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US 2025/0066575 A1Published application
Repulpable and recyclable composite packaging articles and related methods
AssigneeSmart Planet Technologies, Inc.
InventorChristopher R. Tilton
Life of this patent
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Abstract
A reusable, fiber containing pulp product is described that is highly suited for use in the manufacture of paper products. The reusable, fiber containing pulp product provides a mixture of fibers and small, dense polymer/particle fragments. The polymer/particle fragments within the reusable, fiber containing pulp product have a size range and density that facilitates efficient removal of the polymer/particle fragments using pressure screens.
Claims13
A barrier layer of a packaging or container comprising:
- a mineral containing layer comprising a polymer matrix, one or more coupling agents, and a crystalline content that comprises a mixture of crystalline, semi-crystalline, and amorphous structures;
- wherein said polymer matrix comprises a plurality of mineral particles and one or more polymer bonding agents;
- wherein said plurality of mineral particles comprise:
- (i) a plurality of mineral nano-particles that are about 100 nanometers or less in size and
- (ii) a plurality of ultrafine mineral nano-particles ranging in size from about 0.06 microns to 0.10 microns;
- wherein said plurality of mineral nano-particles are selected from the group of minerals consisting of:
- wollastonite (hydrated and non-hydrated);
- magnesium silicate;
- barium sulfate;
- barium ferrite;
- magnesium hydroxide;
- magnesium carbonate;
- aluminum trihydroxide;
- magnesium carbonate;
- natural silica or sand;
- cristobalite;
- diatomite;
- novaculite;
- quartz tripoli clay calcined;
- muscovite;
- nepheline-syenite;
- feldspar;
- calcium sulfate-gypsum;
- terra alba;
- selenite;
- domite;
- silicon mica;
- hydrated aluminum silicates;
- coke;
- montmorillonite (MMT);
- attapulgite (AT) carbon black;
- pecan nut flour;
- cellulose particles;
- wood flour;
- fly ash;
- starch;
- titanium dioxide (TiO2);
- barium carbonate;
- terra alba;
- selenite;
- nepheline-syenite;
- muscovite;
- pectolite;
- chrysotile;
- borates;
- sulfates;
- and
- precipitated and ground calcium carbonate;
- wherein the one or more polymer bonding agents have a physical melt flow index from about 4 g/m2/10 min to about 16 g/m2/10 min;
- wherein said plurality of mineral particles are dispersed within said one or more polymer bonding agents;
- wherein said one or more polymer bonding agents have a molecular weight (Mz) from about 150,000 to about 300,000;
- wherein a polymer content weight of said barrier layer is from about 3.5 lbs/3 msf to about 50 lbs/3 msf;
- wherein said one or more polymer bonding agents have crystallinity from about 40% to about 60%;
- wherein said one or more coupling agents are from about 0.05% to about 15% by weight of said mineral containing layer;
- wherein said mineral containing layer contains from about 0.5% to about 10% plastomers and elastomers with densities from about 0.86 g/cm3 to about 0.89 g/cm3;
- wherein said mineral containing layer has a differential scanning calorimetry (DSC) melting peaks from about 59° C. to about 110° C.;
- wherein said mineral containing layer has molecular weight ranges (Mw) from about 10,000to about 100,000;
- wherein about 10% to about 70% of said mineral containing layer has a branching index (g′) of about 0.99 or less as measured at a Z-average molecular weight (Mz) of said one or more polymer bonding agents;
- and
- wherein said one or more polymer bonding agents have an isotactic run length from about 1 to about 40 per DCS method.
57 more elements
A method of manufacturing a heat sealable and recyclable packaging structure, the method comprising:
- extrusion coating of a plurality of released fibers with a plurality of polymer/particle fragments that during recycling comprise a thermoplastic resin and a plurality of mineral particles;
- wherein said plurality of polymer/particle fragments have a mean surface area in the range of 0.0005 mm2 to 2 mm2 and a density in the range of 1.01 g/cm3 to 4.75 g/cm3;
- wherein said plurality of mineral particles comprise (i) a plurality of mineral nano-particles that are 100 nanometers or less in size and (ii) a plurality of ultrafine mineral nano-particles ranging from 0.06 microns to 0.10 microns in size;
- wherein said extrusion coating process is carried out under the following conditions:
- said thermoplastic resin having a melt flow index in the range of 4.0 g/10 min to 16 g/10 min;
- a melt temperature of 590° F. +20%;
- an extruder screw or tube barrel pressure in the range of 1,200 psi to 2,500 psi;
- an extruder screw or tube barrel air gap in the range of 4 inches to 16 inches;
- extruder screw or tube barrel die gap in the range of 0.020 inches to 0.050 inches;
- a barrel temperature in the range of 400° F. to 640° F.;
- and
- an extrusion lamination line speed from 100 PPM to 3,500 PPM;
- wherein said plurality of mineral particles further comprise a nano-cellulose;
- and
- wherein said nano-cellulose has a crystalline content in the range of 40% to 70%.
12 more elements
Dependencies are inferred from the claim text.