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Patent 2543015 Summary

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(12) Patent Application: (11) CA 2543015
(54) English Title: WATER DISPERSIBLE PRODUCTS
(54) French Title: PRODUITS POUVANT SE DISPERSER DANS L'EAU
Status: Dead
Bibliographic Data
(51) International Patent Classification (IPC):
  • D21H 11/12 (2006.01)
  • B01D 39/18 (2006.01)
  • D21H 11/14 (2006.01)
  • D21H 13/16 (2006.01)
  • D21H 13/26 (2006.01)
  • D21H 13/30 (2006.01)
  • D21H 13/38 (2006.01)
  • D21H 17/02 (2006.01)
  • D21H 17/28 (2006.01)
  • D21H 17/31 (2006.01)
  • D21H 17/36 (2006.01)
  • D21H 17/53 (2006.01)
  • D21H 23/24 (2006.01)
  • D21H 23/50 (2006.01)
  • D21H 27/38 (2006.01)
(72) Inventors :
  • CHOI, WAI MING (United States of America)
  • YU, HOWARD (United States of America)
(73) Owners :
  • HOLLINGSWORTH & VOSE COMPANY (United States of America)
(71) Applicants :
  • HOLLINGSWORTH & VOSE COMPANY (United States of America)
(74) Agent: RICHES, MCKENZIE & HERBERT LLP
(74) Associate agent:
(45) Issued:
(86) PCT Filing Date: 2004-10-29
(87) Open to Public Inspection: 2005-05-12
Examination requested: 2006-04-11
Availability of licence: N/A
(25) Language of filing: English

Patent Cooperation Treaty (PCT): Yes
(86) PCT Filing Number: PCT/US2004/036232
(87) International Publication Number: WO2005/042631
(85) National Entry: 2006-04-11

(30) Application Priority Data:
Application No. Country/Territory Date
60/515,480 United States of America 2003-10-29

Abstracts

English Abstract




Water dispersible fiber products are provided. In one embodiment, a water
dispersible fiber sheet is provided and it is preferably formed from
regenerated cellulose fibers, a second fiber that is adapted to provide
strength to the water dispersible fiber sheet, and a water soluble binder. In
use, the fiber sheet can be formed into a variety of products including, for
example, for labels, packaging, medical and health care products. The fiber
sheet is particularly advantageous in that it is readily dispersible upon
contact with water, yet it will retain its strength when used with other
fluids, such as alcohol and oils. The biodegradability of the fiber sheet will
also allow the fibers to be consumed naturally by environmental bacteria, thus
eliminating the need for special disposal procedures. In another embodiment,
the water dispersible fiber sheet can be incorporated into a filter media.


French Abstract

L'invention a trait à des produits à base de fibres pouvant se disperser dans l'eau. Dans un mode de réalisation, l'invention concerne une feuille de fibres pouvant se disperser dans l'eau, et est formée de préférence de fibres de cellulose régénérée, de secondes fibres qui sont adaptées pour rendre la feuille de fibres pouvant se disperser dans l'eau plus résistante, et un liant hydrosoluble. La feuille de fibres selon l'invention peut servir à former une multitude de produits, notamment, par exemple, des étiquettes, des produits d'emballage, des produits médicaux et d'hygiène. La feuille de fibres selon l'invention est particulièrement avantageuse en ce qu'elle peut être facilement dispersée lorsqu'elle est mise en contact avec de l'eau, et en ce qu'elle conserve sa résistance lorsqu'elle est utilisée avec d'autres fluides, tels que de l'alcool et des huiles. La biodégradabilité de la feuille de fibres permettra également aux fibres d'être consommées de façon naturelle par des bactéries présentes dans l'environnement, ce qui rend inutile tout recours à des procédures d'élimination spéciales. Dans un autre mode de réalisation, la feuille de fibres pouvant se disperser dans l'eau peut être incorporée dans un milieu filtrant.

Claims

Note: Claims are shown in the official language in which they were submitted.





-15-


CLAIMS:

1. A water dispersible fiber sheet, comprising:

a first fiber comprising regenerated cellulose;

a second fiber adapted to provide strength to the water dispersible fiber
sheet;
and

a water soluble binder.

2. The water dispersible fiber sheet of claim 1, wherein the water dispersible
fiber
sheet includes about 20% to 90% of the first fiber, about 10% to 80% of the
second
fiber, and less than about 10% of the water soluble binder.

3. The water dispersible fiber sheet of claim 1, wherein the second fiber
includes
about 10% to 80% of a natural fiber and about 0% to 50% of a synthetic fiber.

4. The water dispersible fiber sheet of claim 1, wherein the water soluble
binder is
added to the water dispersible fiber sheet by applying the water soluble
binder to the first
and second fibers after the first and second fibers are formed into a fiber
sheet.

5. The water dispersible fiber sheet of claim 1, wherein the water soluble
binder is
added to the water dispersible fiber sheet by mixing the water soluble binder
with the
first and second fibers before the mixture is formed into a water dispersible
fiber sheet.

6. The water dispersible fiber sheet of claim 1, wherein the second fiber is
selected
from the group consisting of natural fibers, synthetic fibers, and
combinations thereof.

7. The water dispersible fiber sheet of claim 6, wherein the natural fibers
are
selected from the group consisting of softwood fibers, hardwood fibers,
vegetation
fibers, and combinations thereof.






-16-


8. The water dispersible fiber sheet of claim 6, wherein the synthetic fibers
are
selected from the group consisting of polyethylene terephthalate fibers, nylon
fibers,
polyolefin fibers, synthetic wood pulp fibers, polyvinyl alcohol fibers,
acrylic fibers,
modacrylic fibers, vinyl chloride fibers, vinylidene chloride fibers, acetate
fibers,
regenerated protein fibers, polylactide fibers, poly(lactide-co-glycolide)
fibers, glass
fibers, ceramic fibers, metal fibers, mineral fibers, and combinations
thereof.

9. The water dispersible fiber sheet of claim 1, wherein the water soluble
binder is
selected from the group consisting of water soluble carboxymethyl cellulose,
polyethylene oxide, polyvinyl alcohol, protein, polyacrylic acid, starches,
gums, and
combinations thereof.

10. The water dispersible fiber sheet of claim 1, wherein the fiber sheet will
disperse
in less than about 20 seconds when agitated in water.

11. The water dispersible fiber sheet of claim 1, wherein the fiber sheet will
disperse
in less than about 10 seconds.

12. The water dispersible fiber sheet of claim 1, wherein the fiber sheet will
disperse
in less than about 5 seconds.

13. The water dispersible fiber sheet of claim 1, wherein the fiber sheet has
an MD
tensile strength that is at least about 2 lb/inch.

14. The water dispersible fiber sheet of claim 1, wherein the first fiber has
a length in
the range of about 1 mm to 10 mm.

15. The water dispersible fiber sheet of claim 1, wherein the second fiber has
a
length in the range of about 0.1 mm to 6 mm.







- 17 -

16. The water dispersible fiber sheet of claim 1, wherein the second fiber has
a size
that is in the range of about 0.1 µ to 100 µ.

17. The water dispersible fiber sheet of claim 1, wherein the second fiber has
a
length to diameter ratio that is less than about 1000.

18. The water dispersible fiber sheet of claim 1, wherein the second fiber has
a
length to diameter ratio that is less than about 500.

19. The water dispersible fiber sheet of claim 1, wherein the second fiber has
a
length to diameter ratio that is less than about 200.

20. The water dispersible fiber sheet of claim 1, wherein the fiber sheet is
not soluble
in organic liquids.

21. The water dispersible fiber sheet of claim 1, wherein the fiber sheet is
not soluble
in alcohol.

22. The water dispersible fiber sheet of claim 1, wherein the water
dispersible fiber
sheet forms a first layer of a filter media, the filter media further
comprising a second
layer formed from a water soluble non-woven polymer fiber web.

23. The water dispersible fiber sheet of claim 22, wherein the water soluble
non-
woven polymer fiber web is formed from a water soluble polyether amide.

24. The water dispersible fiber sheet of claim 22, wherein the second layer is
meltblown onto the first layer.

25. The water dispersible fiber sheet of claim 22, wherein the first and
second layers
are adhered to one another with a water soluble polymer.





-18-


26. A water dispersible filter media, comprising:

a first layer formed from regenerated cellulose fibers, a second fiber adapted
to
provide strength to the water dispersible fiber sheet, and a water soluble
binder; and

a second layer formed from a water soluble non-woven polymer fiber web.

27. The water dispersible filter media of claim 26, wherein the water soluble
binder
in the first layer is selected from the group consisting of water soluble
carboxymethyl
cellulose, polyethylene oxide, polyvinyl alcohol, protein, polyacrylic acid,
starches,
gums, and combinations thereof.

28. The water dispersible filter media of claim 26, wherein the water soluble
non-
woven polymer fiber web is formed by extrusion of a water soluble polymer.

29. The water dispersible filter media of claim 26, wherein the water soluble
non-
woven polymer fiber web is formed from a water soluble polyether amide.

30. The water dispersible filter media of claim 26, wherein the second layer
is
meltblown onto the first layer.

31. The water dispersible filter media of claim 26, wherein the first and
second
layers are adhered to one another with a water soluble polymer.

32. The water dispersible filter media of claim 26, where in the first and
second layer
are heat sealed to form a bag.

33. A method for making a water dispersible product, comprising:

forming a first fiber sheet layer from regenerated cellulose fibers, a second
fiber
adapted to provide strength to the water dispersible fiber sheet, and a water
soluble
binder.





-19-


34. The method of claim 33, wherein the step of forming a first fiber sheet
layer
comprises:

forming a fiber mixture containing the regenerated cellulose fibers, the
second
fiber, and water;

passing the mixture through a paper machine to form a fiber sheet; and

applying a water soluble binder to the sheet.

35. The method of claim 33, wherein the step of forming a first fiber sheet
layer
comprises forming a fiber mixture containing the regenerated cellulose fibers,
the
second fiber, the water soluble binder, and water, and passing the mixture
through a
paper machine to form a fiber sheet.

36. The method of claim 33, further comprising the step of melt blowing a
water
soluble non-woven polymer fiber onto the first layer to form a second fiber
sheet layer.

37. The method of claim 36, wherein the water soluble non-woven polymer fiber
is
formed from a water soluble polyether amide.



Description

Note: Descriptions are shown in the official language in which they were submitted.



CA 02543015 2006-04-11
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-1-
WATER DISPERSIBLE PRODUCTS
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims priority from U.S. Provisional Patent Application
Serial
No. 60/515,480, filed on October 29, 2003, entitled "Water Dispersible
Products," which
is hereby expressly incorporated by reference in its entirety.
FIELD OF THE INVENTION
The present invention relates to water dispersible products.
BACKGROUND OF THE INVENTION
With the increasing concern for the environment, it is desirable to provide
products that can be easily disposed of and/or recycled. The products should
have
sufficient strength while they are dry, and they should be capable of
dissolving upon
contact with water. While some water dispersible products are available, they
are
limited to certain uses and/or they require expensive and time-consuming
manufacturing
techniques. Accordingly, there remains a need for a water dispersible product
that can
be used for a variety of purposes, that readily dissolves upon contact with
water, and that
is efficient to produce.
SUMMARY OF THE INVENTION
The present invention provides water dispersible products for use in a variety
of
applications. In one embodiment, a water dispersible fiber sheet is provided
and it is
formed from at least two types of fibers: regenerated cellulose fibers, and a
second fiber
that is adapted to provide strength to the water dispersible fiber sheet. The
water
dispersible fiber sheet also preferably includes a water soluble binder, i.e.,
a binder that
is adapted to lose strength upon coming into contact with water. An exemplary
water
soluble binder is carboxymethyl cellulose (CMC). In use, the fiber sheet is
adapted to
disperse upon contact with water. In an exemplary embodiment, the fiber sheet
is used
for labels, packaging, medical and health care products, such as wipes and
identification
markers, or for industrial and personal use. In another embodiment, the water
dispersible fiber sheet forms part of a filter media. In an exemplary
embodiment, the


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-2_
filter media includes a first layer formed from a water dispersible fiber
sheet, and a
second layer formed from a water soluble meltblown non-woven fiber web. The
water
soluble meltblown non-woven fiber web can be formed from, for example, a
polymer
containing a polyether amide. The filter media can be used in a variety of air
filtration
applications, such as vacuum filters, filter bags, face masks, organic liquid
filters, and
ASHRAE filtration applications. When the filter media is disposed of, it is
adapted to
disperse upon contact with water.
The present invention also provides a method for preparing a water dispersible
fiber sheet by combining regenerated cellulose fibers, a second fiber adapted
to provide
strength to the water dispersible fiber sheet, and a water soluble binder. The
sheet is
then formed from the fibers and the binder, preferably using standard paper-
making
techniques, and the sheet is adapted to disperse upon contact with water. The
sheet can
also be combined with one or more layers of a meltblown fiber web to form a
filter
media.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be more fully understood from the following detailed
description taken in conjunction with the accompanying drawing, in which:
FIG. 1 is a photograph of one embodiment of a water dispersible fiber sheet in
the dry form according to the present invention;
FIG. 2 is a photograph of the water dispersible fiber sheet shown in FIG. 1
after
being sprayed with water for about three (3) seconds;
FIG. 3 is a photograph of the water dispersible fiber sheet shown in FIG. 1
after
being sprayed with water for about five (5) seconds;
FIG. 4 is a photograph of a pleated filter media; and
FIG. 5 is a photograph of a heat sealed filter bag.


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-3-
DETAILED DESCRIPTION OF THE INVENTION
The present invention generally provides a water dispersible fiber sheet that,
in
an exemplary embodiment, is formed from regenerated cellulose fibers, a second
fiber
that is adapted to provide strength to the water dispersible fiber sheet, and
a water
soluble binder. In use, the fiber sheet can be formed into a variety of
products including,
' for example, medical and health products such as packaging and labels. In
another
embodiment, the fiber sheet can be incorporated into a filter media. The fiber
sheet is
particularly advantageous in that it is readily dispersible upon contact with
water, yet it
will retain its strength when used with non-aqueous fluids, such as alcohol,
oils, and
organic solvents. The biodegradability of the fiber sheet will also allow the
fibers to be
consumed naturally by environmental bacteria, thus eliminating the need for
special
disposal procedures. In the case of a dispersible sheet which does not need to
be
biodegradable, synthetic fiber can be used in place of the regenerated
cellulose.
[0002] A variety of different types of regenerated cellulose fibers can be
used to form
the fiber sheet of the present invention. Suitable types of regenerated
cellulose fibers
include, for example, viscose rayon, cuprammonium rayon, high wet modulus
rayon,
polynosic rayon, saponified acetate, and cellulose triacetate. In one
embodiment, the
regenerated cellulose fibers can be present in the fiber sheet in the range of
about 20% to
90% by weight. In an exemplary embodiment, however, the regenerated cellulose
fibers
are present in the fiber sheet in the range of about 30% to 70% by weight. The
fibers are
preferably relatively short, and in particular they preferably have a length
in the range of
about 1 mm to 10 mm. This allows the fibers to disperse more readily when
placed into
contact with water.
The second fiber used to form the fiber sheet can also be present in a variety
of
forms. In an exemplary embodiment, however, the second fiber is a natural
fiber that is
biodegradable. The second fiber can, however, also include synthetic fibers.
Natural
fibers such as softwood fibers and hardwood fibers are preferred, but other
suitable
fibers include, for example, synthetic fibers such as polyethylene
terephthalate fibers,
nylon fibers, polyolefin fibers, synthetic wood pulp fibers, polyvinyl alcohol
fibers,
acrylic fibers, modacrylic fibers, vinyl chloride fibers, vinylidene chloride
fibers, acetate
fibers, regenerated protein fibers, polylactide fibers, poly(lactide-co-
glycolide) fibers,
glass fibers, ceramic fibers, metal fibers, mineral fibers, and combinations
thereof.


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-4-
Other suitable fibers include non-wood vegetation fibers such as cotton, seed
flax, hemp,
abaca, eucalyptus, sisal, bamboo, kenaf, jute, esparto, papyrus, sugar cane
base, corn
straw, wheat straw, rice straw, ramie, and combinations thereof.
When used to form a fiber sheet, the second fiber is effective to provide
tensile
strength and/or to control the density of the sheet. In one embodiment, the
second fiber
can be present in the fiber sheet in the range of about 10% to 75% by weight,
and more
preferably the second fiber includes natural fibers that are present within
the sheet in the
range of about 10% to 80% by weight, and synthetic fibers that are present
within the
sheet in the range of about 0% to 50% by weight. In an exemplary embodiment,
however, the second fiber is present in the fiber sheet in the range of about
30 to 60%
by weight. The size of the second fiber can also vary, especially for the
natural fibers.
In an exemplary embodiment, the second fiber has a diameter that is in the
range of 0.1
p, to 100 w, and more preferably that is in the range of about 0.3 w to 70 ~,,
and most
preferably that is in the range of about 0.3 ~, to 40 p., and they have a
length that is in the
range of about 0.1 mm to 6 mm. The second fiber can also have a length to
diameter
ratio that is less than about 1000, and more preferably that is less than
about 500, and
most preferably that is less than about 200. The short length of the fibers is
particularly
advantageous in that it allows the fibers to more readily disperse when placed
into
contact with water.
As previously stated, the fiber sheet also includes a binder that is effective
to
bind the regenerated cellulose fibers and the second fiber to one another. A
variety of
binders can be used, but the binder should be water soluble to allow the fiber
sheet to
readily disperse upon coming into contact with water. Suitable binders
include, for
example, carboxylmethyl cellulose (CMC), polyvinyl alcohol, protein,
polyethylene
oxide, polyacrylic acid, starches, gums and combinations thereof. The binder
should be
present within the fiber sheet in the range of about 0.05% to 10% by weight.
In an
exemplary embodiment, the binder is water soluble sodium CMC, which has ideal
adsorption, adhesion, water binding, film forming, viscosifying, and
dispersing
properties. An exemplary water soluble CMC binder is manufactured by Hercules
Incorporated, in Wilmington, DE, and it is sold under the name Aqualon~ CMC,
which
is an anionic water soluble polymer.


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-5-
A person skilled in the art will appreciate that the water dispersible fiber
sheet
can include a variety of other components, in addition to the regenerated
cellulose fibers,
the second fiber, and the binder. By way of non-limiting example, the fiber
sheet can
include wetting agents, additives, mineral fillers such as titanium oxide,
calcium
carbonate, silica and silicates. While the amount of wetting agent present in
the
composition will vary depending on the type of wetting agent and the
composition of the
fiber sheet, in an exemplary embodiment the wetting agent is present in the
range of
about 0.01% to 1.0% by weight. One example of a suitable wetting agent is
sulfonated
oil.
A variety of techniques can be used to form a water dispersible fiber sheet in
accordance with the present invention, but preferably the regenerated
cellulose fibers,
the second fiber, e.g., hardwood andlor softwood fibers, and the binder are
all combined
and formed into a fiber sheet using standard paper-making techniques. The
binder can
be added to the fiber sheet using a beater-addition process, or it can be
coated, sprayed,
saturated or foamed saturated onto the fiber sheet during formation of the
sheet. An
exemplary method for making a fiber sheet in accordance with the present
invention will
be discussed in more detail below.
In use, the fiber sheet can be formed into a variety of products including,
for
example, labels, packaging, components for medical, personal and industrial
use,
embroidery backing, paper bags, printing and/or writing paper, decorative
paper,
pouches, alcohol wipes, polishing wipes, industrial wipes, automotive and
aerospace
wipes, filters, fragrance sheets for bathing, publication inserts, seeding
beds, cotton
swabs, test paper, backing paper, toiletries, paper core, paper box, wipes,
applicators and
strips for health care, cosmetic and personal care, home care wipes, packaging
for baby,
adult diapers and feminine hygiene, etc.
In an exemplary embodiment of the present invention, the water dispersible
fiber
sheet has a breaking strength when dry of about 8 lblin, but the sheet is
adapted to
disperse upon coming into contact with water such that it has no breaking
strength when
wet. This is illustrated in FIGS. 1-3. FIG. 1 shows a dry fiber sheet, FIG. 2
shows the
sheet after being spraying with water for less than 3 seconds, and FIG. 3
shows the sheet
after being spray with water for about 5 seconds. As shown, the fibers in the
sheet begin


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-6-
to disperse after 3 seconds, and the sheet falls apart after 5 seconds. This
is particularly
advantageous in that it allows the user to simply place the sheet into contact
with water.
In another embodiment of the present invention, the water dispersible fiber
sheet
can be incorporated into a filter media to form a water dispersible filter
media. While
the filter media can have a variety of configurations, and it can be formed
using any
number of layers of fiber webs formed from various polymeric materials, in one
exemplary embodiment the filter media includes a first layer formed from a
water
dispersible fiber sheet as previously described, and a second layer formed a
water
soluble non-woven meltblown polymer fiber web. The first and second layers can
be
mated to one another using a variety of techniques known in the art, but in an
exemplary
embodiment the layers are adhered together using a water soluble adhesive,
such as a
water soluble polymer.
The non-woven meltblown polymer fiber web can be formed from virtually any
water soluble polymeric material. In an exemplary embodiment, the non-woven
polymer fiber web is formed from a water soluble polyether amide. One method
for
producing the polyether amide is by reacting at least one polyallcylene glycol
diamine
with at least one dicarboxylic acid or ester. The polyalkylene glycol diamine
preferably
has the formula NH2-(CH2)x-(OCH2-CH2)y-O-(CH2)Ox-NH2, where x ranges from 2
to 3 and y ranges from 1 to 2. An exemplary water soluble polyether amide
resin for use
with various embodiments of the present invention is HydromeltTM, available
from H.B.
Fuller, Inc.
The resin can be formed into a non-woven meltblown polymer fiber web by
extruding the resin into fibers. An exemplary process for forming a meltblown
polymer
fiber web is described in more detail in U.S. Patent No. 6,780,226, which is
incorporated herein by reference in its entirety. In an exemplary embodiment,
the
fibers are meltblown onto the first layer, i.e., the water dispersible fiber
sheet, which
functions as a support layer for the meltblown fibers. The resulting fiber web
can be
comprised of fibers having a relatively broad distribution of fiber diameters,
and the
fiber diameter can be adjusted during the extrusion process to form a filter
media having
a desired filtration efficiency as needed based on the intended use. In one
exemplary
embodiment, the average fiber diameter can be in the range of about 5 p. to 20
N., and
more preferably about 1 p, to 15 p,. The basis weight of the meltblown polymer
fiber


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web can also vary, especially considering the intended application. In
general, higher
web basis weights yield better filtration, but there exists a higher
resistance, or pressure
drop, across the filter barrier when the filter media has a higher basis
weight. For most
applications, the basis weight can be in the range of about 10 g/m2 to 520
g/m2, and
more preferably from about 30 g/m2 to 200 g/m2. One of ordinary skill in the
art can
readily determine the optimal web basis weight, considering such factors as
the desired
filter efficiency and permissible levels of resistance. Furthermore, the
number of plies
of the polymer fiber web used in any given filter application can also vary.
Each ply of
the polymer fibrous web can be of a different fiber diameter. One of ordinary
skill in the
art can readily determine the optimal number of plies to be used.
The following non-limiting examples serve to further illustrate the present
invention.
EXAMPLE 1
A cellulose binder spray was made with 1889g of Hercules Aqualon~ CMC in
50 gallons of water. The solution was mixed until the CMC was completely
dissolved.
Trax H-10 wetting agent, produced by Nippon Yushi, was then added to the
solution,
which was set aside. 8 lbs. of Prince George bleached softwood pulp and 300
gallons of
water were combined in a hydropulper and agitated until the pulp was
dispersed. 32 lbs.
of Minifiber Rayon 0.8 denier x 2 mm was then added to the hydropulper and
agitated
until the fibers were dispersed. The fiber mixture was then transferred to a
tank with a
total of 1200 gallons of water and stock. A fiber sheet was then formed on a
fourdrinier
paper machine, and the sheet was sprayed with the CMC solution, and dried to
form a
water dispersible fiber sheet.
The resulting fiber sheet had a basis weight of about 32 1b/ 3000 ftz, a
thickness
of about 0.012 in., a tensile strength of about 8 lb/in, and a peale
elongation of about
1.6%.
EXAMPLE 2
A first layer was formed by combining 30 lbs. of Primacell eucalyptus pulp, 6
lbs. of Prince George bleached softwood pulp, 12 lbs. of Minifiber Rayon 0.8
denier x 2
mm, 18 lbs. of Diawabo Rayon 0.6 denier x 3 mm, and 50 lbs. of Hercules
Aqualon~


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_g_
CMC in 1500 gallons of water. The fiber mixture was then passed through a
fourdrinier
paper machine and dried to form a water dispersible fiber sheet having a basis
weight of
60 g/m2.
A second layer of a water soluble non-woven meltblown polymer fiber web was
then formed by meltblowing H.B. Fuller Hydromelt NP2116 onto the first layer.
The
basis weight of the second layer was 40 g/m2. The resulting filter media is
referred to
below as Sample 1.
The above process was repeated to form a second filter media, referred to
below
as Sample 2, having a first layer with a basis weight of 60 g/m2 and a second
layer with
a basis weight of 80 g/m2.
Table 1 illustrates the resulting properties, of the first layer, Sample 1,
and
Sample 2.
TABLE 1
SAMPLE Basis weightMD Tensile MD elongation0.3 ~. DOP Air
(g/mZ) (lbs/in) (%) efficiency Resistance
(%) (mm H20)


First Layer60 4.16 1.17 98.1 0.8


Sample 1 100 5.31 1.65 92.7 1.1


Sample 2 140 4.64 1.74 84.6 1.5


The filter media can optionally be formed into a pleated filter, as shown in
Figure
4, or it can be formed into a filter bag by heat seat, as shown in Figure 5.
EXAMPLE 3
A water dispersible paper was formed by combining 30 lbs. of Primacell
eucalyptus pulp, 6 lbs. of Prince George bleached softwood pulp, 12 lbs. of
Minifiber
Rayon 0.8 denier x 2 mm, 18 lbs. of Diawabo Rayon 0.6 denier x 3 mm, and 50
lbs. of
Hercules Aqualon~ CMC in 1200 gallons of water. The fiber mixture was then
passed
through a fourdrinier paper machine and dried to form a water dispersible
fiber sheet
having a basis weight of 60 g/m2.


CA 02543015 2006-04-11
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The resulting sheet has a tensile in excess of 4 lbs./in and it can be easily
processed using a paper converting process, such as printing, die cutting,
sheeting, etc.
The resulting sheet can be easily dispersed in water within 20 seconds.
EXAMPLE 4
A water dispersible paper was formed by combining 30 Ibs. of Primacell
eucalyptus pulp, 6 lbs. of Prince George bleached softwood pulp, 12 lbs. of
Minifiber
Rayon 0.8 denier x 2 mm, 18 lbs. of Diawabo Rayon 0.6 denier x 3 mm, and 50
lbs. of
Hercules Aqualon~ CMC in 1200 gallons of water. The fiber mixture was then
passed
through a fourdrinier paper machine and dried to form a water dispersible
fiber sheet
having a basis weight of 60 g/m2. The paper was sprayed with an Eastman AQ
copolyester having an intrinsic viscosity of about 0.2. The AQ copolyesters
are soluble
in water, but they are not soluble in saline or body fluids. The resulting
paper can be
used for hospital wipes, after which they can be placed in water and
eventually dissolved
for disposal.
EXAMPLE 5
A water dispersible paper was formed by combining 30 lbs. of Primacell
eucalyptus pulp, 6 lbs. of Prince George bleached softwood pulp, 12 Ibs. of
Minifiber
Rayon 0.8 denier x 2 mm, 18 lbs. of Diawabo Rayon 0.6 denier x 3 mm, and 50
lbs. of
Hercules Aqualon~ CMC in 1200 gallons of water. The fiber mixture was then
passed
through a fourdrinier paper machine and dried to form a water dispersible
fiber sheet
having a basis weight of 60 g/m2. The fiber sheet is then laminated to another
layer of
paper using an adhesive, such as Hydromelt NP2116. The adhesive can be coated
onto
the paper at a weight ranging from 0.1 g/m2 to 20 g/m2. The resulting paper
can be
formed into a disposal bag, such as a shopping bag, leaf bag, or commercial
bags fox
powder, pellets, flakes and granular materials such as sugar, chemicals,
resin, etc. After
use, the bag can be disposed of in the environment where exposure to rain and
moisture
will dissolve the bag. The bag can also easily be recycled into a usable fiber
in the paper
making process.


CA 02543015 2006-04-11
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EXAMPLE 6
Several samples of water dispersible papers were formed from 2.41 grams of
Primacell eucalyptus pulp, 0.48 grams of Prince George bleached softwood pulp,
2.41
grams of Minifiber Rayon 0.8 denier x 2 mm in 1000 ml of water, along with
various
amounts of Hercules Aqualon~ CMC. The CMC of different degrees of substitution
and molecular weight, and levels was either added to the mixture, passed
through a
handsheet mold, and dried to form a water dispersible fiber sheet, or it was
sprayed onto
the sheet after the sheet was formed and dried to form a water dispersible
fiber sheet.
The samples were vacuumed and dried on photodryers, and the resulting samples
were
tested for tensile strength using a tensile machine which showed results of
about 1.5 to 3
lb./in.. The basis weight was 35 lb./3000ft2. The dispersing time was measured
by the
time it takes for a 2 inch strip to tear apart from being sprayed by a spray
bottle three
inches away. The results are listed below in Table 2.


CA 02543015 2006-04-11
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TABLE 2
FurnishSpray


Runs 7MT 7MT 7H 9H Basis Tensile Dispersing
1 weight (lb/in) time (sec)
(lb/3000ft2)


1 0.000% 0.000%0.000%0.000%32 1.42 4


2 0.010% 0.050%0.000%0.000%34 2.07 5


3 0.020% 0.000%0.000%0.000%34 1.43 6


4 0.010% 0.000%0.000%0.000%35 1.46 6


0.020% 0.050%0.000%0.000%34 2.37 7


6 0.000% 0.100%0.000%0.000%36 2.32 4


7 0.000% 0.050%0.000%0.000%36 2.07 5


8 0.010% 0.100%0.000%0.000%35 2.98 11


9 0.020% 0.100%0.000%0.000%35 2.81 5


0.010% 0.000%0.050%0.000%35 2.37 8


11 0.020% 0.000%0.050%0.000%34 2.15 9


12 0.000% 0.000%0.100%0.000%35 2.73 11


13 0.000% 0.000%0.050%0.000%34 1.89 8


14 0.010% 0.000%0.100%0.000%36 2.79 11


0.020% 0.000%0.100%0.000%34 2.72 14


16 0.010% 0.000%0.000%0.050%35 1.95 9


17 0.020% 0.000%0.000%0.050%34 1.96 14


18 0.000% 0.000%0.000%0.100%35 2.81 14


19 0.000% 0.000%0.000%0.050%34 1.87 6


0.010% 0.000%0.000%0.100%34 2.99 22


21 0.020% 0.000%0.000%0.100%34 2.86 14


E~~AMPLE 7
5 A water dispersible paper was formed by combining 40% eucalyptus pulp, 10%
softwood pulp, 50% of Minifiber Rayon 0.8 denier x 2 mm arid passing the
mixture
through a fourdrinier paper machine. The resulting sheet was saturated with
CMC with
a basis weight of 35 1b./3000 ftz. The original caliper or thickness of the
sheet was
0.0083 inches, and with calendaring a caliper of 0.0021 inches could be
achieved. Table
10 3 shows the calendaring conditions and the resulting caliper. The caliper
reduction can
be as high as 5 to 1.


CA 02543015 2006-04-11
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TABLE 3
IntervalTop Load Bottom Load Thickness
Cell Cell


psi psi inches


B NA NA 0.0083


8 2,500 NA 0.0052


7 3,000 NA 0.0051


6 3,000 56,000 0.0031


3,000 68,000 0.0024


4 3,000 80,000 0.0031


3 3,000 100,000 0.0023


2 3,000 150,000 0.0036


1 3,000 200,000 0.0021


EXAMPLE 8
5 A water dispersible paper was formed by combining 47.5% eucalyptus pulp, 5%
softwood pulp, 47.5% of Minifiber Rayon 0.8 denier x 2 mm. The composition was
saturated with CMC with a basis weight of 35 lb./3000ft2', and then passed
through a
handsheet mold. Table 4 shows that with an increasing level of CMC-7MT added
to the
composition before it is formed into a sheet and/or sprayed onto the resulting
sheet after
it is formed, the tensile strength increases but the dispersion time remains
less than 6
seconds.
TABLE 4
7MT 7MT Tensile Disperse time
Mold Spray (lb/in) (sec)


0.02% 0.50% 6.3 5


0.00% 0.50% 5.8 4


0.02% 0.25% 3.9 'S


0.00% 0.25% 2.9 5


0.01% 0.25% 2.9 6


0.01% 0.50% 4.8 4


EXAMPLE 9
A water dispersible paper was formed by various combinations of eucalyptus
pulp, softwood pulp and rayon fibers of different deniers for the base
composition. The


CA 02543015 2006-04-11
WO 2005/042631 PCT/US2004/036232
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pulp can also be refined to a lower Canadian Standard Freeness (CSF) such as
the Prince
George pulp at 600 CSF. The composition was passed through a handsheet mold. A
1.5% CMC solution was made up with various CMC, such as Aqualon~ CMC-7MT,
Noviant Finnfix~ 30G, 300 and 700. The compositions was saturated with CMC to
a
basis weight of 38 1b./3000 ft2.
Table 5 shows the type and level of both pulp and CMC solution. The samples
were tested using Dispersion Time Test A, which is the time it takes for the
sample to
fall apart while hand spraying a strip of about 1" x 2" sample with cold water
from about
3 inches away, and using Dispersion Time Test B, which is the time it takes
for a 1" x 1"
sample to fall apart in 300 ml of water using a VWR Dynadual~ 942009 magnetic
stir
plate and a magnetic stir rod at a stir setting of 5.
TABLE 5
Prince GeorgeCrestbrookPrimacellSuzano 1.5% MinifiberDiawabo
(g) (g) (g) (g) CMC Rayon Rayon
Dip (g) (g)


A 0.00 1.27 0.00 1.76 30G 1.47 2.41


B 0.00 1.27 0.00 1.76 300 1.47 2.41


C 0.00 1.27 0.00 1.76 700 1.47 2.41


D 0.00 1.27 0.00 1.76 7MT 1.47 2.41


E 0.294 or 0.00 2.65 0.00 7MT 1.47 2.41
ml
(600CSF)


F 0.294 or 0.00 2.65 0.00 300 1.47 2.41
15 ml
(600CSF)


G 1.18 0.00 1.76 0.00 300 1.47 2.41


Thickness Basis Tensile ElongationDispersionDispersionAir
(inches) weight (Iblin) (%) Time Time TestPerm
(#/ream) Test B (cfm)
A (sec)(sec)


A 0.0106 38 16.5 2.3 2 4 56.7


B 0.0095 39 18.3 3.4 3 6 44.9


C 0.0087 39 24.1 4.0 2 7 43.6


D 0.0089 38 18.4 4.4 3 5 49.7


E 0.0084 37 25.3 4.0 2 6 32.7


F 0.0099 42 20.5 3.8 2 4 61.6


G 0.0097 38 18.1 4.3 2 5 63.6




CA 02543015 2006-04-11
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One skilled in the art will appreciate further features and advantages of the
invention based on the above-described embodiments. Accordingly, the invention
is not
to be limited by what has been particularly shown and described, except as
indicated by
the appended claims. All publications and references cited herein are
expressly
incorporated herein by reference in their entirety.
What is claimed is:

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Administrative Status

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Administrative Status

Title Date
Forecasted Issue Date Unavailable
(86) PCT Filing Date 2004-10-29
(87) PCT Publication Date 2005-05-12
(85) National Entry 2006-04-11
Examination Requested 2006-04-11
Dead Application 2009-10-29

Abandonment History

Abandonment Date Reason Reinstatement Date
2007-10-29 FAILURE TO PAY APPLICATION MAINTENANCE FEE 2008-01-15
2008-10-29 FAILURE TO PAY APPLICATION MAINTENANCE FEE

Payment History

Fee Type Anniversary Year Due Date Amount Paid Paid Date
Request for Examination $800.00 2006-04-11
Registration of a document - section 124 $100.00 2006-04-11
Application Fee $400.00 2006-04-11
Maintenance Fee - Application - New Act 2 2006-10-30 $100.00 2006-04-11
Reinstatement: Failure to Pay Application Maintenance Fees $200.00 2008-01-15
Maintenance Fee - Application - New Act 3 2007-10-29 $100.00 2008-01-15
Owners on Record

Note: Records showing the ownership history in alphabetical order.

Current Owners on Record
HOLLINGSWORTH & VOSE COMPANY
Past Owners on Record
CHOI, WAI MING
YU, HOWARD
Past Owners that do not appear in the "Owners on Record" listing will appear in other documentation within the application.
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Description 
Date
(yyyy-mm-dd) 
Number of pages   Size of Image (KB) 
Abstract 2006-04-11 1 61
Claims 2006-04-11 5 166
Drawings 2006-04-11 5 1,386
Description 2006-04-11 14 638
Cover Page 2006-06-23 1 41
Correspondence 2006-06-14 1 26
Assignment 2006-04-11 4 123
Assignment 2006-09-07 3 91
Prosecution-Amendment 2006-09-13 2 43
PCT 2006-04-12 2 93
PCT 2006-04-12 6 284
Prosecution-Amendment 2007-03-27 1 33
Fees 2008-01-15 1 55