# US 2025/0154728 A1 · Recyclable, thermoformable paper base web

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- Number: US 2025/0154728 A1
- Document ID: US20250154728A1
- Status: Published application
- Kind: A1
- Application number: 18/937,558
- Filed: 2024-11-05
- Published: 2025-05-15
- Earliest claimed: 2023-11-13
- Assignees: ProAmpac Holdings Inc.
- Applicants: Proampac Holdings Inc.
- Inventors: Adam West; Raymond J. Recchia; Lynsey A. Maddison; James E. Tierney; Terry J. Leis; Seyed Hesamoddin Tabatabaei; Amir Saffar
- Web page: https://patentgrep.com/patent/US20250154728A1

## CPC

- D21H 27/30: Multi-ply (for surface covering D21H27/18; making on paper-making machines D21F9/00, D21F11/00)
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 27/08: of synthetic resin
- B32B 27/10: of paper or cardboard
- B32B 27/306: {comprising vinyl acetate or vinyl alcohol (co)polymers}
- B32B 27/32: comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)}
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 2250/03: 3 layers
- B32B 2250/40: Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
- B32B 2307/308: Heat stability
- B32B 2307/718: Weight, e.g. weight per square meter
- B32B 2307/738: Thermoformability
- B32B 2439/70: Food packaging
- B32B 2553/00: Packaging equipment or accessories not otherwise provided for
- 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
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM

## Abstract

A thermoformable paper base web comprises an outer paper layer having opposing first and second surfaces, the second surface defining an exterior facing surface of the paper base web. An inner paper layer has opposing first and second surfaces, the first surface laminated to the second surface of the outer paper layer. A first bonding layer joins the outer paper layer second surface to the inner paper layer first surface. A polymer layer has opposing first surface and second surfaces, wherein the second surface of the polymer layer defines an interior-facing surface of the paper base web. The first surface of the polymer layer is joined to the second surface of the inner paper layer. The outer and inner paper layers together comprise at least 80% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

## Claims

### Claim 1

A thermoformable paper base web, comprising:
an outer paper layer having a first surface and a second surface opposite the first surface, wherein the first surface of the outer paper layer defines an exterior-facing surface of the paper base web;
an inner paper layer having a first surface and a second surface opposite the first surface, the first surface of the inner paper layer laminated to the second surface of the outer paper layer;
a first bonding layer between the outer paper layer and inner paper layer, the first bonding layer joining the second surface of the outer paper layer to the first surface of the inner paper layer;
a polymer layer having a first surface and a second surface opposite the first surface, wherein the second surface of the polymer layer defines an interior-facing surface of the paper base web, and wherein the first surface of the polymer layer is joined to the second surface of the inner paper layer; and
said outer and inner paper layers together comprise at least 80% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

### Claim 2 (depends on 1)

The thermoformable paper base web of claim 1, wherein the first bonding layer is attached directly to the second surface of the outer paper layer and the first surface of the inner paper layer.

### Claim 3 (depends on 1)

The thermoformable paper base web of claim 1, wherein the first bonding layer is selected from the group consisting of an adhesive layer and an extruded resin layer.

### Claim 4 (depends on 1)

The thermoformable paper base web of claim 1, wherein the polymer layer is selected from the group consisting of monolayer film and a multilayer film.

### Claim 5 (depends on 1)

The thermoformable paper base web of claim 1, wherein the polymer layer is attached directly to the second surface of the inner paper layer.

### Claim 6 (depends on 1)

The thermoformable paper base web of claim 1, further comprising:
a second bonding layer between the inner paper layer and the polymer layer, the second bonding layer joining the second surface of the inner paper layer to the first surface of the polymer layer.

### Claim 7 (depends on 6)

The thermoformable paper base web of claim 6, wherein the second bonding layer is attached directly to the second surface of the inner paper layer and the first surface of the polymer layer.

### Claim 8 (depends on 6)

The thermoformable paper base web of claim 6, wherein the second bonding layer is an adhesive layer and the inner paper layer is laminated with the polymer layer via the adhesive layer.

### Claim 9 (depends on 1)

The thermoformable paper base web of claim 1, wherein the polymer layer is selected from the group consisting of a barrier film layer and a nonbarrier film layer.

### Claim 10 (depends on 1)

The thermoformable paper base web of claim 1, wherein the outer paper layer and the inner paper layer, which may be the same or different, each comprise paper having a basis weight in the range of 50 GSM to 300 GSM.

### Claim 11 (depends on 1)

The thermoformable paper base web of claim 1, wherein the polymer layer is selected from the group consisting of:
a first coextruded film comprising a first polyolefin layer, a second polyolefin layer, and a first barrier layer disposed intermediate the first and second polyolefin layers, wherein the first barrier layer is formed of a material selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyvinylidene di-chloride (PVcD), polyamide, and polyvinyl alcohol (PVOH); and
a second coextruded film comprising a second barrier layer having a barrier outer surface coupled to the second surface of the inner paper layer and a barrier inner surface opposite the barrier outer surface, and a third polyolefin layer coupled to the barrier inner surface.

### Claim 12 (depends on 11)

The thermoformable paper base web of claim 11, wherein the first and second barrier layers comprise EVOH and the first, second, and third polyolefin layers, which may be the same or different, comprise a polyethylene-based polymer.

### Claim 13 (depends on 11)

The thermoformable paper base web of claim 11, wherein the first bonding layer is selected from the group consisting of:
an adhesive layer formed of an adhesive selected from the group consisting of a high viscosity adhesive having a viscosity in the range of 300 cP to 500,000 cP at 50 degrees C.;
a high solids content adhesive having a solids content in the range of 15% to 100% by weight; and
an extruded polyolefin resin layer.

### Claim 14 (depends on 11)

The thermoformable paper base web of claim 11, wherein the first bonding layer is selected from the group consisting of:
a third coextruded film comprising a fourth polyolefin layer, a fifth polyolefin layer, and a third barrier layer disposed intermediate the fourth and fifth polyolefin layers, wherein the third barrier layer is formed of a material selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyvinylidene di-chloride (PVcD), polyamide, and polyvinyl alcohol (PVOH); and
a fourth coextruded film comprising a fourth barrier layer having a barrier inner surface coupled to the first surface of the inner paper layer and a barrier outer surface opposite the barrier inner surface, and a sixth polyolefin layer coupled to the barrier outer surface and the second surface of the outer paper layer.

### Claim 15 (depends on 14)

The thermoformable paper base web of claim 14, wherein the third and fourth barrier layers comprise EVOH and the fourth, fifth, and sixth polyolefin layers, which may be the same or different, comprise a polyethylene-based polymer.

### Claim 16 (depends on 1)

The thermoformable paper base web of claim 1, wherein the paper base web is thermoformable to a depth of between 1 mm to 153 mm.

### Claim 17 (depends on 1)

The thermoformable paper base web of claim 1, wherein said outer and inner paper layers together comprise at least 85% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

### Claim 18 (depends on 1)

The thermoformable paper base web of claim 1, wherein said outer and inner paper layers together comprise at least 90% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

### Claim 19 (depends on 1)

The thermoformable paper base web of claim 1, wherein said outer and inner paper layers together comprise at least 95% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

### Claim 20

A method for producing a thermoformable paper base web, comprising:
laminating an outer paper layer to an inner paper layer with a first bonding layer therebetween, the outer paper layer having a first surface and a second surface opposite the first surface, wherein the first surface of the outer paper layer defines an exterior-facing surface of the paper base web;
the inner paper layer having a first surface and a second surface opposite the first surface, the first surface of the inner paper layer facing second surface of the outer paper layer; and
attaching a polymer layer to the second surface of the inner paper layer, the polymer layer having a first surface and a second surface opposite the first surface, wherein the first surface of the polymer layer is joined to the second surface of the inner paper layer and the second surface of the polymer layer defines an interior-facing surface of the paper base web;
wherein the outer and inner paper layers together comprise at least 80% by weight of the thermoformable paper base web and less than 100% by weight of the thermoformable paper base web.

### Claim 21 (depends on 20)

The method of claim 20, wherein the first bonding layer is attached directly to the second surface of the outer paper layer and the first surface of the inner paper layer.

### Claim 22 (depends on 20)

The method of claim 20, wherein the first bonding layer is selected from the group consisting of an adhesive layer and an extruded resin layer.

### Claim 23 (depends on 20)

The method of claim 20, wherein the first bonding layer is selected from the group consisting of:
a high viscosity adhesive having a viscosity in the range of 300 cP to 500,000 cP at 50 degrees C.;
a high solids content adhesive having a solids content in the range of 15% to 100% by weight; and
an extruded polyolefin resin layer.

### Claim 24 (depends on 23)

The method of claim 23, wherein the step of attaching the polymer layer to the second surface of the inner paper layer is performed by a process selected from the group consisting of adhesive lamination and extrusion lamination.

### Claim 25 (depends on 20)

The method of claim 20, wherein the step of attaching the polymer layer to the second surface of the inner paper layer includes applying a second bonding layer between the inner paper layer and the polymer layer, the second bonding layer joining the second surface of the inner paper layer to the first surface of the polymer layer.

### Claim 26 (depends on 25)

The method of claim 25, wherein the second bonding layer is selected from the group consisting of an adhesive layer and an extruded resin layer.

### Claim 27 (depends on 25)

The method of claim 25, wherein the second bonding layer is selected from the group consisting of:
a high viscosity adhesive having a viscosity in the range of 300 cP to 500,000 cP at 50 degrees C.;
a high solids content adhesive having a solids content in the range of 15% to 100% by weight; and
an extruded polyolefin resin layer.

### Claim 28 (depends on 26)

The method of claim 26 wherein the second bonding layer is attached directly to the second surface of the inner paper layer and the first surface of the polymer layer.

### Claim 29 (depends on 28)

The method of claim 28 wherein the polymer layer is applied to the second surface of the inner paper layer using a method selected from the group consisting of an extrusion coating process and a coextrusion coating process.

### Claim 30 (depends on 20)

The method of claim 20, wherein the polymer layer is selected from the group consisting of monolayer film and a multilayer film.

### Claim 31 (depends on 20)

The method of claim 20, wherein the polymer layer is selected from the group consisting of a barrier film layer and a nonbarrier film layer.

### Claim 32 (depends on 20)

The method of claim 20, wherein the polymer layer is selected from the group consisting of a barrier film layer and a nonbarrier film layer.

### Claim 33 (depends on 20)

The method of claim 20, wherein the polymer layer is selected from the group consisting of:
a first coextruded film comprising a first polyolefin layer, a second polyolefin layer, and a first barrier layer disposed intermediate the first and second polyolefin layers, wherein the first barrier layer is formed of a material selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyvinylidene di-chloride (PVcD), polyamide, and polyvinyl alcohol (PVOH); and
a second coextruded film comprising a second barrier layer having a barrier outer surface coupled to the second surface of the inner paper layer and a barrier inner surface opposite the barrier outer surface, and a third polyolefin layer coupled to the barrier inner surface.

### Claim 34 (depends on 33)

The method of claim 33, wherein the first and second barrier layers comprise EVOH and the first, second, and third polyolefin layers, which may be the same or different, comprise a polyethylene-based polymer.

### Claim 35 (depends on 33)

The method of claim 33, wherein the first bonding layer is selected from the group consisting of:
an adhesive layer formed of an adhesive selected from the group consisting of a high viscosity adhesive having a viscosity in the range of 300 cP to 500,000 cP at 50 degrees C.;
a high solids content adhesive having a solids content in the range of 15% to 100% by weight; and
an extruded polyolefin resin layer.

### Claim 36 (depends on 33)

The method of claim 33, wherein the first bonding layer is selected from the group consisting of:
a third coextruded film comprising a fourth polyolefin layer, a fifth polyolefin layer, and a third barrier layer disposed intermediate the fourth and fifth polyolefin layers, wherein the third barrier layer is formed of a material selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyvinylidene di-chloride (PVcD), polyamide, and polyvinyl alcohol (PVOH); and
a fourth coextruded film comprising a fourth barrier layer having a barrier inner surface coupled to the first surface of the inner paper layer and a barrier outer surface opposite the barrier inner surface, and a sixth polyolefin layer coupled to the barrier outer surface and the second surface of the outer paper layer.

### Claim 37 (depends on 36)

The method of claim 36, wherein the third and fourth barrier layers comprise EVOH and the fourth, fifth, and sixth polyolefin layers, which may be the same or different, comprise a polyethylene-based polymer.

### Claim 38 (depends on 20)

The method of claim 20, further comprising modifying one or more of the second surface of the outer paper layer, the first surface of the inner paper layer, the second surface of the inner paper layer, and the inner surface of the polymer layer with a surface treatment selected from the group consisting of flame treatment, corona treatment, ozone treatment, and plasma treatment.

### Claim 39 (depends on 1)

A thermoformed packaging article formed from the thermoformable paper base web of claim 1.

### Claim 40 (depends on 20)

A thermoformed packaging article formed by the method of claim 20.