U.S. patent application number 10/750371 was filed with the patent office on 2005-04-21 for texturized fibrous materials from poly-coated paper and compositions and composites made therefrom.
This patent application is currently assigned to Xyleco, Inc., a Massachusetts corporation. Invention is credited to Lagace, Arthur, Medoff, Marshall.
Application Number | 20050084671 10/750371 |
Document ID | / |
Family ID | 34525957 |
Filed Date | 2005-04-21 |
United States Patent
Application |
20050084671 |
Kind Code |
A1 |
Medoff, Marshall ; et
al. |
April 21, 2005 |
Texturized fibrous materials from poly-coated paper and
compositions and composites made therefrom
Abstract
Texturized poly-coated paper, and compositions and composites
made therefrom, are disclosed.
Inventors: |
Medoff, Marshall;
(Brookline, MA) ; Lagace, Arthur; (Newtonville,
MA) |
Correspondence
Address: |
FISH & RICHARDSON PC
225 FRANKLIN ST
BOSTON
MA
02110
US
|
Assignee: |
Xyleco, Inc., a Massachusetts
corporation
|
Family ID: |
34525957 |
Appl. No.: |
10/750371 |
Filed: |
December 31, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10750371 |
Dec 31, 2003 |
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09338209 |
Jun 22, 1999 |
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09338209 |
Jun 22, 1999 |
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08921807 |
Sep 2, 1997 |
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5952105 |
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Current U.S.
Class: |
428/359 ; 162/23;
162/4; 428/361 |
Current CPC
Class: |
B29L 2007/002 20130101;
B32B 15/20 20130101; Y10T 428/2907 20150115; B29K 2311/12 20130101;
B32B 15/12 20130101; A23L 33/24 20160801; Y10T 428/2904 20150115;
Y02W 30/62 20150501; A01N 25/34 20130101; B32B 27/10 20130101; B29B
17/0026 20130101 |
Class at
Publication: |
428/359 ;
428/361; 162/004; 162/023 |
International
Class: |
D21B 001/08; D21B
001/32; D02G 003/00; D21C 005/02 |
Claims
What is claimed is:
1-6. (canceled)
7. A texturized fibrous material comprising poly-coated paper
having internal fibers, wherein said poly-coated paper is sheared
to the extent that the internal fibers are substantially
exposed.
8-9. (canceled)
10. The texturized fibrous material of claim 7, wherein said
texturized fibrous material has a bulk density less than about 0.5
grams per cubic centimeter.
11. The texturized fibrous material of claim 7, wherein said
texturized fibrous material has a bulk density less than about 0.2
grams per cubic centimeter.
12-36. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation-in-part of U.S. patent
application Ser. No. 08/921,807, filed Sep. 2, 1997.
BACKGROUND OF THE INVENTION
[0002] The invention relates to texturized fibrous materials
prepared from poly-coated paper, and compositions and composites
made from such materials.
[0003] Paper coated with a polymer (poly-coated paper) is used in a
number applications. For example, poly-coated paper is used to make
a variety of food containers, including individual-serving size
juice cartons and boxes for frozen foods.
SUMMARY OF THE INVENTION
[0004] In general, the invention features texturized poly-coated
paper and compositions and composites made therefrom.
[0005] In one embodiment, the invention features a process for
preparing a texturized fibrous material. The process includes
shearing poly-coated paper having internal fibers, to the extent
that the internal fibers are substantially exposed, resulting in a
texturized fibrous material. The poly-coated paper can, for
example, be made of polyethylene and paper, and, in some cases, one
or more layers of aluminum. The exposed fibers of the texturized
fibrous material can have a length/diameter (L/D) ratio of at least
about 5 (e.g., at least about 5, 10, 25, 50, or more). For example,
at least about 50% of the fibers can have L/D ratios of this
magnitude.
[0006] In another embodiment, the invention features a texturized
fibrous material that includes poly-coated paper having internal
fibers, where the poly-coated paper is sheared to the extent that
the internal fibers are substantially exposed.
[0007] The texturized fibrous material can, for example, be
incorporated into (e.g., associated with, blended with, adjacent
to, surrounded by, or within) a structure or carrier (e.g., a
netting, a membrane, a flotation device, a bag, a shell, or a
biodegradable substance). Optionally, the structure or carrier may
itself be made from a texturized fibrous material (e.g., a
texturized fibrous material of the invention), or of a composition
or composite of a texturized fibrous material.
[0008] The texturized fibrous material can have a bulk density less
than about 0.5 grams per cubic centimeter (g/cm.sup.3), or even
less than about 0.2 g/cm.sup.3.
[0009] Compositions that include the texturized fibrous materials
described above, together with a chemical or chemical formulation
(e.g., a pharmaceutical such as an antibiotic or contraceptive,
optionally with an excipient; an agricultural compound such as a
fertilizer, herbicide, or pesticide; or a formulation that includes
enzymes) are also within the scope of the invention, as are
compositions that include the texturized fibrous materials and
other liquid or solid ingredients (e.g., particulate, powdered, or
granulated solids such as plant seed, foodstuffs, or bacteria).
[0010] Composites that include thermoplastic resin and the
texturized fibrous materials are also contemplated. The resin can
be, for example, polyethylene, polypropylene, polystyrene,
polycarbonate, polybutylene, a thermoplastic polyester, a
polyether, a thermoplastic polyurethane, polyvinylchloride, or a
polyamide, or a combination of two or more resins.
[0011] In some cases, at least about 5% by weight (e.g., 5%, 10%,
25%, 50%, 75%, 90%, 95%, 99%, or about 100%) of the fibrous
material included in the composites is texturized.
[0012] The composite may include, for example, about 30% to about
70% by weight resin and about 30% to about 70% by weight texturized
fibrous material, although proportions outside of these ranges may
also be used.
[0013] The composites can also, optionally, include lignocellulosic
fiber (e.g., wood or derivatives of trees or other plants) or
cellulosic fiber (e.g., paper or paper products).
[0014] The composites can be quite strong, in some cases having a
flexural strength of at least about 6,000 to 10,000 psi.
[0015] The composites can also include inorganic additives such as
calcium carbonate, graphite, asbestos, wollastonite, mica, glass,
fiber glass, chalk, talc, silica, ceramic, ground construction
waste, tire rubber powder, carbon fibers, or metal fibers (e.g.,
stainless steel or aluminum). The inorganic additives can represent
about 0.5% to about 20% of the total weight of the composite.
[0016] The composite can be in the form of, for example, a pallet
(e.g., an injection molded pallet), pipes, panels, decking
materials, boards, housings, sheets, poles, straps, fencing,
members, doors, shutters, awnings, shades, signs, frames, window
casings, backboards, wallboards, flooring, tiles, railroad ties,
forms, trays, tool handles, stalls, bedding, dispensers, staves,
films, wraps, totes, barrels, boxes, packing materials, baskets,
straps, slips, racks, casings, binders, dividers, walls, indoor and
outdoor carpets, rugs, wovens, and mats, frames, bookcases,
sculptures, chairs, tables, desks, art, toys, games, wharves,
piers, boats, masts, pollution control products, septic tanks,
automotive panels, substrates, computer housings, above- and
below-ground electrical casings, furniture, picnic tables, tents,
playgrounds, benches, shelters, sporting goods, beds, bedpans,
thread, filament, cloth, plaques, trays, hangers, servers, pools,
insulation, caskets, bookcovers, clothes, canes, crutches, and
other construction, agricultural, material handling,
transportation, automotive, industrial, environmental, naval,
electrical, electronic, recreational, medical, textile, and
consumer products. The composites can also be in the form of a
fiber, filament, or film.
[0017] The terms "texturized poly-coated paper" and "texturized
fibrous material", as used herein, mean that the poly-coated paper
has been sheared to the extent that its internal fibers are
substantially exposed. At least about 50%, more preferably at least
about 70%, of these fibers, as well as the external polymer fibers,
have a length/diameter (L/D) ratio of at least 5, more preferably
at least 25, or at least 50. An example of texturized poly-coated
paper is shown in FIG. 1.
[0018] The texturized fibrous materials of the invention have
properties that render them useful for various applications. For
example, the texturized fibrous materials have absorbent
properties, which can be exploited, for example, for pollution
control. The fibers are generally biodegradable, making them
suitable, for example, for drug or chemical delivery (e.g., in the
treatment of humans, animals, or in agricultural applications). The
texturized fibrous materials can also be used to reinforce
polymeric resins.
[0019] Those composites that include texturized fibrous material
and resin are strong, light-weight, and inexpensive. The raw
materials used to make the composites are available as virgin or
recycled materials; for example, they may include discarded
containers composed of resins, and discarded containers composed of
poly-coated paper.
[0020] Poly-coated paper can be difficult to recycle because the
paper and the polymer layers generally cannot be separated. In the
present invention, both the paper and the polymer portions are
utilized, so there is no need to separate the two. Poly-coated
paper including one or more layers of aluminum can similarly be
used. The invention thus helps to recycle discarded post-consumer
containers, while at the same time producing useful products.
[0021] Other features and advantages of the invention will be
apparent from the following detailed description, and from the
claims.
BRIEF DESCRIPTION OF THE DRAWING
[0022] FIG. 1 is a photograph of texturized poly-coated paper,
magnified 50 times.
[0023] FIG. 2 is a photograph of a half-gallon polyboard juice
carton.
[0024] FIG. 3 is a photograph of shredded half-gallon polyboard
juice cartons.
[0025] FIG. 4 is a photograph of texturized fibrous material
prepared by shearing the shredded half-gallon polyboard juice
cartons of FIG. 3.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Poly-coated paper is available in a variety of forms. For
example, whole sheets of virgin poly-coated paper can be purchased
from International Paper, New York. Alternatively, virgin waste
poly-coated paper (e.g., edge trimmings, surplus, misprinted stock)
can be obtained from International Paper or other paper
manufacturers. Used poly-coated paper, in the form of discarded
food and beverage containers, can be gathered from various sources,
including waste and recycling streams. Poly-coated paper that
includes one or more layers of aluminum foil as is commonly used
for airtight liquid storage, may also be used. Used, waste, or
scrap poly-coated paper (e.g., post-consumer waste, industrial
offal) can also be purchased from brokers of this material.
[0027] Preparation of the Texturized Fibrous Material
[0028] If scrap poly-coated paper is used, it should be clean and
dry. The poly-coated paper can be texturized using any one of a
number of mechanical means, or combinations thereof. During the
texturizing process, the polymer layers are sheared away from the
paper layers, thus exposing the paper fibers. A preferred method of
texturizing includes first cutting the poly-coated paper into
{fraction (1/4)}- to 1/2-inch pieces, if necessary, using a
standard paper-cutting apparatus. Counter-rotating screw shredders
and segmented rotating screw shredders such as those manufactured
by Munson (Utica, N.Y.) can also be used, as can a standard
document shredder as found in many offices.
[0029] The paper is then sheared with a rotary cutter, such as the
one manufactured by Sprout, Waldron Companies, as described in
Perry's Chem. Eng. Handbook, 6th Ed., at 8-29 (1984). Although
other settings can be used, the spacing between the rotating knives
and bed knives of the rotary cutter is typically set to 0.020" or
less, and blade rotation is set to 750 rpm or more. The rotary
cutter can be cooled to 100.degree. C. or lower during the process,
for example, using a water jacket.
[0030] The texturized material is passed through a discharge
screen. Larger screens (e.g., up to 6 mm) can be used in
large-scale production. The poly-coated paper feedstock is
generally kept in contact with the blades of the rotary cutter
until the fibers are pulled apart; smaller screens (e.g., 2 mm
mesh) provide longer residence times and more complete
texturization, but can result in lower length/diameter (L/D) aspect
ratios. A vacuum drawer can be attached to the screen to maximize
and maintain fiber length/diameter aspect ratio.
[0031] The texturized fibrous material can be directly stored in
sealed bags or may be dried at approximately 105.degree. C. for
4-18 hours (e.g., until the moisture content is less than about
0.5%) immediately before use. FIG. 1 is an SEM photograph of the
texturized poly-coated paper.
[0032] Alternative texturizing methods include stone grinding,
mechanical ripping or tearing, and other methods whereby the
paper's internal fibers can be exposed (e.g., pin grinding, air
attrition milling).
[0033] Uses of Texturized Fibrous Material
[0034] Texturized fibrous material and compositions of such
materials with other chemicals and chemical formulations can be
prepared to take advantage of the material's properties. The
materials can be used to absorb chemicals, for example, potentially
absorbing many times their own weight. Thus, the material could,
for instance, be used to absorb spilled oil, or for clean-up of
environmental pollution, for example, in water, in the air, or on
land. Similarly, the material's absorbent properties, together with
its biodegradability, also make them useful for delivery of
chemicals or chemical formulations. For example, the materials can
be treated with solutions of enzymes or pharmaceuticals such as
antibiotics, nutrients, or contraceptives, and any necessary
excipients, for drug delivery (e.g., for treatment of humans or
animals, or for use as or in animal feed and/or bedding), as well
as with solutions of fertilizers, herbicides, or pesticides. The
texturized fibrous materials can optionally be chemically treated
to enhance a specific absorption property. For example, the
materials can be treated with silanes to render them
lipophilic.
[0035] Compositions including texturized materials combined with
liquids or particulate, powdered, or granulated solids can also be
prepared. For example, the texturized fibrous materials can be
blended with seeds (i.e., with or without treatment with a solution
of fertilizer, pesticides, etc.), foodstuffs, or bacteria (e.g.,
bacteria that digest toxins). The ratio of fibrous material to the
other components of the compositions will depend on the nature of
the components and readily be adjusted for a specific product
application.
[0036] In some cases, it may be advantageous to associate the
texturized fibrous materials, or compositions or composites of such
materials, with a structure or carrier such as a netting, a
membrane, a flotation device, a bag, a shell, or a biodegradable
substance optionally, the structure or carrier may itself be made
of a texturized fibrous material (e.g., a material of the
invention), or a composition or composite thereof.
[0037] Composites of Texturized Fibrous Material and Resin
[0038] Texturized fibrous materials can also be combined with
resins to form strong, lightweight composites. Materials that have
been treated with chemicals or chemical formulations, as described
above, can similarly be combined with biodegradable or
non-biodegradable resins to form composites, allowing the
introduction of, for example, hydrophilic substances into otherwise
hydrophobic polymer matrices. Alternatively, the composites
including texturized fibrous materials and resin can be treated
with chemicals or chemical formulations.
[0039] The texturized poly-coated paper provides the composite with
strength. The composite may include from about 10% to about 90%,
more preferably from about 30% .to about 70%, of the texturized
poly-coated paper by weight. Examples of poly-coated paper include
materials having layers of polymer and paper, and materials having
layers of polymer, paper, and aluminum.
[0040] The resin encapsulates the texturized poly-coated paper and
helps control the shape of the composites. The resin also transfers
external loads to the poly-coated paper and protect the poly-coated
paper from environmental and structural damage. Composites include,
for example, about 10% to about 90%, more preferably about 30% to
about 70%, by weight, of the resins.
[0041] Examples of resins include polyethylene (including, e.g.,
low density polyethylene and high density polyethylene),
polypropylene, polystyrene, polycarbonate, polybutylene,
thermoplastic polyesters, polyethers, thermoplastic polyurethane,
PVC, polyamides (e.g., nylon), and other resins. It is preferred
that the resins have a low melt flow index. Preferred resins
include polyethylene and polypropylene with melt flow indices of
less than 3 g/10 min, and more preferably less than 1 g/10 min.
[0042] The resins can be purchased as virgin material, or obtained
as waste materials, and can be purchased in pelletized or
granulated form. One source of resin is used polyethylene milk
bottles. If surface moisture is present on the pelletized or
granulated resin, however, it should be dried before use.
[0043] The composites can also include coupling agents. The
coupling agents help to bond the hydrophilic fibers of the
poly-coated paper to the hydrophobic resins. Examples of coupling
agents include maleic anhydride modified polyethylenes, such those
in the FUSABOND.RTM. (available from Dupont, Del.) and
POLYBOND.RTM. (available from Uniroyal Chemical, Conn.) series. One
suitable coupling agent is a maleic anhydride modified high density
polyethylene such as FUSABOND.RTM. MB 100D.
[0044] The composites can also include other cellulosic or
lignocellulosic fibers such as paper and paper products, wood, wood
fibers, and wood-related materials, as well as materials derived
from kenaf, grasses, rice hulls, bagasse, cotton, and jute. These
fibers provide extra strength to the composite.
[0045] The quantity of fiber which is incorporated into the
composites can vary, depending on the desired physical and
mechanical properties of the finished products. Preferred
composites contain about 5% to about 50%, more preferably about 10%
to about 30%, by weight of the cellulosic or lignocellulosic fiber.
The fibers may have, for example, a L/D ratio of at least 5, or at
least 25 or 50. If cellulosic or lignocellulosic fibers are used,
they can be texturized, using the process described above.
[0046] The composites can also contain additives known to those in
the art of compounding, such as plasticizers, lubricants,
antioxidants, opacificers, heat stabilizers, colorants, impact
modifiers, photostabilizers, flame retardants, biocides, and
antistatic agents.
[0047] The composites can also include inorganic additives such as
calcium carbonate, graphite, asbestos, wollastonite, mica, glass,
fiber glass, chalk, silica, talc, ceramic, ground construction
waste, tire rubber powder, carbon fibers, or metal fibers (e.g.,
aluminum, stainless steel). When such additives are included, they
are typically present in quantities of from about 0.5% up to about
20-30% by weight. For example, submicron calcium carbonate can be
added to the composites of texturized fibrous material and resin to
improve impact modification characteristics or to enhance composite
strength.
[0048] Preparation of Compositions
[0049] Compositions containing the texturized cellulosic or
lignocellulosic materials and chemicals, chemical formulations, or
other solids can be prepared, for example, in various immersion,
spraying, or blending apparatuses, including, but not limited to,
ribbon blenders, cone blenders, double cone blenders, and
Patterson-Kelly "V" blenders.
[0050] For example, a composition containing 90% by weight
texturized cellulosic or lignocellulosic material and 10% by weight
ammonium phosphate or sodium bicarbonate can be prepared in a cone
blender to create a fire-retardant material for absorbing oil.
[0051] Preparation of Composites of Texturized Fibrous Material and
Resin
[0052] Composites of texturized poly-coated paper and resin can be
prepared as follows. A standard rubber/plastic compounding 2-roll
mill is heated to 325-400.degree. F. The resin (usually in the form
of pellets or granules) is added to the heated roll mill. After
about 5 to 10 minutes, the coupling agent is added to the roll
mill. After another five minutes, the texturized poly-coated paper
is added to the molten resin/coupling agent mixture. The texturized
poly-coated paper is added over a period of about 10 minutes.
[0053] The composite is removed from the roll mill, cut into sheets
and allowed to cool to room temperature. It is then compression
molded into plaques using standard compression molding
techniques.
[0054] Alternatively, a mixer, such as a Banbury internal mixer, is
charged with the ingredients. The ingredients are mixed, while the
temperature is maintained at less than about 190.degree. C. The
mixture can then be compression molded.
[0055] In another embodiment, the ingredients can be mixed in an
extruder mixer, such as a twin-screw extruder equipped with
co-rotating screws. The resin and the coupling agent are introduced
at the extruder feed throat; the texturized poly-coated paper (and
cellulosic or lignocellulosic fiber, if used) are introduced about
1/3 of the way down the length of the extruder into the molten
resin. The internal temperature of the extruder is maintained at
less than about 190.degree. C. At the output, the composite can be,
for example, pelletized by cold strand cutting.
[0056] Alternatively, the mixture can first be prepared in a batch
mixer, then transferred to an extruder.
[0057] In another embodiment, the composite can be formed into
filaments for knitting, warping, weaving, and braiding, and to make
non-wovens. In a further embodiment, the composite can be made into
film.
[0058] Properties of the Composites of Texturized Fibrous Material
and Resin
[0059] The resulting composites include a network of fibers,
encapsulated within a resin matrix. The fibers form a lattice
network, which provides the composite with strength. Since the
poly-coated paper is texturized, the amount of surface area
available to bond to the resin is increased, in comparison to
composites prepared with un-texturized poly-coated paper. The resin
binds to the surfaces of the exposed fibers, creating an intimate
blend of the fiber network and the resin matrix. The intimate
blending of the fibers and the resin matrix further strengthens the
composites. Cellulosic or lignocellulosic fibers may also be added
to strengthen the composite further.
[0060] Uses of the Composites of Texturized Fibrous Material and
Resin
[0061] The poly-coated paper/resin composites can be used in a
number of applications. The composites are strong and light weight;
they can be used, for example, as wood substitutes. The resin
coating renders the composites water-resistant, so they may be used
in outdoor applications. For example, the composites may be used to
make pallets which are stored outdoors for extended periods of
time, wine staves, rowboats, furniture, skis, and oars. Many other
uses are contemplated, including pipes, panels, decking materials,
boards, housings, sheets, poles, straps, fencing, members, doors,
shutters, awnings, shades, signs, frames, window casings,
backboards, wallboards, flooring, tiles, railroad ties, forms,
trays, tool handles, stalls, bedding, dispensers, staves, films,
wraps, totes, barrels, boxes, packing materials, baskets, straps,
slips, racks, casings, binders, dividers, walls, indoor and outdoor
carpets, rugs, wovens, and mats, frames, bookcases, sculptures,
chairs, tables, desks, art, toys, games, wharves, piers, boats,
masts, pollution control products, septic tanks, automotive panels,
substrates, computer housings, above- and below-ground electrical
casings, furniture, picnic tables, tents, playgrounds, benches,
shelters, sporting goods, beds, bedpans, thread, filament, cloth,
plaques, trays, hangers, servers, pools, insulation, caskets,
bookcovers, clothes, canes, crutches, and other construction,
agricultural, material handling, transportation, automotive,
industrial, environmental, naval, electrical, electronic,
recreational, medical, textile, and consumer products. Numerous
other applications are also envisioned. The composites may also be
used, for example, as the base or carcass for a veneer product.
[0062] Moreover, the composites can be, for example, surface
treated, grooved, milled, shaped, imprinted, textured, compressed,
punched, or colored. The surface of the composites can be smooth or
rough.
[0063] The following examples illustrate certain embodiments and
aspects of the present invention and not to be construed as
limiting the scope thereof.
EXAMPLES
Example 1
[0064] A 1500 pound skid of virgin, half-gallon juice cartons made
of poly-coated white kraft board was obtained from International
Paper. One such carton is shown in FIG. 2. Each carton was folded
flat.
[0065] The cartons were fed into a 3 hp Flinch Baugh shredder at a
rate of approximately 15 to 20 pounds per hour. The shredder was
equipped with two rotary blades, each 12" in length, two fixed
blades, and a 0.3" discharge 30 screen. The gap between the rotary
and fixed blades was 0.10".
[0066] A sample of the output from the shredder, consisting
primarily of confetti-like pieces, about 0.1" to 0.5" in width and
about 0.25" to 1" in length, is shown in FIG. 3.
[0067] The shredder output was then fed into a Thomas Wiley Mill
Model 2D5 rotary cutter. The rotary cutter had four rotary blades,
four fixed blades, and a 2 mm discharge screen. Each blade was
approximately 2" long. The blade gap was set at 0.020".
[0068] The rotary cutter sheared the confetti-like pieces across
the knife edges, tearing the pieces apart and releasing a finely
texturized fiber at a rate of about one pound per hour. The fiber
had an average minimum L/D ratio of between five and 100 or more.
The bulk density of the texturized fiber was on the order of 0.1
g/cm.sub.3. A sample of texturized fiber is shown in FIG. 4 at
normal magnification, and in FIG. 1 at fifty-fold
magnification.
Example 2
[0069] Composites of texturized poly-coated paper and resin were
prepared as follows. A standard rubber/plastic compounding 2-roll
mill was heated to 325-400.degree. F. The resin (usually in the
form of pellets or granules) was added to the heated roll mill.
After about 5 to 10 minutes, the resin banded on the rolls (i.e.,
it melted and fused on the rolls). The coupling agent was then
added to the roll mill. After another five minutes, the texturized
poly-coated paper was added to the molten resin/coupling agent
mixture. The poly-coated paper was added over a period of about 10
minutes.
[0070] The composite was then removed from the roll mill, cut into
sheets, and allowed to cool to room temperature. Batches of about
80 g each were compression molded into 6".times.6".times.1/8"
plaques using standard compression molding techniques.
[0071] One composition contains the following ingredients:
1 Composition No. 1 Ingredient Amount (g) High density
polyethylene.sup.1 160 Poly-coated paper.sup.2 240 Coupling
agent.sup.3 8 .sup.1Marlex 6007, melt flow index 0.65 g/10 min,
commercially available from Phillips .sup.2Texturized using rotary
cutter with 2 mm mesh .sup.3POLYBOND .RTM. 3009, commercially
available from Uniroyal Chemical
[0072] The plaques were machined into appropriate test specimens
and tested according to the procedures outlined in the method
specified. Three different specimens were tested for each property,
and the mean value for each test was calculated.
[0073] The properties of Composition No. 1 are as follows:
2 Tensile modulus (10.sup.5 psi) 8.63 (ASTM D638) Tensile strength
at break (psi) 6820 (ASTM D638) Ultimate elongation (%) <5 (ASTM
D638) Flexural Strength (psi) 12,200 (ASTM D790) Flexural modulus
(10.sup.5 psi) 6.61 (ASTM D790)
[0074] A second composition contains the following ingredients:
3 Composition No. 2 Ingredient Amount (g) High density
polyethylene.sup.1 160 Poly-coated paper.sup.2 240 Coupling
agent.sup.3 8 .sup.1Scrapped milk jugs, melt flow index
approximately 0.8 g/10 min .sup.2Texturized using rotary cutter
with 2 mm mesh .sup.3POLYBOND .RTM. 3009
[0075] The properties of Composition No. 2 are as follows:
4 Tensile modulus (10.sup.5 psi) 7.38 (ASTM D638) Tensile strength
at break (psi) 6500 (ASTM D638) Ultimate elongation (%) <5 (ASTM
D638) Flexural Strength (psi) 11,900 (ASTM D790) Flexural modulus
(10.sup.5 psi) 6.50 (ASTM D790)
[0076] A third composition contains the following ingredients:
5 Composition No. 3 Ingredient Amount (g) High density
polyethylene.sup.1 160 Poly-coated paper.sup.2 240 Coupling
agent.sup.3 8 .sup.1Scrap milk jugs, melt flow index approximately
0.8 g/10 min .sup.2Texturized using rotary cutter with 2 mm mesh
.sup.3FUSABOND .RTM. MB 100D, commercially available from
DuPont
[0077] The properties of Composition No. 3 are as follows:
6 Tensile modulus (10.sup.5 psi) 7.08 (ASTM D638) Tensile strength
at break (psi) 6480 (ASTM D638) Ultimate elongation (%) <5 (ASTM
D638) Flexural Strength (psi) 10,200 (ASTM D790) Flexural modulus
(10.sup.5 psi) 5.73 (ASTM D790)
[0078] A fourth composition contains the following ingredients:
7 Composition No. 4 Ingredient Amount (g) High density
polyethylene.sup.1 160 Poly-coated paper.sup.2 240 Coupling
agent.sup.3 8 .sup.1Marlex 6007, melt flow index 0.65 g/10 min
.sup.2texturized using rotary cutter with 2 mm mesh .sup.3FUSABOND
.RTM. MB 100D
[0079] The properties of Composition No. 4 are as follows:
8 Tensile modulus (10.sup.5 psi) 7.17 (ASTM D638) Tensile strength
at break (psi) 6860 (ASTM D638) Ultimate elongation (%) <5 (ASTM
D638) Flexural Strength (psi) 12,200 (ASTM D790) Flexural modulus
(10.sup.5 psi) 7.50 (ASTM D790)
[0080] A fifth composition contains the following ingredients:
9 Composition No. 5 Ingredient Amount (g) SUPERFLEX .TM. CaCO.sub.3
33 Fiber.sup.2,4 67 HDPE (w/3% compatibilizer).sup.1,3 100
.sup.4virgin poly-coated milk cartons
[0081] The properties of Composition No. 5 are as follows:
10 Flexural strength (10.sup.5 psi) 8.29 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural modulus (10.sup.5 psi)
10.1 (ASTM D790) Notch Izod (ft-lb/in) 1.39 (ASTM D256-97)
[0082] A sixth composition contains the following ingredients:
11 Composition No. 6 Ingredient Amount (parts) SUPERFLEX .TM.
CaCO.sub.3 22 Fiber.sup.2,4 67 HDPE (w/3% compatibilizer).sup.1,3
100
[0083] The properties of Composition No. 6 are as follows:
12 Flexural strength (10.sup.5 psi) 8.38 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural modulus (10.sup.5 psi)
9.86 (ASTM D790) Notch Izod (ft-lb/in) 1.37 (ASTM D256-97)
[0084] A seventh composition contains the following
ingredients:
13 Composition No. 7 Ingredient Amount (parts) ULTRAFLEX .TM.
CaCO.sub.3 33 Fiber.sup.2,4 67 HDPE/compatibilizer.sup.1,3 100
[0085] The properties of Composition No. 7 are as follows:
14 Flexural strength (10.sup.5 psi) 7.43 (ASTM D790) Ultimate
elongation (%) <5 (ASTM D638) Flexural modulus (10.sup.5 psi)
11.6 (ASTM D790) Notch Izod (ft-lb/in) 1.27 (ASTM D256-97)
[0086] other embodiments are with the claims.
* * * * *