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

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- Number: US 10,118,368 B2
- Document ID: US10118368B2
- Status: Granted
- Kind: B2
- Application number: 15/524,061
- Filed: 2014-11-04
- Published: 2017-12-21
- Granted: 2018-11-06
- Earliest claimed: 2014-11-04
- Assignees: Sca Forest Products AB
- Applicants: SCA Forest Products AB
- Inventors: Kent Malmgren
- Web page: https://patentgrep.com/patent/US10118368B2

## CPC

- B32B 15/12: of paper or cardboard
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B32B 27/10: of paper or cardboard
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B65D 65/40: Applications of laminates for particular packaging purposes {(B65D1/0215, B65D1/28, B65D3/22, B65D5/0281, B65D5/563, B65D9/30, B65D29/02, B65D31/02, B65D75/26, B65D77/2024, B65D81/1275, B65D81/3811, B65D81/3823, B65D81/3834, B65D81/3846, B65D81/3858, B65D81/3874, B65D81/3886, B65D81/3897 take precedence; laminates per se or laminated packages characterised by the composition or)}
- C08L 3/02: Starch; Degradation products thereof, e.g. dextrin
- C08L 97/02: Lignocellulosic material, e.g. wood, straw or bagasse {(manufacture of articles made from lignocellulosic material by dry processes B27N)}
- C09D 5/00: Coating compositions, e.g. paints, varnishes or lacquers, characterised by their physical nature or the effects produced {(electrically insulating plastics, resins or waxes H01B3/30)}; Filling pastes
- C09D 103/02: Starch; Degradation products thereof, e.g. dextrin
- D21H 19/12: applied as a solution using water as the only solvent, e.g. in the presence of acid or alkaline compounds
- D21H 19/20: comprising macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds
- D21H 21/54: being spherical, e.g. microcapsules, beads
- D21H 23/22: Addition to the formed paper
- D21H 27/10: Packing paper (packaging materials of special type or form B65D65/38)
- D21H 27/32: with materials applied between the sheets (attaching together paper or cardboard sheets B31F5/00; adhesives C09J)
- B32B 2255/12: on paper layer
- B32B 2255/26: Polymeric coating
- B32B 2264/00: Composition or properties of particles which form a particulate layer or are present as additives
- B32B 2307/54: Yield strength; Tensile strength
- B32B 2307/546: Flexural strength; Flexion stiffness
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/72: Density
- B32B 2307/7244: Oxygen barrier
- B32B 2307/7265: Non-permeable
- B32B 2553/00: Packaging equipment or accessories not otherwise provided for
- D21H 17/28: Starch
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B65D: CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- C08L: COMPOSITIONS OF MACROMOLECULAR COMPOUNDS (compositions based on polymerisable monomers C08F, C08G; artificial filaments or fibres D01F; textile treating compositions D06)
- C09D: COATING COMPOSITIONS, e.g. PAINTS, VARNISHES OR LACQUERS; FILLING PASTES; CHEMICAL PAINT OR INK REMOVERS; INKS; CORRECTING FLUIDS; WOODSTAINS; PASTES OR SOLIDS FOR COLOURING OR PRINTING; USE OF MATERIALS THEREFOR (cosmetics A61K; processes for applying liquids or other fluent materials to surfaces, in general, B05D; staining wood B27K5/02; glazes or vitreous enamels C03C; natural resins, French polish, drying-oils, driers, turpentine, per se, C09F; polishing compositions other than French polish, ski waxes C09G; adhesives or use of materials as adhesives C09J; materials for sealing or packing joints or covers C09K3/10; materials for stopping leaks C09K3/12; processes for the electrolytic or electrophoretic production of coatings C25D)
- D21H: PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR

## 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.

## Claims

### Claim 1

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.

### Claim 2 (depends on 1)

The intermediate laminate product of claim 1, wherein the polysaccharide is a modified starch having reduced viscosity after gelatinisation as compared to native starch.

### Claim 3 (depends on 1)

The intermediate laminate product of claim 1, wherein the plasticizing additive is chosen from the group consisting of urea, glycerol, citric acid, formamide, acetamide, sorbitol, and glycol, combinations thereof.

### Claim 4 (depends on 1)

The intermediate laminate product of claim 1, wherein the dry coating further comprises 1-25 wt-% of one or more polymer compounds, based on the dry weight of the dry coating.

### Claim 5 (depends on 1)

The intermediate laminate product of claim 1, wherein the dry coating comprises 5-30 wt-% of the expandable microspheres, based on the dry weight of the dry coating.

### Claim 6 (depends on 1)

The intermediate laminate product of claim 1, wherein the dry coating comprises, based on the dry weight of the dry coating, 7-20 wt-% of the expandable microspheres, 40-75 wt-% of starch as the polysaccharide, the plasticizing additive as a combination of 5-10 wt-% of urea and 5-10 wt-% of glycerol, and 5-20 wt-% of polymer compounds.

### Claim 7 (depends on 2)

An expanded laminate structure comprising:
the intermediate laminate product of claim 2, and
a second paper layer comprising lignocellulose fibres, wherein the dry coating layer is in expanded form, and the second paper layer has been attached to the dry coating by heat lamination.

### Claim 8 (depends on 7)

A liquid packaging board comprising:
the expanded laminate structure of claim 7, and
a liquid barrier layer on at least one of said first or second paper layers.

### Claim 9

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.

### Claim 10 (depends on 9)

A process, comprising the process of claim 9, and further comprising:
introducing the intermediate laminate product into a heat lamination step;
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.

### Claim 11 (depends on 10)

The process of claim 10, wherein said second temperature (T2) is 120-200° C.

### Claim 12 (depends on 1)

An expanded laminate structure comprising:
two layers of the intermediate laminate product of claim 1, and
a barrier layer of plastic or metal sheet material positioned between the two layers of intermediate laminate product, in which the coating layers are in expanded form,
wherein the two layers of intermediate laminate product are oriented in the laminate such that the expanded coating of each layer is turned towards the barrier layer.

### Claim 13 (depends on 12)

The expanded laminate structure of claim 12, wherein the barrier layer is made from an oxygen-barrier material.

### Claim 14 (depends on 12)

The expanded laminate structure of claim 12, further comprising a liquid barrier layer on at least one of said first or second paper layers, on the side of the second paper layer facing away from the coating layer.

### Claim 15 (depends on 9)

A process comprising the process of claim 9 to form two intermediate laminate products, and further comprising:
introducing a first of the intermediate laminate products into a heat lamination step;
applying a barrier layer of plastic or metal sheet material to the coating of the first of the intermediate laminate products;
applying a second of the intermediate laminate products to the barrier layer, such that the coating layer of the second of the intermediate laminate products is turned towards the barrier layer; and
subjecting said barrier layer to 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 thermoplastic blend.

### Claim 16 (depends on 7)

A method comprising using the expanded laminate structure of claim 7 as a packaging board to form a package.

### Claim 17 (depends on 4)

The intermediate laminate product of claim 4, wherein said polymer compounds are selected from the group consisting of styrene-butadiene polymers, acrylonitrile-butadiene polymers, vinyl acetate-ethylene polymers, styrene-butylacrylate polymers, polyvinyl-acetate polymers, polyhydroxy alkanoate polymers, nitrile polymers, and natural rubber.

### Claim 18 (depends on 1)

A process comprising:
providing a previously manufactured intermediate laminate product according to claim 1;
introducing the intermediate laminate product into a heat lamination step;
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.

### Claim 19 (depends on 12)

The expanded laminate structure of claim 12, wherein the barrier layer comprises polyethylene-vinylalcohol film or aluminium film.

### Claim 20 (depends on 1)

A process comprising:
providing two previously manufactured intermediate laminates according to claim 1;
introducing a first of the intermediate laminate products into a heat lamination step;
applying a barrier layer of plastic or metal sheet material to the coating of the first of the intermediate laminate products;
applying a second of the intermediate laminate products to the barrier layer, such that the coating layer of the second of the intermediate laminate products is turned towards the barrier layer; and
subjecting said barrier layer to 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 thermoplastic blend.