Note: Descriptions are shown in the official language in which they were submitted.
CA 02428320 2010-10-06
REAM WRAP COMPRISING PLA RESIN
Field of the Invention
The present invention relates to the use of PLA for ream wraps.
Background of the Invention
U.S. Patent No. 6,197,380 relates to a paper having a melt-stable lactide
polymer
coating and process for manufacture thereof. A lactide polymer coating results
in a
strong, repulpable, high gloss, paper coating. The lactide polymer comprises a
plurality
of polylactide polymer chains, residual lactide in concentration of less than
about
5 percent in water in concentration of less than about 2000 parts per million.
The patent
also relates to a method for coating paper comprising extruding a lactide
polymer
composition onto a moving paper to provide a coated paper wherein the lactide
polymer
composition comprises: a lactide level of less than about 1 wt. % if any
lactide present, a
number average molecular weight of between about 10,000 and about 200,000; a
catalyst
comprising a ring opening polymerization catalyst; and catalyst deactivating
agent in an
amount sufficient to reduce catalytic depolymerization, relative to an absence
of the
catalyst deactivating agent.
U.S. Patent No. 6,291,597 relates to a viscosity modified lactide polymer
composition and process for the manufacture. The polylactide polymer is
prepared by
providing in the composition polylactide polymer molecules which have been
modified,
relative to linear non-substituted polylactide, to provide increased molecular
interaction
among polylactide backbone chains in the composition.
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U.S. Patent No. 6,093,791 relates to a melt-stable semi-crystalline lactide
polymer
film and process for the manufacture. The lactide polymer comprises a
plurality of
polylactide polymer chains, residual lactide in concentration of less than
about 5 percent
and water in concentration of less than about 2000 parts per million.
U.S. Patent No. 6,103,809 relates to a thermoplastic composition comprising at
least one crystalline water sensitive polymer and at least one amorphous water
sensitive
polymer. The thermoplastic compositions are useful in a variety of
applications wherein
water or moisture sensitive thermoplastic materials are employed such as
various
packaging adhesive applications including case and carton sealing,
remoistenable
adhesives, repulpable/recyclable adhesives and multiwall bag applications. The
invention is also useful for moisture activatable reinforcement strings and
opening tapes
for corrugated containers, as well as a variety of nonwoven applications such
as body
fluid impermeable barriers, core stabilization adhesives and construction
adhesives.
U.S. Patent No. 6,114,042 relates to biodegradable polymers, the production
thereof and use thereof for producing biodegradable moldings.
U.S. Patent No. 6,114,495 relates to a lactic acid residue containing polymer
composition and product having improved stability and to methods for the
preparation
and use thereof. The lactic acid residue containing polymer preferably
includes a
polylactide polymer having a number average molecular weight of between about
25,000
and about 200,000 lactide, if present at all, present in a concentration of
less than
0.5 wt. % based on the weight of the composition, and deactivating agents.
Articles
which can be manufactured from the lactic acid residue containing polymer
composition
include fibers, coated paper, films, moldings and foam.
U.S. Patent No. 5,852,166 relates to a lactide polymer coating resulting in a
strong, repulpable, high gloss, paper coating. The lactide polymer comprises a
plurality
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of poly(lactide) polymer chains, residual lactide in concentration of less
than about
percent and water in concentration of less than about 2000 parts per million.
A process
for coating paper with the lactide polymer composition is also disclosed.
U.S. Patent No. 5,736,204 relates to a compostable paperboard container and
5 -- package for liquids which is coated with a material capable of degrading
to carbon
dioxide, water and biomass under composting conditions.
U.S. Patent No. 6,312,823 relates to a compostable multilayer film which
includes
a core layer having a first surface and a second surface, a first blocking
reducing layer
covering the first surface of the core layer, and a second blocking reducing
layer covering
-- the second surface of the core layer. The core layer comprises a lactic
acid residue
containing polymer having a glass transition temperature below 20 degrees C.
At least
one of the first and second blocking reducing layers comprise a
semicrystalline aliphatic
polyester. The core layer may be peroxide modified polylactide polymer which
exhibits
bridging between polylactide polymer chains. The compostable multilayer
structures are
-- films having desirable properties of flexibility and tear resistance and
can be used to
provide disposable bags or wrappers.
U.S. Patent No. 6,183,814 relates to coated grade polylactide and coated
paper,
preparations thereof and articles prepared therefrom. A coated paper product
including a
paper layer and a polymer layer, wherein the polymer layer includes a
polylactide
-- polymer composition having a ratio of Mz to Mn of greater than about 6. The
polymer
composition when melted, exhibits a die swell of greater than about 1.25 for a
melt flow
index of greater than about 2.
U.S. Patent No. 6,153,306 relates to a paper coated with polylactide and a
method
for making it. The invention relates to a polylactide coated paper or board
product which
-- is made by coextrusion wherein the polylactide is extruded together with a
conventional
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polymer, such as polyolefin, onto the surface of the paper, and after
extrusion the
polyolefin film is removed and recycled.
U.S. Patent No. 5,925,726 relates to a thermoplastic biodegradable polyester,
a
process for the preparation thereof, and articles manufactured therefrom. The
invention
relates to a melt processible copolyester and a process and prepolymer for the
preparation
thereof. The copolymer contains structural units derived from a polyester and
structural
units derived from diepoxy, and the polyester units at least essentially
consist of hydroxy
acid monomers. The copolyester is hydrolytically degradable and it can be used
as a
biodegradable polymer for the manufacture of injection molded articles as well
as
thermoformed and blow molded packages, pouches, sacks and bottles, for the
coating of
sacks, bags and films made from paper or cardboard and for the preparation of
fibers,
fiber cloths and expanded polymer articles.
U.S. Patent No. 5,936,045 relates to biodegradable polymers, the preparation
thereof, and the use thereof for producing biodegradable moldings.
U.S. Patent No. 6,075,118 relates to water responsive, biodegradable film
compositions comprising polylactide and polyvinyl alcohol and a method for
making the
films. The films are useful as a component in flushable and degradable
articles.
U.S. Patent No. 6,080,478 relates to a multilayer material including a
cellulose
based naturally decomposing basic layer, at least one polyhydroxyalkanoate
layer on the
basic layer and at least one biodegradable polylactide layer between the basic
layer and
the at least one polyhydroxyalkanoate layer.
U.S. Patent No. 5,540,962 relates to a compostable paperboard container and
package for liquids coated with a polymeric material capable of degrading
under
composting conditions and subsequently in the presence of light to form carbon
dioxide,
water and biomass.
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U.S. Patent No. 5,665,474 relates to a lactide polymer coating resulting in a
strong, repulpable, high gloss, paper coating. The lactide polymer comprises a
plurality
of polylactide polymer chains, residual lactide in concentration of less than
about
percent and water in concentration of less than about 2000 parts per million.
A process
5 for coating the paper with the lactide polymer composition is also
disclosed.
U.S. Patent No. 5,807,973 relates to a nonwoven fabric comprised of a lactide
polymer. The lactide polymer comprises a plurality of polylactide chains,
residual lactide
in concentration of less than about 2 percent and water in concentration of
less than about
2000 parts per million. The patent also discloses a process for manufacturing
a
nonwoven fabric with the lactide polymer composition.
U.S. Patent Nos. 5,849,374 and 5,849,401 relate to a compostable, multilayer
structure in the form of a film, sheet, laminate, and the like, which
comprises a core layer
having a first surface and a second surface, a first blocking reducing layer
covering the
first surface of the core layer, and a second blocking reducing layer covering
the second
surface of the core layer. The core layer contains a lactic acid residue-
containing
polymer and has a glass transition temperature below about 20 degrees C. The
first and
second blocking reducing layers include a polymer composition of a
hydrolyzable
polymer having a glass transition temperature above about 50 degrees Celsius.
The
multilayer structure can be used for preparing bags and wrappers.
Summary of the Invention
The present invention relates to the use of PLA resin in ream wraps. PLA resin
is
substituted for poly coating in current ream wrap applications. One advantage
is
compostability.
The present invention relates to a ream wrap comprising: one or more layers of
paper or film and a PLA resin.
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The present invention relates to a composite wrap material comprising: a layer
or
sheet of cellulosic material, and a layer of PLA film that is integrally
bonded together by
means of an adhesive layer. It is an object of the present invention for the
adhesive to
comprise PLA. It is an object of the present invention for the film layer
and/or adhesive
layer to provide a moisture vapor barrier to protect contents of a package
within the wrap
material. It is an object of the present invention for the wrap material to
provide a clear
or transparent wrap such that a consumer can see the paper layer laminated to
the film
layer. It is an object of the present invention for one or more of the layers
to optionally
contain a pigment to provide coloration.
The present invention relates to a method of preparing a composite wrap
material
comprising: laminating a three-layer structure comprising a layer of paper, a
PLA layer
or film layer and an adhesive layer, using a nip roller apparatus or other
suitable
laminating device. The paper and film layers are passed with the adhesive
layer
thereinbetween through a pair of nip rollers bonding the layers together.
The present invention relates to a ream wrapper comprising: an unbleached
(brown), semi-bleached (tan), or bleached (white) paper; and a PLA coating. it
is an
object of the present invention for the paper to have a weight of between
about
30 to 70 pounds per 3,000 sq. ft. It is an object of the present invention for
paper to be
coated with about 7 to 15 pounds per 3,000 sq. ft. of PLA resin. It is an
object of the
present invention for the coating to be made by mixing PLA with a dye or
pigment.
The present invention relates to a method of preparing a ream wrapper
comprising: mixing PLA with a dye or pigment, and coating the mixture on
either side of
an about 30 to 70 pound unbleached (brown), semi-bleached (tan), or bleached
(white)
paper. It is an object of the present invention for the coating to provide a
high quality
printing surface for outside of the ream wrap in a color that enhances
printing graphics,
instantly identifies a manufacturer of a wrapped paper product, and/or
identifies color of
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paper encased in the ream wrap. It is an object of the present invention for
the ream wrap
to act as a moisture barrier, protect against physical damage, and use, more
environmentally friendly unbleached (brown) or semi-bleached (tan) papers
while still
providing an enhanced printing surface. It is an object of the present
invention for the
ream wrapper to be compostable.
The present invention relates to a ream wrapper comprising: an unbleached
(brown) paper or a semi-bleached (tan) paper, and a with a white PLA coating.
It is an
object of the present invention for the coating to be made by mixing PLA with
a white
dye or pigment.
The present invention relates to a ream wrap comprising: a first layer of
paper, a
second layer of transparent film, and a layer of PLA between the first and
second layers.
The paper has holes precut at various locations. The holes are covered by the
layer of
film.
The present invention relates to a high strength poly one side ream wrapper
comprising: copolymer and/or terpolymer resins. The copolymer and terpolymer
resins
comprise butene, hexene, and/or octene with ethylene feed stocks. The
copolymer or
terpolymer are applied to a paper surface alone or blended with PLA resins. It
is an
object of the present invention for the paper to comprise an additional coat
of PLA resin.
The present invention relates to a method for producing a high strength poly
one
side ream wrapper comprising: blending a PLA resin with a copolymer and/or
terpolymer resin. The mixture is fed into an extruder die creating an
extrudate. The
extrudate is applied to a paper surface between a backing roll and a chill
roll creating a
coated paper with PLA monomer and copolymer or terpolymer blended into the
monomer.
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The present invention relates to a method for producing a high strength poly
one
side ream wrapper comprising: coextruding a copolymer and/or terpolymer with a
PLA
layer by feeding the copolymer and/or terpolymer layer and the PLA layer
through a
coextruder die forming a coextrudate. The copolymer and/or terpolymer layer
can be
blended with PLA. The coextrudate is applied to a surface of a paper wherein
the
copolymer and/or terpolymer layer face the paper surface. The coextrudate is
applied to
the paper surface between a backing roll and a chill roll creating a coated
paper having
one layer of copolymer or terpolymer and one layer of PLA.
The present invention relates to a high strength poly one side ream wrapper
comprising: a coextruded coated paper having one layer of copolymer and/or
terpolymer
on top of the paper and one layer of PLA on top of the copolymer or terpolymer
layer; the
copolymer and/or terpolymer layer can also contain PLA.
The present invention relates to a method for producing a high strength poly
one
side ream wrapper comprising: coextruding a copolymer and/or terpolymer layer
with a
PLA layer by feeding the copolymer and/or terpolymer layer and the PLA layer
through a
coextruder die to form a coextrudate. The copolymer and/or terpolymer layer
can be
blended with PLA. The coextrudate is applied to a paper surface with the PLA
layer
facing the paper. The coextrudate is applied to the paper surface between a
backing roll
and a chill roll, creating a coated paper with one layer of copolymer and/or
terpolymer
and one layer of PLA.
The present invention relates to a high strength poly one side ream wrapper
comprising: a coextruded coated paper having one layer of PLA on top of the
paper layer
and a layer of copolymer and/or terpolymer on top of the PLA layer. The
copolymer
and/or terpolymer layer can be blended with PLA.
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The present invention relates to a method for producing a high strength poly
one
side ream wrapper comprising: coextruding a layer of copolymer and/or
terpolymer and
a layer of PLA on each side of a copolymer and/or terpolymer layer by feeding
the
copolymer and/or terpolymer layer and the PLA layers through a coextruder die
forming
a coextrudate. The copolymer and/or terpolymer layer can also contain PLA. The
coextrudate is applied to a paper surface so that one of the PLA layers faces
paper by
running the coextrudate and the paper between a backing roll and a chill roll,
creating a
coated paper with one layer of copolymer and/or terpolymer between two layers
of PLA.
The present invention relates to a high strength poly one side ream wrapper
comprising: a poly coated paper having one layer of PLA on top of a paper
layer
followed by a layer of copolymer and/or terpolymer having on top of it a layer
of PLA.
The copolymer and/or terpolymer layer can also contain PLA.
The present invention relates to a composite wrap material comprising: a layer
or
sheet of cellulosic material and a layer of PLA film material that are
integrally bonded
together by means of an adhesive layer comprising PLA interposed
thereinbetween. It is
an object of the present invention for the PLA film layer and/or said adhesive
layer to
provide a moisture vapor barrier to protect contents packaged within the wrap
material.
It is an object of the present invention for the wrap material to provide a
clear or
transparent wrap such that a consumer can see the paper layer laminated to the
PLA film
layer. It is an object of the present invention for one or more of the layers
to contain a
pigment to provide coloration. It is an object of the present invention for
the wrap to be
provided with a high gloss print surface or a standard paper print surface. It
is an object
of the present invention for the paper material and/or film to be a metalized
material. It is
an object of the present invention for the paper to be printed before
lamination so that the
print shows through the film layer.
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The present invention relates to a ream wrap comprising: a film layer, PLA
layer
and a paper layer having an additional layer of PLA coated on the paper. It is
an object
of the present invention for the inner layer of PLA bond to the outer film
layer through
heat.
The present invention relates to a high strength poly film ream wrapper
comprising: two sheets of PLA film laminated together with a layer of
copolymer and/or
terpolymer resins. The copolymer and/or terpolymer resins comprise butene,
hexene,
and/or octene with ethylene in feed stocks.
The present invention relates to a method for producing a high strength poly
film
ream wrapper comprising: applying or extruding copolymer and/or terpolymer
resins
between two sheets of solid plastic PLA film; or laminating two separate
layers of solid
plastic PLA film with a copolymer and/or terpolymer resin.
The present invention relates to a high strength poly film ream wrap material
comprising: a first layer comprising a polypropylene, biaxially oriented
polypropylene
(BOPP), polyester or PLA solid film; a second layer comprising a
polypropylene,
biaxially oriented polypropylene (BOPP), polyester, or PLA solid film; and a
third layer
comprising copolymer and/or terpolymer resins, alone, or blended with
polyethylene or
PLA. The third layer is interposed between the first layer and the second
layer.
The present invention relates to a method of making a high strength poly film
ream wrapper comprising: applying a copolymer and/or terpolymer layer to
either of
solid plastic PLA film layers, and conveying the layers toward a pair of nip
rollers. The
film layers are directed to an adjacent, noncontact position with the
copolymer and/or
terpolymer resin layer on its respective opposite sides prior to passing
through the nip
rollers. The layers are passed through the nip rollers, forming the poly film
ream
wrapper.
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The present invention relates to an insulation facing material comprising: a
coextruded coated paper material comprising: a first layer of paper, a second
layer of
PLA resin material and a third outside sealant layer of low melt polymer
resin,
comprising, PLA; wherein all three layers are integrally bonded together.
The present invention relates to a process for making a composite material
comprising: providing a first sheet of cellulosic material and a second
coextruded layer
comprising two layers of PLA resin materials, and applying the coextrusion
layers to a
surface of the first sheet. The first sheet and second coextrusion layers are
conveyed into
a laminating apparatus, bonding the layers to form an integral composite
material.
Description of the Preferred Embodiments
In one embodiment a composite wrap material comprises a layer or sheet of
cellulosic material and a layer of polymer film or PLA film that is integrally
bonded
together by means of an adhesive layer, which in one embodiment, comprises
PLA,
interposed thereinbetween. The film layer and/or the adhesive layer function
to provide a
moisture vapor barrier to protect the contents of the package within the wrap
material.
The wrap material can provide a clear or transparent wrap such that a consumer
can see
the paper layer laminated to the film layer. One or more layers can optionally
contain a
pigment to provide coloration. The composite paper/film wrap material can be
prepared
by laminating a three-layer structure comprising the layer of paper, the PLA
layer or film
layer and an adhesive layer, using a nip roller apparatus or other suitable
laminating
device. The paper and film layers with the adhesive layer thereinbetween can
be passed
through a pair of nip rollers to bond the two layers together. Advantageously,
the
resulting composite wrap facilitates high burst strength of the final package,
the option of
a high gloss print surface or a standard paper print surface, a moisture
barrier to prevent
moisture absorption by the wrapped paper, and the fold characteristics of
paper. The
composite wrap material is also compostable.
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In a further embodiment of the present invention a ream wrapper is made of
either
an unbleached (brown), semi-bleached (tan), or bleached (white) paper with a
PLA
coating. The paper has a weight of between about 30 to 70 pounds per 3,000 sq.
ft. The
paper is coated with about 7 to 15 pounds per 3,000 sq. ft. of PLA resin. The
coating is
made by mixing PLA with a dye or pigment. The mixture is then coated on either
side of
the about 30 to 70 pound unbleached (brown), semi-bleached (tan), or bleached
(white)
paper. The invention provides a high quality printing surface for the outside
of the ream
wrap in a color that enhances printing graphics, instantly identifies the
manufacturer of
the wrapped paper product, and/or identifies the color of the paper encased in
the ream
wrap. The present invention also provides a ream wrap that also acts as a
moisture
barrier, protects against physical damage, and uses, where possible, the more
environmentally friendly unbleached (brown) or semi-bleached (tan) papers
while still
providing an enhanced printing surface. The ream wrapper is also compostable.
In a further embodiment, the ream wrapper is made of an unbleached (brown)
paper or a semi-bleached (tan) paper with a white poly coating. This results
in a white
print surface for the outside of the ream wrap. The white poly coating is made
by mixing
PLA with a white dye or pigment.
In an embodiment, a ream wrap comprises a first layer of paper, a second layer
of
transparent film and a layer of PLA between the first and second layers. The
paper has
holes precut at various locations, the holes being covered by the layer of
film.
In a further embodiment, a high strength poly one side ream wrapper is made by
utilizing copolymer and/or terpolymer resins. The copolymer and terpolymer
resins are
made by combining butene, hexene, and/or octene with ethylene feed stocks
being used
to make the resin. The product can be produced by applying the copolymer or
terpolymer
to the paper surface or by blending the copolymer and/or terpolymer resins
with PLA
resins before applying it to the paper surface. The product can be produced by
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coextruding a PLA resin with copolymer or terpolymer resins. The paper can be
additionally coated with PLA resins.
In a further embodiment, the present invention relates to a method for
producing a
high strength poly one side ream wrapper comprising: feeding a copolymer
and/or
terpolymer into an extruder die creating an extrudate and then coating a paper
surface
with the extrudate between a backing roll and a chill roll. This forms a poly
coated paper
with the copolymer and/or terpolymer coating.
In a further embodiment, the present invention relates to a method for
producing a
high strength poly one side ream wrapper comprising: blending a PLA resin with
a
copolymer and/or terpolymer resin and feeding the mixtures into an extruder
die creating
an extrudate. The extrudate is applied to a paper surface between a backing
roll and a
chill roll creating a coated paper with PLA monomer and copolymer or
terpolymer
blended into the monomer.
In an embodiment, the present invention relates to a method for producing a
high
strength poly one side ream wrapper comprising: coextruding a copolymer and/or
terpolymer with a PLA layer by feeding the copolymer and/or terpolymer layer
and the
PLA layer through a coextruder die forming a coextrudate. The copolymer and/or
terpolymer layer can be blended with PLA. The coextrudate is applied to a
surface of a
paper wherein the copolymer and/or terpolymer layer face the paper surface,
the
coextrudate being applied to the paper surface between a backing roll and a
chill roll;
creating a coated paper having one layer of copolymer or terpolymer and one
layer of
PLA.
In a further embodiment, the present invention relates to a high strength poly
one
side ream wrapper comprising: a coextruded coated paper having one layer of
copolymer
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and/or terpolymer on top of the paper and one layer of PLA on top of the
copolymer or
terpolymer layer. The copolymer and/or terpolymer layer can also contain PLA.
In a further embodiment, the present invention relates to a method for
producing a
high strength poly one side ream wrapper comprising: coextruding a copolymer
and/or
terpolymer layer with a PLA layer by feeding the copolymer and/or terpolymer
layer and
the PLA layer through a coextruder die to form a coextrudate. The copolymer
and/or
terpolymer layer can be blended with PLA. The coextrudate is applied to a
paper surface
with the PLA layer facing the paper; the coextrudate applied to the paper
surface between
a backing roll and a chill roll. This creates a coated paper with one layer of
copolymer
and/or terpolymer and one layer of PLA.
In a further embodiment, the present invention relates to a high strength poly
one
side ream wrapper comprising: a coextruded coated paper having one layer of
PLA on
top of a paper layer and a layer of copolymer and/or terpolymer on top of the
PLA layer.
The copolymer and/or terpolymer layer can be blended with PLA.
In an embodiment, the present invention relates to a method for producing a
high
strength poly one side ream wrapper comprising: coextruding a layer of
copolymer
and/or terpolymer and a layer of PLA on each side of the copolymer and/or
terpolymer
layer by feeding the copolymer and/or terpolymer layer and the PLA layers
through a
coextruder die forming a coextrudate. The copolymer and/or terpolymer layer
can also
contain PLA. The coextrudate is applied to a paper surface so that one of the
PLA layers
faces the paper by running the coextrudate and the paper between a backing
roll and a
chill roll. This creates a coated paper with one layer of copolymer and/or
terpolymer
between two layers of PLA.
In a further embodiment, the present invention relates to a high strength poly
one
side ream wrapper comprising: a poly coated paper having one layer of PLA on
top of a
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paper layer followed by a layer of copolymer and/or terpolymer having on top
of it a
layer of PLA. The copolymer and/or terpolymer layer can also contain PLA.
In a further embodiment, the present invention relates to a composite wrap
material comprising a layer or sheet of cellulosic material and a layer of PLA
film
material that are integrally bonded together by means of an adhesive layer
comprising
PLA interposed thereinbetween. The PLA film layer and/or the adhesive layer
function
to provide a moisture vapor barrier to protect the contents packaged within
the wrap
material. The wrap material can provide a clear or transparent wrap such that
a consumer
can see the paper layer laminated to the PLA film layer. One or more layers
can
optionally contain a pigment to provide coloration. The wrap can also be
provided with a
high gloss print surface or a standard paper print surface. The paper material
and/or film
can be a metalized material. Also the paper can be printed before lamination
so that the
print shows through the film layer.
The composite paper/film wrap material can be prepared by laminating a three
layer structure comprising a layer of paper, an adhesive layer, for example,
PLA, and the
PLA film layer using a nip roller apparatus or other suitable laminating
device. The
paper and film layers with the adhesive layer thereinbetween can be passed
through a pair
of nip rollers to bond the two layers together.
Advantageously, the resulting composite wrap facilitates high burst strength
of
the final package, the option of a high gloss print surface or a standard
paper print
surface, a moisture barrier to prevent moisture absorption. The composite wrap
material
is also compostable.
In a further embodiment, the present invention relates to a ream wrap
comprising
a film-PLA-paper having an additional layer of PLA coated on the paper. The
ream wrap
comprises a film/PLA/paper/PLA configuration. This additional layer can be
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CA 02428320 2010-10-06
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polyethylene, polypropylene or PLA. This allows the inner layer of PLA to bond
to the
outer film layer through heat. This eliminates the need for gluing the
product. There
may be additional coatings or treatments, or other layers that can be added to
the outside
of the film to provide the heat seal.
In a further embodiment, the present invention relates to a high strength poly
film
ream wrapper. The product is made by using a copolymer and/or terpolymer
resins alone
or blended with PLA, in the place of an adhesive, between two layers of solid
plastic
film. The copolymer and terpolymer resins are made by combining butene,
hexene,
and/or octene with ethylene in the feed stocks. The product is produced by
applying or
extruding the copolymer and/or terpolymer resins alone or blended with PLA
between
two sheets of solid plastic film.
In a further embodiment, the present invention relates to a high strength poly
film
ream wrapper comprising: two sheets of PLA film laminated together with a
layer of
copolymer and/or terpolymer resins. The copolymer and/or terpolymer resins
comprise
butene, hexene, and/or octene with ethylene in feed stocks. The copolymer
and/or
terpolymer resins are applied or extruded between two sheets of PLA film. This
creates a
product whereby two separate layers of PLA film are laminated together with a
layer of
copolymer and/or terpolymer resins in between the film layers.
In an embodiment, the present invention relates to a method for producing a
high
strength poly film ream wrapper comprising: applying or extruding copolymer
and/or
terpolymer resins between two sheets of solid plastic PLA film or laminating
two
separate layers of solid plastic PLA film with a copolymer and/or terpolymer
resin. This
creates a PLA film/copolymer and/or terpolymer resin/PLA film combination.
In a further embodiment, the present invention relates to a high strength poly
film
ream wrap material comprising: a first layer comprising a polypropylene,
biaxially
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=
oriented polypropylene (BOPP), polyester or PLA solid film. A second layer
comprises a
polypropylene, biaxially oriented polypropylene (BOPP), polyester, or PLA
solid film. A
third layer comprises copolymer and/or terpolymer resins, alone, or blended
with
polyethylene or PLA. The third layer is interposed between the first layer and
the second
layer.
In a further embodiment, the present invention relates to a method of making a
high strength poly film ream wrapper comprising: applying a copolymer and/or
terpolymer layer to either of solid plastic PLA film layers. The layers are
conveyed
toward a pair of nip rollers. The film layers are directed to an adjacent,
noncontact
position with the copolymer and/or terpolymer resin layer on its respective
opposite sides
prior to passing through the nip rollers. The layers pass through the nip
rollers, forming
the poly film ream wrapper.
In a further embodiment, the present invention relates to a composite wrap
material comprising a layer of paper or cellulosic material and a layer of
coextruded
resin. The coextrusion process comprises applying two or more layers of
different resins
simultaneously to one side of the paper. The composite wrap material has one
resin with
low moisture transmission rates and/or high strength characteristics and the
other resin
has heat seal or glueable characteristics similar to the polyethylene coated
wraps
currently used in the market.
The inside coextrusion layer comprises a layer of polypropylene homopolymer or
copolymer, high density polyethylene, PLA, or linear low density polyethylene
which
provides higher strength characteristics and lower moisture vapor transmission
rates. The
outside layer may comprise low density polyethylene, or PLA which provides a
heat seal
or glueable surface.
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=
In a further embodiment, the present invention relates to an insulation facing
material comprising: a coextruded coated paper material comprising: a first
layer of
paper, a second layer of PLA resin material and a third outside sealant layer
of low melt
polymer resin, for example, PLA, wherein all three layers are integrally
bonded together.
The PLA resin layer provides a moisture vapor barrier and improved strength to
the
coextruded material. The third layer provides an adhesion or bond to the
insulation. The
coextruded material is faced with a roll or batt of insulation.
In an embodiment, the present invention relates to a process for making a
composite material comprising: providing a first sheet of cellulosic material
and a
second coextruded layer comprising two layers of PLA resin materials. The
coextrusion
layers are applied to the surface of the first sheet. The first sheet and the
second
coextrusion layers are conveyed into a laminating apparatus where the layers
are bonded
to form an integral composite material.
The present invention further relates to coextrusion of PLA based materials to
be
part of a paper substrate structure used for insulation facing. Fiberglass and
other
insulating type materials are incorporated with the coextruded substrate,
laminated to the
PLA surface to form a composite product used in the building industry.
In a further embodiment, the present invention provides a thin, high strength,
moisture barrier coating that address the installers concerns for tear
strength, and allows
maximum footage at normal roll diameters and meets or exceeds the moisture
barrier
specifications.
In a further embodiment, the coextrusion process comprises applying two
different resins simultaneously, to one side of a paper. One resin has a high
strength
(burst values at approximately 60 or greater versus with a single layer LPDE
of
comparable thickness), and low moisture transmission rates (WVTR test values
of 0.50 or
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less versus 1.00 with a single LPDE layer of comparable thickness). The other
layer
provides the low temperature (100 degrees C. or less) seal strength required
for good
adherence to fiberglass or other insulation product. This composite coextruded
product
provides the desired improvements at the same or lower cost to the fiberglass
or other
insulation producer.
The coextrusion layer of this embodiment can comprise either a layer of
polypropylene homopolymer or copolymer, high density polyethylene, PLA or
linear low density polyethylene all of which provide higher strength and lower
moisture
vapor transmission rates. The outer coex is a high melt index (approximately
10.0 melt
index or higher) low density polyethylene or PLA providing improved bond
(visual
pulling away of fiberglass strands when separated) or adhesion to the
fiberglass or other
insulation product.
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