US 10,118,368 B2 · Intermediate laminate product, an expanded laminate structure, and process manufacturing thereof

Abstract

An intermediate laminate product includes a first paper layer including lignocellulose fibers, and a dry coating layer applied to one surface of the first paper layer, the coating including expandable microspheres having an expansion temperature (TE), at least one polysaccharide, and a plasticizing additive which is capable of forming a thermoplastic blend with the polysaccharide. An expanded laminate structure includes the intermediate laminate product and a second paper layer comprising lignocellulose fibers, which is attached to the dry coating by heat lamination. A liquid packaging board includes the expanded laminate structure and a liquid barrier layer. A process for forming the expanded laminate structure includes applying a second paper layer to the coating of the intermediate product at a second temperature (T2), which is above the expansion temperature (TE) of the microspheres, whereby the microspheres expand, and at which the plasticizing additive causes plasticizing of the polysaccharide, to form a thermoplastic blend.

Claims20

Dependent claims

An intermediate laminate product, comprising a first paper layer comprising lignocellulose fibres, and a dry coating layer applied to one surface of the first paper layer,

wherein the dry coating comprises:
2-50 wt-% of expandable microspheres based on the dry weight of the dry coating, said microspheres having an expansion temperature (TE) of 120-230° C.,
30-93 wt-% of at least one polysaccharide, based on the dry weight of the dry coating, wherein the polysaccharide is a native or modified starch, and
5-30 wt-% of a plasticizing additive for forming a thermoplastic blend with the polysaccharide, based on the dry weight of the dry coating, and
wherein the dry coating is applied in an amount of 5-299 g/m2.

2 more elements

A process, comprising:

applying a coating in an amount of 5-299 g/m2 to a first paper layer to form a coated paper layer, wherein the coating comprises an aqueous mixture of:
30-93 wt-% of at least one polysaccharide, based on the dry weight of the coating, wherein the polysaccharide is a native or modified starch,
5-30 wt-% of a plasticizing additive for forming a thermoplastic blend with the polysaccharide, based on the dry weight of the coating, and
2-50 wt-% expandable microspheres based on the dry weight of the coating, said microspheres having an expansion temperature (TE) of 120-230° C., and optionally a latex dispersion;
drying the coated paper layer at a first temperature (T1) below the expansion temperature (TE) of the microspheres, wherein said first temperature (T1) is 80-110° C., whereby a dry intermediate laminate product is obtained;
packing the dry intermediate laminate product for transport or storage, or transferring it directly to a lamination step for lamination with a second paper layer.

3 more elements

Dependencies are inferred from the claim text.

Intermediate laminate product, an expanded laminate structure, and process manufacturing thereof

Life of this patent

Intermediate laminate product, an expanded laminate structure, and process manufacturing thereof

Life of this patent

Abstract

Claims20