non-covalently attached to the cellulose. The surface chemical may physically attach to the cellulose. The surface chemical may, for example, impregnate the layer at least partially formed from the mixture and / or the base layer and / or any other additional layers to provide the product with desired physical properties.

[0068] The article may further include a layer at least partially formed from the mixture and / or a coating over the base layer or any other layer.

[0069] This coating may be the outermost layer of the product.

[0070] The coating may be or may be applied as, for example, a hot melt coating, a dip coating, or a carton coating. Such a coating, for example a hot melt coating, may improve the heat seal properties of the product.

[0071] The product may further include a cellulose film layer. In other words, the product may further include a coating that is a cellulose film layer. This cellulose film layer may be formed by coagulating an alkali cellulose dope. The cellulose film layer may cover the layer at least partially formed from the mixture and / or the base layer, or any other layers, if present. The cellulose film layer may cover the layer at least partially formed from the mixture and / or the base layer, or any other layers, if present, and thus 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, such embodiments may not necessarily be formable. The cellulose film layer may be added when the product is formed. When the coating is a cellulose film layer, it may be biodegradable. Thus, the entire product may be cellulosic and optionally biodegradable, as opposed to, for example, a product that includes a plastic coating.

[0072] In the context of this specification, the term "alkali cellulose dope" may be understood as a solution containing cellulose solubilized in an alkaline solution, often a cold alkaline solution. For example, the alkali cellulose dope may 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, electrospinning, molding, casting, film formation, film extrusion, cellulose pearl production, coating, spraying, and / or 3D printing. In other words, the term "alkali cellulose dope" may refer to a cellulose material in an alkaline solution suitable for use in, for example, spinning filaments, staple fibers, film production, cellulose pearl production, and various other purposes. The cellulose alkali cellulose dope may be coagulated under suitable conditions to form solid cellulose, such as type II cellulose.

[0073] Providing a cold alkaline solution may typically involve mixing and / or dissolving an alkaline agent such as NaOH, and optionally a dissolving or stabilizing agent, e.g., a zinc compound such as ZnO, with water. These may be mixed under conditions suitable for dissolving the components in water, e.g., at an elevated temperature, such that the 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, for example, include NaOH, LiOH, KOH, and / or any mixture or combination thereof, or may be NaOH, LiOH, KOH, and / or any mixture or combination thereof.

[0074] The cellulose film layer may be applied, for example, by calendering. This may be done, for example, so that the cellulose film is prepared, for example, by extruding an alkali cellulose dope, coagulating it, and separately preparing a product. The product and the cellulose film may be combined and calendered so that the cellulose film adheres to the product to form the cellulose film layer.

[0075] Alternatively, the cellulose film layer may be formed by a surface treatment. For example, the product may be surface-treated with a hydroxide such as NaOH, such that the cellulose fibers on the surface of the product are at least partially solubilized and subsequently coagulated, thereby forming a cellulose film layer. The cellulose film layer formed by the surface treatment may be similar to a cellulose film layer prepared, for example, by coagulating an alkali cellulose dope.

[0076] The product may further include an adhesive layer between the layer at least partially formed from the mixture and an additional layer, such as a base layer. A product, such as a multi-layer product, may include an adhesive layer (or additional adhesive layers) between one or more other layers. The adhesive layer may attach the layer at least partially formed from the mixture and the base layer, and / or any other layers (depending on the embodiment and the presence and arrangement of layers) to one another. The adhesive may be, for example, a bio-based and / or biodegradable adhesive, such as a bio-based and / or biodegradable glue.

[0077] The product may further comprise an ink layer and / or a lacquer layer, which may be formed, for example, by printing ink onto the surface of the product or by lacquering the surface of the product.

[0078] The product, especially if it does not contain a cellulose film layer, has a maximum thickness of 1000 cm 3 / (m 2 .days) or less, or 100cm 3 / (m 2 .day) or less, or 20cm 3 / (m 2 In other embodiments, the product may have an oxygen transmission rate of 20 cm or less, particularly if it includes a cellulose film layer. 3 / (m 2 .day) or less, or 5cm 3 / (m 2 .day) or less, or 1cm 3 / (m 2 The oxygen permeability may be less than 0.5%.

[0079] Oxygen transmission rate may be measured at 23°C and 50% relative humidity. Oxygen transmission rate may be measured using a MOCON OX-TRAN® instrument. The instrument design and operation may conform to ASTM D 3985 standard. In some embodiments, oxygen transmission rate may be measured according to one of standards ASTM D3985, ASTM F1927, or ISO 15105-2 using a Mocon Ox-Tran 2 / 21 MH instrument. In one embodiment, oxygen transmission rate is measured at 23°C, 0% relative humidity, and 100% O2 for one day using a MOCON OX-TRAN instrument according to ASTM D3985 standard.

[0080] The product, especially when it does not contain a cellulose film layer, has a 1000cm 3 / (m 2 .days) or less, or 100cm 3 / (m 2 .day) or less, or 20cm 3 / (m 2 In other embodiments, the product, particularly if it includes a cellulose film layer, may have an oxygen transmission rate of 20 cm or less, measured at 23° C., 0% relative humidity, and 100% O2 for 1 day. 3 / (m 2 .day) or less, or 5cm 3 / (m 2 .day) or less, or 1cm 3 / (m 2 The oxygen permeability may be less than 0.5%.

[0081] The composition of the product, for example, the presence or absence of a cellulose film layer or surface chemistry, or densification and / or compression, may significantly affect water vapor permeability and oil permeability (e.g., as measured by heptane vapor transmission rate). Thus, the values ​​of such parameters may vary significantly for the products according to the various embodiments described herein.

[0082] The water vapor transmission rate of such products, especially those containing a cellulose film layer, is, for example, 300 g / (m 2.day) or less, or 100g / (m 2 .day) or less, or 30g / (m 2 The water vapor transmission rate may be determined at 23°C and 50% relative humidity.

[0083] The water vapor transmission rate of such products, particularly those that include a cellulose film layer and a surface chemistry (such as any surface chemistry described herein) and / or that have been densified, for example, by calendaring, is typically 100 g / (m 2 .day) or less, or 50g / (m 2 .day) or less, or 20g / (m 2 The water vapor transmission rate may be determined at 23°C and 50% relative humidity.

[0084] Such products, especially those containing a cellulose film layer, may have a thickness of, for example, 100 g / (m 2 .day) or less, or 50g / (m 2 .day) or less, or 5g / (m 2 The heptane vapor transmission rate may be determined at 23°C and 50% relative humidity.

[0085] The product may be semi-transparent and / or translucent. This may depend, for example, on the composition of the layer at least partially formed from the mixture and any other additional layers. The layer at least partially formed from the mixture and, for example, the base layer, may be densified to the extent that it is translucent and / or semi-transparent.

[0086] The light transmittance of the product may be in the range of 0-70%, or in the range of 1-70%, or in the range of 20-70%. Light transmittance may be understood to refer to visible light transmittance. Light transmittance may be measured, for example, with an optical profiler.

[0087] Disclosed is a method of making the article according to one or more embodiments described herein, which may include forming the layer from the mixture including the reinforcing component, such as cellulose fibers, and the cellulose fibers having the surface-closing properties.

[0088] The method may include providing a mixture comprising a reinforcing component, such as cellulose fibers, and cellulose fibers having surface-closing properties, and forming a layer, whereby the product may be obtained. For example, a single-layer product may be obtained in this manner.

[0089] The method may include providing a mixture comprising a reinforcing component, such as cellulose fibers, and cellulose fibers having surface-closing properties; providing a base layer material; forming a layer from the mixture comprising a reinforcing component, such as cellulose fibers, and cellulose fibers having surface-closing properties; forming the base layer; and forming a product therefrom.

[0090] The materials and compositions of the above layers and, for example, the material of the base layer, if present, may be in accordance with one or more embodiments described herein.

[0091] The mixture comprising the reinforcing cellulose fibers and the cellulose fibers having surface closure properties may be formed into a web, which may be calendered to form a layer at least partially formed from the mixture. Densification may be carried out, for example, by wet or dry calendering. Wet calendering may further improve densification. The web may be calendered, for example, using a nip pressure of 3 to 350 kN / m.

[0092] The method may further comprise the step of forming the product, which may be formed from a dry web or from a suspension.

[0093] The cellulose film layer may be applied by calendering. This may be done, for example, so that the cellulose film is prepared by extruding an alkali cellulose dope, coagulating it, and separately preparing the product. The product and cellulose film may be combined and calendered so that the cellulose film adheres to the product to form the cellulose film layer.

[0094] The method may further include forming a cellulose film layer on the product by surface treatment. The product may be surface-treated with, for example, a hydroxide such as NaOH, such that cellulose fibers on the surface of the product are at least partially solubilized and subsequently coagulated, thereby forming a cellulose film layer. The cellulose film layer formed by the surface treatment may be similar to a cellulose film layer prepared, for example, by coagulating an alkali cellulose dope. [Example]

[0095] Reference will now be made in detail to various embodiments, examples of which are illustrated in the accompanying drawings.

[0096] The following description discloses some embodiments in sufficient detail to enable those skilled in the art to utilize the embodiments based on the present disclosure. Not every step or feature of an embodiment is discussed in detail, as many steps or features will be apparent to those skilled in the art based on this specification.

[0097] 1A shows one embodiment of product 1 in cross-section. Product 1 is a single-layer product including layer 2 formed from a mixture including cellulose fibers as a reinforcing component and at least 10% (w / w) of cellulose fibers having surface closure properties. The composition of the mixture forming layer 2 can be any of the mixture compositions described herein. Product 1 in this exemplary embodiment can be flat or sheet-like and moldable into a desired shape.

[0098] FIG. 1B shows another embodiment of product 1. This product 1 is similar to that depicted in FIG. 1A, except that product 1 further includes coating 3. The coating may be, for example, a plastic coating. In some embodiments, coating 3 may be, for example, a cellulose film layer. Coating 3 is disposed on layer 2 formed from the above mixture. Coating 3 covers layer 2 at least partially, or completely, as shown in FIG. 1B.

[0099] Figure 1C shows in cross section another embodiment of product 1. This product 1 is similar to that depicted in Figure 1A, except that it is a molded product, such as a cup or tray. As one skilled in the art will appreciate, various other shapes may be contemplated.

[0100] Figure 2A shows one embodiment of product 1 in cross-section. In this exemplary embodiment, product 1 is a multi-layer product. Multi-layer product 1 includes layer 2 formed from a mixture including cellulose fibers as a reinforcing component and at least 10% (w / w) of cellulose fibers having surface closure properties, and base layer 4 formed from a reinforcing component such as, for example, cellulose fibers. Layer 2 covers base layer 4 at least partially, or completely as shown in Figure 2A.

[0101] FIG. 2B shows another embodiment of multi-layer product 1. This multi-layer product 1 is similar to that depicted in FIG. 2A, except that multi-layer product 1 further includes coating 3. The coating may be similar to that depicted in FIG. 1B, for example, a plastic coating. In some embodiments, coating 3 may be, for example, a cellulose film layer. Coating 3 is disposed on layer 2 formed from the above mixture. Coating 3 covers layer 2 at least partially, or completely, as shown in FIG. 2B. However, as one skilled in the art will understand, coating 3 may alternatively or additionally be disposed on base layer 4. One skilled in the art will also understand that coating 3 may be included in any one of the embodiments depicted in FIGS. 2C-2E.

[0102] Figure 2C shows another embodiment of a multi-layer product 1. This multi-layer product 1 is similar to that depicted in Figure 2A, except that the multi-layer product 1 includes three layers: a base layer 4 and two layers 2 and 2' formed from the above mixture. Layers 2 and 2' are disposed on either side of the base layer 4.

[0103] Figure 2D shows yet another embodiment of a multi-layer product 1. This multi-layer product 1 is similar to that depicted in Figure 2C, except that the multi-layer product 1 includes three layers: two base layers 4 and 4', and layer 2 formed from the above mixture. Base layers 4 and 4' are disposed on either side of layer 2.

[0104] 2E illustrates yet another embodiment of a multi-layer product 1. This multi-layer product 1 is similar to that depicted in FIG. 2A, except that the multi-layer product 1 further includes an adhesive layer 5 between the base layer 4 and the layer 2 at least partially formed from the mixture. The adhesive layer 5 may extend between the base layer 4 and the layer 2, adhering the base layer 4 and the layer 2 to one another. The adhesive in the adhesive layer 5 may be, for example, any adhesive described herein.

[0105] The exemplary embodiments shown in Figures 2A-2E are flat or sheet-like and may be moldable or formed into a desired shape.

[0106] Example 1 The oxygen transmission rate (OTR) and grease permeability of the cellulose films were measured. The cellulose films were prepared by regenerating an alkali cellulose dope in citric acid with or without a plasticizer and drying the resulting films at 180°C and 410 kPa for 3 minutes. The oxygen transmission rate and grease permeability of the films were measured.

[0107] The oxygen permeability of the cellulose film at 23°C and 50% relative humidity is shown in Figure 3A, and the grease permeability at 40°C is shown in Figure 3B.

[0108] Example 2 The coating of a fiber composition (a fiber body, i.e., a base layer) with a cellulose film layer was evaluated. The cellulose film layer was directly applied by sandwiching the structure in a compression molding process. First, the fiber body and the film layer were conditioned in a suitable humidity chamber, and compression molding was carried out at 80°C for 20 minutes under a pressure of 410 kp or at 95°C for 20 minutes under a pressure of 650 kp. The preconditioning of the fiber body and the film, and the applied pressure and temperature can be adjusted as needed.

[0109] FIG. 4 shows a packaging material produced by compression molding a fibrous body having a cellulose film layer.

[0110] Example 3 The coating of a fibrous composition (fibrous body, i.e., base layer) with a cellulose film applied by a calendering process was evaluated. The fibrous body and / or film were first conditioned in a suitable humidity chamber, and calendering was carried out at 80°C and 500 kp pressure, or at 100°C and 6000 kp pressure. The preconditioning of the fibrous body and film, as well as the applied pressure and temperature, can be adjusted as needed.

[0111] FIG. 5 shows a packaging material produced by calendering a fibrous body with a cellulose film.

[0112] Example 4 The physical and mechanical properties of blends containing softwood kraft pulp fibers with different CED viscosities were evaluated. Pulp 1 refers to hydrolyzed softwood kraft pulp fibers with a CED viscosity of 166 ml / g, and Pulp 2 refers to hydrolyzed softwood kraft pulp fibers with a CED viscosity of 200 ml / g. The blend x:y represents the dry weight fiber mixture of softwood kraft pulp fiber to either Pulp 1 or Pulp 2. For example, 60:40 represents a blend with 60% softwood kraft pulp fiber and 40% Pulp 1 or Pulp 2. The physical and mechanical properties of the blends are shown in Figures 6A, 6B, and 6C, respectively.

[0113] FIG. 6A shows the apparent bulk density values ​​of certain fiber blends.

[0114] FIG. 6B shows the tensile index values ​​for certain fiber blends.

[0115] FIG. 6C shows the strain-to-break values ​​for certain fiber blends.

[0116] Example 5 Multilayer sheets were produced as two- or three-ply combinations by combining different base softwood layers with Pulp 1 (hydrolyzed softwood kraft pulp fibers with a CED viscosity of 166 ml / g). For example, a two-ply sheet was produced by laminating a Pulp 1 layer to a softwood base layer. For three-ply, the Pulp 1 layer was sandwiched between two softwood layers. The air permeability of the resulting multilayer structures was measured according to ISO 5636-3. The air permeability is shown in Figure 7.

[0117] It is obvious to those skilled in the art that with the advancement of technology, the basic idea may be implemented in various ways. Therefore, the embodiments are not limited to the above examples, instead, the embodiments may vary within the scope of the claims.

[0118] The embodiments described hereinbefore may be used in any combination with each other. Some of the embodiments may be combined together to form further embodiments. The processes, products, or uses disclosed herein may include at least one of the embodiments described hereinabove. It will be understood that the benefits and advantages described above may relate to one embodiment or to several embodiments. The embodiments are not limited to those that solve any or all of the stated problems or have any or all of the stated benefits and advantages. It will be further understood that reference to "an" or "an" item refers to one or more of those items. The term "comprising" is used herein to mean including the features or acts listed after the term "comprising" (before the term "including"), without excluding the presence of one or more additional features or acts.

Claims

1. An article comprising a layer at least partially formed from a mixture comprising a reinforcing component and at least 10% (w / w) of cellulose fibers having surface closure properties.

2. 10. The product of claim 1, wherein the product is formed primarily from cellulosic materials and / or the reinforcing component includes or is cellulosic fibers.

3. 3. The product of claim 1 or claim 2, which is a packaging material, wrapping paper, wrapping paper, protective paper, packaging board, 3D packaging material, decorative paper, envelope, container, or release liner.

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

5. 5. The product of any one of claims 1 to 4, wherein the product is biodegradable as determined by standard OECD 301F for the testing of chemical substances.

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

7. 7. The product of any one of claims 1 to 6, wherein the cellulose fibres with surface closure properties have a CED viscosity in the range of 50 to 500 ml / g, or in the range of 50 to 400 ml / g, or in the range of 120 to 300 ml / g, or in the range of 140 to 200 ml / g.

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

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

10. 10. A product according to any one of claims 1 to 9, wherein the layer is densified and / or compressed.

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

12. 12. The article of claim 1, wherein the article does not contain any plastic or metal.

13. 13. The product of any one of claims 1 to 12, wherein the product further comprises a cellulose film layer (4) which may be formed by coagulating an alkali cellulose dope.

14. 1000cm ３ / (m ２ .. day) below, 100cm ３ / (m ２ . days) or less, or 20 cm ３ / (m ２ 13. The product according to any one of claims 1 to 12, having an oxygen transmission rate of 20 cm or less (. 1 day), ３ / (m ２ . days) or less, or 5 cm ３ / (m ２ . days) or less, or 1 cm ３ / (m ２ 14. The article of claim 13, having an oxygen transmission rate of 0.5% or less.

15. 15. The product of any one of claims 1 to 14, wherein the product is semi-transparent and / or translucent.

16. 16. A method of manufacturing a product according to any one of claims 1 to 15, comprising forming the layer from the mixture comprising the reinforcing component and cellulose fibres having the surface closure properties.

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

18. 18. The method of claim 16 or claim 17, further comprising forming the product, optionally from a dry web or from a suspension.

Images