U.S. patent application number 17/691624 was filed with the patent office on 2022-06-23 for processes for making improved cellulose-based materials and containers.
The applicant listed for this patent is INTERNATIONAL PAPER COMPANY. Invention is credited to SADAKAT HUSSAIN, JAMES D. REGEL.
Application Number | 20220195660 17/691624 |
Document ID | / |
Family ID | 1000006193487 |
Filed Date | 2022-06-23 |
United States Patent
Application |
20220195660 |
Kind Code |
A1 |
HUSSAIN; SADAKAT ; et
al. |
June 23, 2022 |
PROCESSES FOR MAKING IMPROVED CELLULOSE-BASED MATERIALS AND
CONTAINERS
Abstract
The present disclosure provides processes for making
cellulose-based material and containers utilizing the
cellulose-based material. More particularly, the present disclosure
provides processes to make cellulose-based material comprising
strength-enhancing preparations and processes to make improved
containers with the strength-enhanced cellulose-based
materials.
Inventors: |
HUSSAIN; SADAKAT; (RENO,
NV) ; REGEL; JAMES D.; (LOVELAND, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INTERNATIONAL PAPER COMPANY |
Memphis |
TN |
US |
|
|
Family ID: |
1000006193487 |
Appl. No.: |
17/691624 |
Filed: |
March 10, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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17325300 |
May 20, 2021 |
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17691624 |
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16916382 |
Jun 30, 2020 |
11015287 |
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17325300 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D21F 11/12 20130101;
D06M 2101/06 20130101; D06M 15/267 20130101; D06M 15/59
20130101 |
International
Class: |
D06M 15/59 20060101
D06M015/59; D21F 11/12 20060101 D21F011/12; D06M 15/267 20060101
D06M015/267 |
Claims
1. A process for making a cellulose-based material, the process
comprising the step of treating cellulosic fibers with i) a dry
strength chemistry preparation and ii) a wet strength chemistry
preparation in a paper-making machine to provide the
cellulose-based material.
2. The process of claim 1, wherein the cellulose-based material is
capable of being recycled.
3. The process of claim 1, wherein the dry strength chemistry
preparation comprises glyoxalated polyacrylamide (GPAM).
4. The process of claim 1, wherein the wet strength chemistry
preparation comprises a polyamide resin.
5. The process of claim 1, wherein the cellulose-based material has
a basis weight and a short-span compression strength (SCT), and
wherein the SCT is greater than a comparative SCT for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation.
6. The process of claim 1, wherein the cellulose-based material has
a basis weight and a short-span compression strength (SCT), and
wherein the dry strength chemistry preparation and the wet strength
chemistry preparation provide a synergistic increase in SCT for the
cellulose-based material in comparison to the comparative
cellulose-based material.
7. The process of claim 1, wherein the cellulose-based material has
a basis weight and a short-span compression strength index (SCT
Index), and wherein the SCT Index is greater than a comparative SCT
Index for a comparative cellulose-based material made on the
paper-making machine, wherein the comparative cellulose-based
material having the basis weight and lacking the dry strength
chemistry preparation.
8. The process of claim 1, wherein the cellulose-based material has
a basis weight and a short-span compression strength index (SCT
Index), and wherein the dry strength chemistry preparation and the
wet strength chemistry preparation provide a synergistic increase
in SCT Index for the cellulose-based material in comparison to the
comparative cellulose-based material.
9. The process of claim 1, wherein the cellulose-based material has
a basis weight and a Concora value, and wherein the Concora value
is greater than a comparative Concora value for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation.
10. The process of claim 1, wherein the cellulose-based material
has a basis weight and a Concora value, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in the Concora value for the
cellulose-based material in comparison to the comparative
cellulose-based material.
11. A process for making a container, the process comprising the
steps of treating cellulosic fibers with i) a dry strength
chemistry preparation and ii) a wet strength chemistry preparation
in a paper-making machine to provide a cellulose-based material
forming a container blank using the cellulose-based material, and
forming a container using the cellulose-based material.
12. The process of claim 11, wherein the cellulose-based material
is capable of being recycled.
13. The process of claim 11, wherein the dry strength chemistry
preparation comprises glyoxalated polyacrylamide (GPAM).
14. The process of claim 11, wherein the wet strength chemistry
preparation comprises a polyamide resin.
15. The process of claim 11, wherein the process further comprises
a step of treating cellulosic fibers with a sizing agent.
16. The process of claim 15, wherein the sizing agent is selected
from the group consisting of alkenyl succinic anhydride (ASA),
rosin, and alkyl ketene dimer (AKD).
17. The process of claim 11, wherein the container has a box
compression strength (BCT50) measured at 50% relative humidity, and
wherein the BCT50 is greater than a comparative box compression
strength (CBCT50) measured at 50% relative humidity of a
comparative container comprising comparative cellulose-based
material made on the paper machine at the basis weight and lacking
the dry strength chemistry preparation.
18. The process of claim 11, wherein the container has a box
compression strength (BCT50) measured at 50% relative humidity, and
wherein the dry strength chemistry preparation and the wet strength
chemistry preparation provide a synergistic increase in BCT50 for
the container in comparison to the comparative container.
19. The process of claim 11, wherein the container has a box
compression strength (BCT85) measured at 85% relative humidity, and
wherein the BCT85 is greater than a comparative box compression
strength (CBCT85) measured at 85% relative humidity of a
comparative container comprising comparative cellulose-based
material made on the paper machine at the basis weight and lacking
the dry strength chemistry preparation.
20. The process of claim 11, wherein the container has a box
compression strength (BCT85) measured at 85% relative humidity, and
wherein the dry strength chemistry preparation and the wet strength
chemistry preparation provide a synergistic increase in BCT85 for
the container in comparison to the comparative container.
Description
BACKGROUND
[0001] The present disclosure relates to processes for making
cellulose-based material and processes to making containers
utilizing the cellulose-based material. More particularly, the
present disclosure relates to processes for making cellulose-based
material comprising strength-enhancing preparations and processes
for making improved containers with the strength-enhanced
cellulose-based materials.
SUMMARY
[0002] Containers are used to store, ship, and protect a multitude
of products from damage. Typically, such containers may be stacked
on top of each other during general use, thus exposing certain
containers within the stack to significant weight loads. As a
result, the strength of the containers and the materials that
comprise the containers is of extreme importance.
[0003] Moreover, environmental factors must be taken into
consideration when designing containers. For instance, containers
comprising cellulosic fibers are subject to swelling due to the
absorbance of water by the fibers, thus weakening the containers.
As a result, containers used in activities that have a high
relative humidity (e.g., the food supply chain) must be prepared
with sufficient strength characteristics in order to avoid
weakening due to the humid conditions.
[0004] Therefore, the present disclosure provides processes for
making cellulose-based materials and processes for making
containers therefrom that address the desired strength and
performance issues known in the art. A processes for making
cellulose-based material in accordance with the present disclosure
includes a step of treating cellulosic fibers with i) a dry
strength chemistry preparation and ii) a wet strength chemistry
preparation in a paper-making machine to provide the
cellulose-based material. Furthermore, the cellulose-based material
made in accordance with the processes of the present disclosure can
be utilized in making containers as described herein.
[0005] The processes of making the cellulose-based materials and
containers of the present disclosure provide several advantages and
improvements compared to the state of the art. First, process to
make the cellulose-based material includes treating cellulosic
fibers with both a dry strength chemistry preparation and a wet
strength chemistry preparation in order to provide significant
strength improvement (i.e., a significant reduction in strength
loss) that is observed in both the cellulose-based material and
containers made using the cellulose-based material. Further, the
improvement in strength can be observed at conditions of high
relative humidity in order to provide significant advantages for
activities performed in such humid conditions. In addition, the
cellulose-based materials and containers made according to the
processes of the present disclosure are recyclable, repulpable, and
capable of being recycled, which are highly desired from an
environmental perspective. Moreover, a synergistic effect in
strength improvement can be observed for containers prepared using
a combination of a dry strength chemistry preparation and a wet
strength preparation in the cellulose-based materials. This
synergistic effect was surprising and unexpected.
[0006] In illustrative embodiments, a process for making a
cellulose-based material is provided. For these embodiments, the
process comprises the step of treating cellulosic fibers with i) a
dry strength chemistry preparation and ii) a wet strength chemistry
preparation in a paper-making machine to provide the
cellulose-based material.
[0007] In illustrative embodiments, process for making a container
is provided. For these embodiments, the process comprising the
steps of treating cellulosic fibers with i) a dry strength
chemistry preparation and ii) a wet strength chemistry preparation
in a paper-making machine to provide a cellulose-based material;
forming a container blank using the cellulose-based material; and
forming a container using the cellulose-based material.
[0008] Additional features of the present disclosure will become
apparent to those skilled in the art upon consideration of
illustrative embodiments exemplifying the best mode of carrying out
the disclosure as presently perceived.
BRIEF DESCRIPTIONS OF THE DRAWINGS
[0009] The detailed description particularly refers to the
accompanying figures in which:
[0010] FIG. 1 is a view of an exemplary containerboard formed from
processes to make the cellulose-based material described herein. As
shown in FIG. 1, two linerboard compositions are provided for the
outer layers of the containerboard and one medium composition is
provided for the fluted inner layer that is sinusoidal in
shape.
[0011] FIG. 2 shows that a higher BCT at 85% relative humidity for
containers prepared using a combination of a dry strength chemistry
preparation plus a wet strength preparation in the cellulose-based
materials.
[0012] FIG. 3 shows a synergistic strength improvement was observed
for containers prepared using a combination of a dry strength
chemistry preparation plus a wet strength preparation in the
cellulose-based materials.
[0013] FIG. 4 shows that inclusion of a dry strength chemistry
preparation plus a wet strength chemistry preparation demonstrated
an increase in SCT when normalized to 36 lbs/1000 ft.sup.2 compared
to other cellulose-based materials that did not include a dry
strength chemistry preparation.
[0014] FIG. 5 shows a synergistic strength improvement was observed
for containers prepared using a combination of a dry strength
chemistry preparation plus a wet strength preparation in the
cellulose-based materials.
DETAILED DESCRIPTION
[0015] In illustrative aspect, a process for making a
cellulose-based material is provided. The process comprises the
step of treating cellulosic fibers with i) a dry strength chemistry
preparation and ii) a wet strength chemistry preparation in a
paper-making machine to provide the cellulose-based material.
[0016] In an embodiment, the cellulose-based material is a
paper-based material. In an embodiment, the cellulose-based
material is paper. In an embodiment, the cellulose-based material
is a paper board. In an embodiment, the cellulose-based material is
a medium. A "medium" is well known in the art as an inner layer of
a containerboard. For instance, in some embodiments, a medium may
be fluted and/or sinusoidal in shape. In an embodiment, the
cellulose-based material is a liner. A "liner" is well known in the
art as an outer layer of a containerboard. In an embodiment, the
cellulose-based material is a containerboard. In an embodiment, the
cellulose-based material is recyclable. For instance,
cellulose-based materials are known in the art to be certified for
recycling. One such example of certification is by the Fibre Box
Association (FBA) and various certifications are well known in the
art.
[0017] In an aspect, the cellulosic fibers comprise virgin fibers.
In an aspect, the cellulosic fibers comprise recycled fibers. In an
aspect, the cellulosic fibers comprise a combination of virgin
fibers and recycled fibers. In an aspect, the cellulosic fibers are
capable of being recycled. In an aspect, the cellulose-based
material is capable of being recycled.
[0018] The combination of virgin fibers and recycled fibers may
fall within one of several different ranges. The combination may be
one of the following ranges (in which the total percentage is
100%): about 1% to about 99% virgin fibers and about 1% to about
99% recycled fibers, about 5% to about 95% virgin fibers and about
5% to about 95% recycled fibers, about 10% to about 90% virgin
fibers and about 10% to about 90% recycled fibers, about 15% to
about 85% virgin fibers and about 15% to about 85% recycled fibers,
about 20% to about 80% virgin fibers and about 20% to about 80%
recycled fibers, about 25% to about 75% virgin fibers and about 25%
to about 75% recycled fibers, about 30% to about 70% virgin fibers
and about 30% to about 70% recycled fibers, about 35% to about 65%
virgin fibers and about 35% to about 65% recycled fibers, about 40%
to about 60% virgin fibers and about 40% to about 60% recycled
fibers, about 45% to about 55% virgin fibers and about 45% to about
55% recycled fibers, about 48% to about 52% virgin fibers and about
48% to about 52% recycled fibers, and about 50% virgin fibers and
about 50% recycled fibers.
[0019] In an embodiment, the dry strength chemistry preparation
comprises an aldehyde functionalized polymer. In an embodiment, the
dry strength chemistry preparation comprises glyoxalated
polyacrylamide (GPAM). GPAM can be supplied, for example, as
Solenis Hercobond Plus 555 (aka BASF Luredur Plus 555), as Solenis
Hercobond Plus HC (aka BASF Luredur Plus HC), or as other GPAM
formulations known in the art.
[0020] In an embodiment, the GPAM is applied to the cellulosic
fibers between 1-16 dry lbs/ton. In an embodiment, the GPAM is
applied to the cellulosic fibers between 2-8 dry lbs/ton. In an
embodiment, the GPAM is applied to the cellulosic fibers at 2 dry
lbs/ton. In an embodiment, the GPAM is applied to the cellulosic
fibers at 4 dry lbs/ton. In an embodiment, the GPAM is applied to
the cellulosic fibers at 6 dry lbs/ton. In an embodiment, the GPAM
is applied to the cellulosic fibers at 8 dry lbs/ton.
[0021] In an aspect, the wet strength chemistry preparation
comprises a polyamide resin. In an aspect, the poly amide resin is
a poly amidoamine epihalohydrin resin. In an aspect, the polyamide
resin is selected from the group consisting of EPI-Polyamide resin,
Polyamide-Epichlorohydrin resin (PAE), and Epichlorohydrin
polyamide resin. In an aspect, the polyamide resin is
Polyamide-Epichlorohydrin resin (PAE). The wet strength chemistry
preparation can be supplied, for example, as Kymene 1500LV, as
Nalco 63642, or as other wet strength chemistry formulations known
in the art.
[0022] In an aspect, the polyamide resin is applied to the
cellulosic fibers between 1-32 dry lbs/ton. In an aspect, the
polyamide resin is applied to the cellulosic fibers between 2-16
dry lbs/ton. In an aspect, the polyamide resin is applied to the
cellulosic fibers between 2-8 dry lbs/ton. In an aspect, the
polyamide resin is applied to the cellulosic fibers at 2 dry
lbs/ton. In an aspect, the polyamide resin is applied to the
cellulosic fibers at 4 dry lbs/ton. In an aspect, the polyamide
resin is applied to the cellulosic fibers at 6 dry lbs/ton. In an
aspect, the polyamide resin is applied to the cellulosic fibers at
8 dry lbs/ton.
[0023] In an embodiment, the process further comprises a step of
treating cellulosic fibers with a sizing agent. In an embodiment,
the sizing agent is an internal sizing agent. In an embodiment, the
sizing agent is a surface sizing agent. In an embodiment, the
sizing agent is alkenyl succinic anhydride (ASA). In an embodiment,
the sizing agent is rosin. In an embodiment, the sizing agent is
alkyl ketene dimer (AKD).
[0024] In an aspect, the cellulosic fibers are treated with the dry
strength chemistry preparation and the wet strength chemistry
preparation at the same time. In an aspect, the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation sequentially, in either order. In an
aspect, the cellulosic fibers are treated with the dry strength
chemistry preparation and the wet strength chemistry preparation
separately. In an aspect, the dry strength chemistry preparation
and the wet strength chemistry preparation are combined prior to
treating the cellulosic fibers.
[0025] In an embodiment, the process further comprises treating
cellulosic fibers with an enzymatic preparation. In an embodiment,
the enzymatic preparation comprises a polypeptide having amylase
activity. In an embodiment, the process does not comprise treating
cellulosic fibers with an enzymatic preparation.
[0026] In an aspect, the process further comprises treating
cellulosic fibers with an anionic surface preparation. In an
aspect, the anionic surface preparation is an anionic
polyacrylamide. In an aspect, the anionic surface preparation is a
copolymer of acrylamide and unsaturated carboxylic acid monomers,
being (meth)acrylic acid, maleic acid, crotonic acid, itaconic
acid, or any combination thereof. In an aspect, the process does
not comprise treating cellulosic fibers with an anionic surface
preparation.
[0027] The cellulose-based materials made by the process of the
present disclosure may be determined to have certain properties.
For example, the cellulose-based material has a basis weight. A
basis weight is generally understood in the paper making arts to
represent the mass per unit of area of the cellulose-based
materials. For instance, the cellulose-based materials of the
present disclosure can be contrasted to comparative cellulose-based
materials having a similar basis weight in which the comparative
cellulose-based materials lack the wet strength chemistry
preparation, lack the dry strength chemistry preparation, or lack
both the wet strength chemistry preparation and the dry strength
chemistry preparation.
[0028] In an embodiment, the cellulose-based material has a basis
weight and a short-span compression strength (SCT). Means of
evaluating compression strength of a cellulose-based material via
SCT (also known as "STFI") are well known in the art. In an
embodiment, the SCT is greater than a comparative SCT for a
comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the dry strength chemistry preparation
and the wet strength chemistry preparation. In an embodiment, the
greater SCT is observed at a dry relative humidity. In an
embodiment, the greater SCT is observed at a high relative
humidity. For instance, a "high relative humidity" can refer to a
relative humidity of 50% or greater, a relative humidity of 55% or
greater, a relative humidity of 60% or greater, a relative humidity
of 65% or greater, a relative humidity of 70% or greater, a
relative humidity of 75% or greater, a relative humidity of 80% or
greater, a relative humidity of 85% or greater, a relative humidity
of 90% or greater, or a relative humidity of 95% or greater.
[0029] In an embodiment, the SCT is greater than a comparative SCT
for a comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the dry strength chemistry
preparation. In an embodiment, the greater SCT is observed at a dry
relative humidity. In an embodiment, the greater SCT is observed at
a high relative humidity.
[0030] In an embodiment, the SCT is greater than a comparative SCT
for a comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the wet strength chemistry
preparation. In an embodiment, the greater SCT is observed at a dry
relative humidity. In an embodiment, the greater SCT is observed at
a high relative humidity.
[0031] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in SCT for the cellulose-based material in comparison to
the comparative cellulose-based material. In an embodiment, the
synergistic increase in SCT is observed at a dry relative humidity.
In an embodiment, the synergistic increase in SCT is observed at a
high relative humidity. The synergistic increase in SCT for the
cellulose-based materials of the present disclosure is demonstrated
in the subsequent examples and was unexpected.
[0032] In an embodiment, the cellulose-based material has a basis
weight and short-span compression strength index (SCT Index).
Generally, determining the SCT Index of a cellulose-based material
is well known in the art by dividing the average SCT value of the
cellulose-based material by the average basis weight of the
cellulose-based material. In an embodiment, the SCT Index is
greater than a comparative SCT Index for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation and the wet
strength chemistry preparation. In an embodiment, the greater SCT
Index is observed at a dry relative humidity. In an embodiment, the
greater SCT Index is observed at a high relative humidity.
[0033] In an embodiment, the SCT Index is greater than a
comparative SCT Index for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation. In an embodiment, the greater
SCT Index is observed at a dry relative humidity. In an embodiment,
the greater SCT Index is observed at a high relative humidity.
[0034] In an embodiment, the SCT Index is greater than a
comparative SCT Index for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
wet strength chemistry preparation. In an embodiment, the greater
SCT Index is observed at a dry relative humidity. In an embodiment,
the greater SCT Index is observed at a high relative humidity.
[0035] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in SCT Index for the cellulose-based material in
comparison to the comparative cellulose-based material. In an
embodiment, the synergistic increase in SCT Index is observed at a
dry relative humidity. In an embodiment, the synergistic increase
in SCT Index is observed at a high relative humidity. The
synergistic increase in SCT Index for the cellulose-based materials
of the present disclosure is demonstrated in the subsequent
examples and was unexpected.
[0036] In an embodiment, the cellulose-based material has a basis
weight and a Concora value. Means of evaluating flat crush of a
cellulose-based material via Concora are well known in the art. In
an embodiment, the Concora value is greater than a comparative
Concora value for a comparative cellulose-based material made on
the paper-making machine, wherein the comparative cellulose-based
material having the basis weight and lacking the dry strength
chemistry preparation and the wet strength chemistry preparation.
In an embodiment, the greater Concora value is observed at a dry
relative humidity. In an embodiment, the greater Concora value is
observed at a high relative humidity.
[0037] In an embodiment, the Concora value is greater than a
comparative Concora value for a comparative cellulose-based
material made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation. In an embodiment, the greater
Concora value is observed at a dry relative humidity. In an
embodiment, the greater Concora value is observed at a high
relative humidity.
[0038] In an embodiment, the Concora value is greater than a
comparative Concora value for a comparative cellulose-based
material made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
wet strength chemistry preparation. In an embodiment, the greater
Concora value is observed at a dry relative humidity. In an
embodiment, the greater Concora value is observed at a high
relative humidity.
[0039] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in Concora value for the cellulose-based material in
comparison to the comparative cellulose-based material. In an
embodiment, the synergistic increase in Concora value is observed
at a dry relative humidity. In an embodiment, the synergistic
increase in Concora value is observed at a high relative humidity.
The synergistic increase in Concora value for the cellulose-based
materials of the present disclosure is demonstrated in the
subsequent examples and was unexpected.
[0040] In an illustrative aspect, a process for making a container
is provided. The process comprising the steps of treating
cellulosic fibers with i) a dry strength chemistry preparation and
ii) a wet strength chemistry preparation in a paper-making machine
to provide a cellulose-based material, forming a container blank
using the cellulose-based material, and forming a container using
the cellulose-based material.
[0041] In an embodiment, the cellulose-based material is
recyclable. For instance, cellulose-based materials are known in
the art to be certified for recycling. One such example of
certification is by the Fibre Box Association (FBA) and various
certifications are well known in the art. In an embodiment, the
container is corrugated cardboard.
[0042] In an aspect, the cellulosic fibers comprise virgin fibers.
In an aspect, the cellulosic fibers comprise recycled fibers. In an
aspect, the cellulosic fibers comprise a combination of virgin
fibers and recycled fibers. In an aspect, the cellulosic fibers are
capable of being recycled. In an aspect, the container is capable
of being recycled.
[0043] The combination of virgin fibers and recycled fibers may
fall within one of several different ranges. The combination may be
one of the following ranges (in which the total percentage is
100%): about 1% to about 99% virgin fibers and about 1% to about
99% recycled fibers, about 5% to about 95% virgin fibers and about
5% to about 95% recycled fibers, about 10% to about 90% virgin
fibers and about 10% to about 90% recycled fibers, about 15% to
about 85% virgin fibers and about 15% to about 85% recycled fibers,
about 20% to about 80% virgin fibers and about 20% to about 80%
recycled fibers, about 25% to about 75% virgin fibers and about 25%
to about 75% recycled fibers, about 30% to about 70% virgin fibers
and about 30% to about 70% recycled fibers, about 35% to about 65%
virgin fibers and about 35% to about 65% recycled fibers, about 40%
to about 60% virgin fibers and about 40% to about 60% recycled
fibers, about 45% to about 55% virgin fibers and about 45% to about
55% recycled fibers, about 48% to about 52% virgin fibers and about
48% to about 52% recycled fibers, and about 50% virgin fibers and
about 50% recycled fibers.
[0044] In an embodiment, the dry strength chemistry preparation
comprises an aldehyde functionalized polymer. In an embodiment, the
dry strength chemistry preparation comprises glyoxalated
polyacrylamide (GPAM). GPAM can be supplied, for example, as
Solenis Hercobond Plus 555 (aka BASF Luredur Plus 555), as Solenis
Hercobond Plus HC (aka BASF Luredur Plus HC), or as other GPAM
formulations known in the art.
[0045] In an embodiment, the GPAM is applied to the cellulosic
fibers between 1-16 dry lbs/ton. In an embodiment, the GPAM is
applied to the cellulosic fibers between 2-8 dry lbs/ton. In an
embodiment, the GPAM is applied to the cellulosic fibers at 2 dry
lbs/ton. In an embodiment, the GPAM is applied to the cellulosic
fibers at 4 dry lbs/ton. In an embodiment, the GPAM is applied to
the cellulosic fibers at 6 dry lbs/ton. In an embodiment, the GPAM
is applied to the cellulosic fibers at 8 dry lbs/ton.
[0046] In an aspect, the wet strength chemistry preparation
comprises a polyamide resin. In an aspect, the poly amide resin is
a poly amidoamine epihalohydrin resin. In an aspect, the polyamide
resin is selected from the group consisting of EPI-Polyamide resin,
Polyamide-Epichlorohydrin resin (PAE), and Epichlorohydrin
polyamide resin. In an aspect, the polyamide resin is
Polyamide-Epichlorohydrin resin (PAE). The wet strength chemistry
preparation can be supplied, for example, as Kymene 1500LV, as
Nalco 63642, or as other wet strength chemistry formulations known
in the art.
[0047] In an aspect, the polyamide resin is applied to the
cellulosic fibers between 1-32 dry lbs/ton. In an aspect, the
polyamide resin is applied to the cellulosic fibers between 2-16
dry lbs/ton. In an aspect, the polyamide resin is applied to the
cellulosic fibers between 2-8 dry lbs/ton. In an aspect, the
polyamide resin is applied to the cellulosic fibers at 2 dry
lbs/ton. In an aspect, the polyamide resin is applied to the
cellulosic fibers at 4 dry lbs/ton. In an aspect, the polyamide
resin is applied to the cellulosic fibers at 6 dry lbs/ton. In an
aspect, the polyamide resin is applied to the cellulosic fibers at
8 dry lbs/ton.
[0048] In an embodiment, the process further comprises a step of
treating cellulosic fibers with a sizing agent. In an embodiment,
the sizing agent is an internal sizing agent. In an embodiment, the
sizing agent is a surface sizing agent. In an embodiment, the
sizing agent is alkenyl succinic anhydride (ASA). In an embodiment,
the sizing agent is rosin. In an embodiment, the sizing agent is
alkyl ketene dimer (AKD).
[0049] In an aspect, the cellulosic fibers are treated with the dry
strength chemistry preparation and the wet strength chemistry
preparation at the same time. In an aspect, the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation sequentially, in either order. In an
aspect, the cellulosic fibers are treated with the dry strength
chemistry preparation and the wet strength chemistry preparation
separately. In an aspect, the dry strength chemistry preparation
and the wet strength chemistry preparation are combined prior to
treating the cellulosic fibers.
[0050] In an embodiment, the process further comprises treating
cellulosic fibers with an enzymatic preparation. In an embodiment,
the enzymatic preparation comprises a polypeptide having amylase
activity. In an embodiment, the process does not comprise treating
cellulosic fibers with an enzymatic preparation.
[0051] In an aspect, the process further comprises treating
cellulosic fibers with an anionic surface preparation. In an
aspect, the anionic surface preparation is an anionic
polyacrylamide. In an aspect, the anionic surface preparation is a
copolymer of acrylamide and unsaturated carboxylic acid monomers,
being (meth)acrylic acid, maleic acid, crotonic acid, itaconic
acid, or any combination thereof. In an aspect, the process does
not comprise treating cellulosic fibers with an anionic surface
preparation.
[0052] The cellulose-based materials made by the process of the
present disclosure may be determined to have certain properties.
For example, the cellulose-based material has a basis weight. A
basis weight is generally understood in the paper making arts to
represent the mass per unit of area of the cellulose-based
materials. For instance, the cellulose-based materials of the
present disclosure can be contrasted to comparative cellulose-based
materials having a similar basis weight in which the comparative
cellulose-based materials lack the wet strength chemistry
preparation, lack the dry strength chemistry preparation, or lack
both the wet strength chemistry preparation and the dry strength
chemistry preparation.
[0053] In an embodiment, the cellulose-based material has a basis
weight and a short-span compression strength (SCT). Means of
evaluating compression strength of a cellulose-based material via
SCT (also known as "STFI") are well known in the art. In an
embodiment, the SCT is greater than a comparative SCT for a
comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the dry strength chemistry preparation
and the wet strength chemistry preparation. In an embodiment, the
greater SCT is observed at a dry relative humidity. In an
embodiment, the greater SCT is observed at a high relative
humidity. For instance, a "high relative humidity" can refer to a
relative humidity of 50% or greater, a relative humidity of 55% or
greater, a relative humidity of 60% or greater, a relative humidity
of 65% or greater, a relative humidity of 70% or greater, a
relative humidity of 75% or greater, a relative humidity of 80% or
greater, a relative humidity of 85% or greater, a relative humidity
of 90% or greater, or a relative humidity of 95% or greater.
[0054] In an embodiment, the SCT is greater than a comparative SCT
for a comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the dry strength chemistry
preparation. In an embodiment, the greater SCT is observed at a dry
relative humidity. In an embodiment, the greater SCT is observed at
a high relative humidity.
[0055] In an embodiment, the SCT is greater than a comparative SCT
for a comparative cellulose-based material made on the paper-making
machine, wherein the comparative cellulose-based material having
the basis weight and lacking the wet strength chemistry
preparation. In an embodiment, the greater SCT is observed at a dry
relative humidity. In an embodiment, the greater SCT is observed at
a high relative humidity.
[0056] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in SCT for the cellulose-based material in comparison to
the comparative cellulose-based material. In an embodiment, the
synergistic increase in SCT is observed at a dry relative humidity.
In an embodiment, the synergistic increase in SCT is observed at a
high relative humidity. The synergistic increase in SCT for the
cellulose-based materials of the present disclosure is demonstrated
in the subsequent examples and was unexpected.
[0057] In an embodiment, the cellulose-based material has a basis
weight and short-span compression strength index (SCT Index).
Generally, determining the SCT Index of a cellulose-based material
is well known in the art by dividing the average SCT value of the
cellulose-based material by the average basis weight of the
cellulose-based material. In an embodiment, the SCT Index is
greater than a comparative SCT Index for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation and the wet
strength chemistry preparation. In an embodiment, the greater SCT
Index is observed at a dry relative humidity. In an embodiment, the
greater SCT Index is observed at a high relative humidity.
[0058] In an embodiment, the SCT Index is greater than a
comparative SCT Index for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation. In an embodiment, the greater
SCT Index is observed at a dry relative humidity. In an embodiment,
the greater SCT Index is observed at a high relative humidity.
[0059] In an embodiment, the SCT Index is greater than a
comparative SCT Index for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
wet strength chemistry preparation. In an embodiment, the greater
SCT Index is observed at a dry relative humidity. In an embodiment,
the greater SCT Index is observed at a high relative humidity.
[0060] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in SCT Index for the cellulose-based material in
comparison to the comparative cellulose-based material. In an
embodiment, the synergistic increase in SCT Index is observed at a
dry relative humidity. In an embodiment, the synergistic increase
in SCT Index is observed at a high relative humidity. The
synergistic increase in SCT Index for the cellulose-based materials
of the present disclosure is demonstrated in the subsequent
examples and was unexpected.
[0061] In an embodiment, the cellulose-based material has a basis
weight and a Concora value. Means of evaluating flat crush of a
cellulose-based material via Concora are well known in the art. In
an embodiment, the Concora value is greater than a comparative
Concora value for a comparative cellulose-based material made on
the paper-making machine, wherein the comparative cellulose-based
material having the basis weight and lacking the dry strength
chemistry preparation and the wet strength chemistry preparation.
In an embodiment, the greater Concora value is observed at a dry
relative humidity. In an embodiment, the greater Concora value is
observed at a high relative humidity.
[0062] In an embodiment, the Concora value is greater than a
comparative Concora value for a comparative cellulose-based
material made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation. In an embodiment, the greater
Concora value is observed at a dry relative humidity. In an
embodiment, the greater Concora value is observed at a high
relative humidity.
[0063] In an embodiment, the Concora value is greater than a
comparative Concora value for a comparative cellulose-based
material made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
wet strength chemistry preparation. In an embodiment, the greater
Concora value is observed at a dry relative humidity. In an
embodiment, the greater Concora value is observed at a high
relative humidity.
[0064] In an embodiment, the dry strength chemistry preparation and
the wet strength chemistry preparation provide a synergistic
increase in Concora value for the cellulose-based material in
comparison to the comparative cellulose-based material. In an
embodiment, the synergistic increase in Concora value is observed
at a dry relative humidity. In an embodiment, the synergistic
increase in Concora value is observed at a high relative humidity.
The synergistic increase in Concora value for the cellulose-based
materials of the present disclosure is demonstrated in the
subsequent examples and was unexpected.
[0065] The containers made by the process of the present disclosure
may be determined to have certain properties. For example, the
containers can comprise a cellulose-based material having a basis
weight. A basis weight is generally understood in the paper making
arts to represent the mass per unit of area of the cellulose-based
materials. For instance, the containers of the present disclosure
can be contrasted to comparative containers comprising
cellulose-based materials having a similar basis weight in which
the comparative cellulose-based materials lack the wet strength
chemistry preparation, lack the dry strength chemistry preparation,
or lack both the wet strength chemistry preparation and the dry
strength chemistry preparation.
[0066] In an embodiment, the container has a box compression
strength (BCT50) measured at 50% relative humidity. In an
embodiment, the BCT50 is greater than a comparative box compression
strength (CBCT50) measured at 50% relative humidity of a
comparative container comprising comparative cellulose-based
material made on the paper machine at the basis weight and lacking
the dry strength chemistry preparation and the wet strength
chemistry preparation. In an embodiment, the BCT50 is greater than
a CBCT50 measured at 50% relative humidity of a comparative
container comprising comparative cellulose-based material made on
the paper machine at the basis weight and lacking the dry strength
chemistry preparation. In an embodiment, the BCT50 is greater than
a comparative box compression strength CBCT50 measured at 50%
relative humidity of a comparative container comprising comparative
cellulose-based material made on the paper machine at the basis
weight and lacking the wet strength chemistry preparation. In an
embodiment, the dry strength chemistry preparation and the wet
strength chemistry preparation provide a synergistic increase in
BCT50 for the container in comparison to the comparative container.
The synergistic increase in BCT50 for the containers of the present
disclosure is demonstrated in the subsequent examples and was
unexpected.
[0067] In an embodiment, the container has a box compression
strength (BCT85) measured at 85% relative humidity. In an
embodiment, the BCT85 is greater than a comparative box compression
strength (CBCT85) measured at 85% relative humidity of a
comparative container comprising comparative cellulose-based
material made on the paper machine at the basis weight and lacking
the dry strength chemistry preparation and the wet strength
chemistry preparation. In an embodiment, the BCT85 is greater than
a CBCT85 measured at 85% relative humidity of a comparative
container comprising comparative cellulose-based material made on
the paper machine at the basis weight and lacking the dry strength
chemistry preparation. In an embodiment, the BCT85 is greater than
a comparative box compression strength CBCT85 measured at 85%
relative humidity of a comparative container comprising comparative
cellulose-based material made on the paper machine at the basis
weight and lacking the wet strength chemistry preparation. In an
embodiment, the dry strength chemistry preparation and the wet
strength chemistry preparation provide a synergistic increase in
BCT85 for the container in comparison to the comparative container.
The synergistic increase in BCT85 for the containers of the present
disclosure is demonstrated in the subsequent examples and was
unexpected.
[0068] The following numbered embodiments are contemplated and are
non-limiting:
[0069] 1. A process for making a cellulose-based material, the
process comprising the step of treating cellulosic fibers with i) a
dry strength chemistry preparation and ii) a wet strength chemistry
preparation in a paper-making machine to provide the
cellulose-based material.
[0070] 2. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is a paper-based material.
[0071] 3. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is paper.
[0072] 4. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is a paper board.
[0073] 5. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is a medium.
[0074] 6. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is a liner.
[0075] 7. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is a containerboard.
[0076] 8. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is recyclable.
[0077] 9. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise virgin fibers.
[0078] 10. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise recycled fibers.
[0079] 11. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise a combination of virgin fibers and recycled fibers.
[0080] 12. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are capable of being recycled.
[0081] 13. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is capable of being recycled.
[0082] 14. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation comprises an aldehyde functionalized
polymer.
[0083] 15. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation comprises glyoxalated polyacrylamide
(GPAM).
[0084] 16. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers between 1-16 dry lbs/ton.
[0085] 17. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers between 2-8 dry lbs/ton.
[0086] 18. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 2 dry lbs/ton.
[0087] 19. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 4 dry lbs/ton.
[0088] 20. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 6 dry lbs/ton.
[0089] 21. The process of clause 15, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 8 dry lbs/ton.
[0090] 22. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the wet strength
chemistry preparation comprises a polyamide resin.
[0091] 23. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
a polyamidoamine epihalohydrin resin.
[0092] 24. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
selected from the group consisting of EPI-Polyamide resin,
Polyamide-Epichlorohydrin resin (PAE), and Epichlorohydrin
polyamide resin.
[0093] 25. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
Polyamide-Epichlorohydrin resin (PAE).
[0094] 26. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, The process of clause 22, any
other suitable clause, or any combination of suitable clauses,
wherein the polyamide resin is applied to the cellulosic fibers
between 1-32 dry lbs/ton.
[0095] 27. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers between 2-16 dry lbs/ton.
[0096] 28. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers between 2-8 dry lbs/ton.
[0097] 29. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers at 2 dry lbs/ton.
[0098] 30. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers at 4 dry lbs/ton.
[0099] 31. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers at 6 dry lbs/ton.
[0100] 32. The process of clause 22, any other suitable clause, or
any combination of suitable clauses, wherein the polyamide resin is
applied to the cellulosic fibers at 8 dry lbs/ton.
[0101] 33. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises a step of treating cellulosic fibers with a sizing
agent.
[0102] 34. The process of clause 33, any other suitable clause, or
any combination of suitable clauses, wherein the sizing agent is an
internal sizing agent.
[0103] 35. The process of clause 33, any other suitable clause, or
any combination of suitable clauses, wherein the sizing agent is a
surface sizing agent.
[0104] 36. The process of clause 33, any other suitable clause, or
any combination of suitable clauses, wherein the sizing agent is
alkenyl succinic anhydride (ASA).
[0105] 37. The process of clause 33, any other suitable clause, or
any combination of suitable clauses, wherein the sizing agent is
rosin.
[0106] 38. The process of clause 33, any other suitable clause, or
any combination of suitable clauses, wherein the sizing agent is
alkyl ketene dimer (AKD).
[0107] 39. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation at the same time.
[0108] 40. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation sequentially.
[0109] 41. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation separately.
[0110] 42. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
are combined prior to treating the cellulosic fibers.
[0111] 43. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises treating cellulosic fibers with an enzymatic
preparation.
[0112] 44. The process of clause 43, any other suitable clause, or
any combination of suitable clauses, wherein the enzymatic
preparation comprises a polypeptide having amylase activity.
[0113] 45. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the process does not
comprise treating cellulosic fibers with an enzymatic
preparation.
[0114] 46. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises treating cellulosic fibers with an anionic surface
preparation.
[0115] 47. The process of clause 46, any other suitable clause, or
any combination of suitable clauses, wherein the anionic surface
preparation is an anionic polyacrylamide.
[0116] 48. The process of clause 46, any other suitable clause, or
any combination of suitable clauses, wherein the anionic surface
preparation is a copolymer of acrylamide and unsaturated carboxylic
acid monomers, being (meth)acrylic acid, maleic acid, crotonic
acid, itaconic acid, or any combination thereof.
[0117] 49. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the process does not
comprise treating cellulosic fibers with an anionic surface
preparation.
[0118] 50. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material has a basis weight and a short-span compression strength
(SCT).
[0119] 51. The process of clause 50, any other suitable clause, or
any combination of suitable clauses, wherein the SCT is greater
than a comparative SCT for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation and the wet strength chemistry
preparation.
[0120] 52. The process of clause 51, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a dry relative humidity.
[0121] 53. The process of clause 51, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a high relative humidity.
[0122] 54. The process of clause 50, any other suitable clause, or
any combination of suitable clauses, wherein the SCT is greater
than a comparative SCT for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
dry strength chemistry preparation.
[0123] 55. The process of clause 54, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a dry relative humidity.
[0124] 56. The process of clause 54, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a high relative humidity.
[0125] 57. The process of clause 50, any other suitable clause, or
any combination of suitable clauses, wherein the SCT is greater
than a comparative SCT for a comparative cellulose-based material
made on the paper-making machine, wherein the comparative
cellulose-based material having the basis weight and lacking the
wet strength chemistry preparation.
[0126] 58. The process of clause 57, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a dry relative humidity.
[0127] 59. The process of clause 57, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT is
observed at a high relative humidity.
[0128] 60. The process of clause 50, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in SCT for the cellulose-based
material in comparison to the comparative cellulose-based
material.
[0129] 61. The process of clause 60, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in SCT is observed at a dry relative humidity.
[0130] 62. The process of clause 60, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in SCT is observed at a high relative humidity.
[0131] 63. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material has a basis weight and a short-span compression strength
index (SCT Index).
[0132] 64. The process of clause 63, any other suitable clause, or
any combination of suitable clauses, wherein the SCT Index is
greater than a comparative SCT Index for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation and the wet
strength chemistry preparation.
[0133] 65. The process of clause 64, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a dry relative humidity.
[0134] 66. The process of clause 64, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a high relative humidity.
[0135] 67. The process of clause 63, any other suitable clause, or
any combination of suitable clauses, wherein the SCT Index is
greater than a comparative SCT Index for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation.
[0136] 68. The process of clause 67, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a dry relative humidity.
[0137] 69. The process of clause 67, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a high relative humidity.
[0138] 70. The process of clause 63, any other suitable clause, or
any combination of suitable clauses, wherein the SCT Index is
greater than a comparative SCT Index for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the wet strength chemistry preparation.
[0139] 71. The process of clause 70, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a dry relative humidity.
[0140] 72. The process of clause 70, any other suitable clause, or
any combination of suitable clauses, wherein the greater SCT Index
is observed at a high relative humidity.
[0141] 73. The process of clause 63, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in SCT Index for the cellulose-based
material in comparison to the comparative cellulose-based
material.
[0142] 74. The process of clause 73, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in SCT Index is observed at a dry relative humidity.
[0143] 75. The process of clause 73, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in SCT Index is observed at a high relative humidity.
[0144] 76. The process of clause 1, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material has a basis weight and a Concora value.
[0145] 77. The process of clause 76, any other suitable clause, or
any combination of suitable clauses, wherein the Concora value is
greater than a comparative Concora value for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation and the wet
strength chemistry preparation.
[0146] 78. The process of clause 77, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a dry relative humidity.
[0147] 79. The process of clause 77, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a high relative humidity.
[0148] 80. The process of clause 76, any other suitable clause, or
any combination of suitable clauses, wherein the Concora value is
greater than a comparative Concora value for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the dry strength chemistry preparation.
[0149] 81. The process of clause 80, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a dry relative humidity.
[0150] 82. The process of clause 80, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a high relative humidity.
[0151] 83. The process of clause 76, any other suitable clause, or
any combination of suitable clauses, wherein the Concora value is
greater than a comparative Concora value for a comparative
cellulose-based material made on the paper-making machine, wherein
the comparative cellulose-based material having the basis weight
and lacking the wet strength chemistry preparation.
[0152] 84. The process of clause 83, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a dry relative humidity.
[0153] 85. The process of clause 83, any other suitable clause, or
any combination of suitable clauses, wherein the greater Concora
value is observed at a high relative humidity.
[0154] 86. The process of clause 76, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in the Concora value for the
cellulose-based material in comparison to the comparative
cellulose-based material.
[0155] 87. The process of clause 86, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in the Concora value is observed at a dry relative
humidity.
[0156] 88. The process of clause 86, any other suitable clause, or
any combination of suitable clauses, wherein the synergistic
increase in the Concora value is observed at a high relative
humidity.
[0157] 89. A process for making a container, the process comprising
the steps of [0158] treating cellulosic fibers with i) a dry
strength chemistry preparation and ii) a wet strength chemistry
preparation in a paper-making machine to provide a cellulose-based
material [0159] forming a container blank using the cellulose-based
material, and [0160] forming a container using the cellulose-based
material.
[0161] 90. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulose-based
material is recyclable.
[0162] 91. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the container is
corrugated cardboard
[0163] 92. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise virgin fibers.
[0164] 93. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise recycled fibers.
[0165] 94. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
comprise a combination of virgin fibers and recycled fibers.
[0166] 95. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are capable of being recycled.
[0167] 96. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the container is
capable of being recycled.
[0168] 97. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation comprises an aldehyde functionalized
polymer.
[0169] 98. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation comprises glyoxalated polyacrylamide
(GPAM).
[0170] 99. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers between 1-16 dry lbs/ton.
[0171] 100. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers between 2-8 dry lbs/ton.
[0172] 101. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 2 dry lbs/ton.
[0173] 102. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 4 dry lbs/ton.
[0174] 103. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 6 dry lbs/ton.
[0175] 104. The process of clause 98, any other suitable clause, or
any combination of suitable clauses, wherein the GPAM is applied to
the cellulosic fibers at 8 dry lbs/ton.
[0176] 105. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the wet strength
chemistry preparation comprises a polyamide resin.
[0177] 106. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is a polyamidoamine epihalohydrin resin.
[0178] 107. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is selected from the group consisting of EPI-Polyamide resin,
Polyamide-Epichlorohydrin resin (PAE), and Epichlorohydrin
polyamide resin.
[0179] 108. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is Polyamide-Epichlorohydrin resin (PAE).
[0180] 109. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers between 1-32 dry lbs/ton.
[0181] 110. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers between 2-16 dry lbs/ton.
[0182] 111. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers between 2-8 dry lbs/ton.
[0183] 112. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers at 2 dry lbs/ton.
[0184] 113. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers at 4 dry lbs/ton.
[0185] 114. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers at 6 dry lbs/ton.
[0186] 115. The process of clause 105, any other suitable clause,
or any combination of suitable clauses, wherein the polyamide resin
is applied to the cellulosic fibers at 8 dry lbs/ton.
[0187] 116. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises a step of treating cellulosic fibers with a sizing
agent.
[0188] 117. The process of clause 116, any other suitable clause,
or any combination of suitable clauses, wherein the sizing agent is
an internal sizing agent.
[0189] 118. The process of clause 116, any other suitable clause,
or any combination of suitable clauses, wherein the sizing agent is
a surface sizing agent.
[0190] 119. The process of clause 116, any other suitable clause,
or any combination of suitable clauses, wherein the sizing agent is
alkenyl succinic anhydride (ASA).
[0191] 120. The process of clause 116, any other suitable clause,
or any combination of suitable clauses, wherein the sizing agent is
rosin.
[0192] 121. The process of clause 116, any other suitable clause,
or any combination of suitable clauses, wherein the sizing agent is
alkyl ketene dimer (AKD).
[0193] 122. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation at the same time.
[0194] 123. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation sequentially.
[0195] 124. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the cellulosic fibers
are treated with the dry strength chemistry preparation and the wet
strength chemistry preparation separately.
[0196] 125. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
are combined prior to treating the cellulosic fibers.
[0197] 126. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises treating cellulosic fibers with an enzymatic
preparation.
[0198] 127. The process of clause 126, any other suitable clause,
or any combination of suitable clauses, wherein the enzymatic
preparation comprises a polypeptide having amylase activity.
[0199] 128. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the process does not
comprise treating cellulosic fibers with an enzymatic
preparation.
[0200] 129. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the process further
comprises treating cellulosic fibers with an anionic surface
preparation.
[0201] 130. The process of clause 129, any other suitable clause,
or any combination of suitable clauses, wherein the anionic surface
preparation is an anionic polyacrylamide.
[0202] 131. The process of clause 129, any other suitable clause,
or any combination of suitable clauses, wherein the anionic surface
preparation is a copolymer of acrylamide and unsaturated carboxylic
acid monomers, being (meth)acrylic acid, maleic acid, crotonic
acid, itaconic acid, or any combination thereof.
[0203] 132. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the process does not
comprise treating cellulosic fibers with an anionic surface
preparation.
[0204] 133. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the container has a
box compression strength (BCT50) measured at 50% relative
humidity.
[0205] 134. The process of clause 133, any other suitable clause,
or any combination of suitable clauses, wherein the BCT50 is
greater than a comparative box compression strength (CBCT50)
measured at 50% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the dry strength chemistry
preparation and the wet strength chemistry preparation.
[0206] 135. The process of clause 133, any other suitable clause,
or any combination of suitable clauses, wherein the BCT50 is
greater than a comparative box compression strength (CBCT50)
measured at 50% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the dry strength chemistry
preparation.
[0207] 136. The process of clause 133, any other suitable clause,
or any combination of suitable clauses, wherein the BCT50 is
greater than a comparative box compression strength (CBCT50)
measured at 50% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the wet strength chemistry
preparation.
[0208] 137. The process of clause 133, any other suitable clause,
or any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in BCT50 for the container in
comparison to the comparative container.
[0209] 138. The process of clause 89, any other suitable clause, or
any combination of suitable clauses, wherein the container has a
box compression strength (BCT85) measured at 85% relative
humidity.
[0210] 139. The process of clause 138, any other suitable clause,
or any combination of suitable clauses, wherein the BCT85 is
greater than a comparative box compression strength (CBCT85)
measured at 85% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the dry strength chemistry
preparation and the wet strength chemistry preparation.
[0211] 140. The process of clause 138, any other suitable clause,
or any combination of suitable clauses, wherein the BCT85 is
greater than a comparative box compression strength (CBCT85)
measured at 85% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the dry strength chemistry
preparation.
[0212] 141. The process of clause 138, any other suitable clause,
or any combination of suitable clauses, wherein the BCT50 is
greater than a comparative box compression strength (CBCT85)
measured at 85% relative humidity of a comparative container
comprising comparative cellulose-based material made on the paper
machine at the basis weight and lacking the wet strength chemistry
preparation.
[0213] 142. The process of clause 138, any other suitable clause,
or any combination of suitable clauses, wherein the dry strength
chemistry preparation and the wet strength chemistry preparation
provide a synergistic increase in BCT85 for the container in
comparison to the comparative container.
EXAMPLES
Example 1
Paper Trial #1 [Mill A]
[0214] An exemplary cellulose-based material in accordance with
certain aspects of the present disclosure is provided in the
instant example. Evaluations in the instant example include
short-span compression strength (SCT), SCT Index, and Concora
values.
[0215] For the instant example, several different cellulose-based
materials with a basis weight of 36 were prepared and compared.
Preparation of the different cellulose-based materials included
varying the basis weight of the material, the presence of a wet
strength chemistry preparation, and the presence and amount of a
dry strength chemistry preparation.
[0216] The various cellulose-based materials with a basis weight of
36 were compared to other cellulose-based materials with a basis
weight of 40 or a basis weight of 45. The evaluations of the other
cellulose-based materials (i.e., with a basis weight of 40 or a
basis weight of 45) are based on average production runs at the
mill for Paper Trial #1.
[0217] The characteristics of the different cellulose-based
materials are presented in Table 1.
TABLE-US-00001 TABLE 1 Material Basis Wet Strength Dry Strength No.
Weight (dry lbs/ton) (dry lbs/ton) 1 36 8.5 0 2 36 4 4 3 36 4 8 4
40 0 0 5 40 3-4* 0 6 45 0 0 7 45 3-4* 0 *Average wet strength
added; modified as wet strength concentrations stabilized in the
system.
[0218] As an exemplary procedure, cellulose-based material can be
produced using an aqueous slurry comprising cellulosic fibers. The
general process for making cellulose-based material is well known
in the art and can utilize starting materials such as trees, logs,
and/or chips to provide the cellulosic fibers. Such starting
materials are heated in a "defibering" method and the resultant
cellulosic fibers are then further processed with water to form the
aqueous slurry. The general process for making cellulose-based
materials is described, for instance, in U.S. Pat. Nos. 7,648,772
and 7,682,486, both herein incorporated by reference in their
entireties.
[0219] For instance, virgin fibers, recycled fibers (e.g., old
corrugated containers, other recycled paper products, and the
like), or combinations thereof can be used in the aqueous slurry.
The aqueous slurry can also comprise, for example, water,
mechanical fibers (e.g., NSSC), ash content, and other materials
known in the art.
[0220] The wet strength chemistry preparation and the dry strength
chemistry preparation are then added to the aqueous slurry. The wet
strength chemistry preparation and the dry strength chemistry
preparation can be added to the aqueous slurry separately or
together and can also be added to the aqueous slurry in any
order.
[0221] Following the combination of ingredients, the aqueous slurry
is formed into a web and then dried to produce the cellulose-based
material.
[0222] The cellulose-based materials were evaluated for SCT values
according to the procedures of TAPPI 826, entitled "Short span
compression strength of containerboard." The SCT evaluation can
determine the edgewise compressive strength of cellulose-based
materials such as paperboard with a span-to-thickness ratio of 5 or
less (basis wt. 20 #/msf or greater.) A L&W 152 STFI Tester can
be utilized as equipment for the SCT evaluation.
[0223] The cellulose-based materials were evaluated for SCT Index
by calculating the average SCT value divided by the average weight
of the sample (i.e., basis weight). For basis weight
determinations, the procedures of TAPPI T 410, entitled "Grammage
of paper and paperboard (weight per unit area)," were utilized. For
instance, a Toledo Basis Weight Scale or Mettler analytical balance
can be utilized as equipment for the basis weight evaluation.
[0224] The cellulose-based materials were evaluated for Concora
values according to the procedures of TAPPI 809, entitled "Flat
crush of corrugating medium (CMT Test)." Testing of flat crush
resistance is necessary to prevent crushing the structure on the
corrugator or finishing equipment, and Concora evaluation allows
for testing prior to fabrication of board or containers from the
cellulose-based materials. Concora evaluation is also utilized for
determining fabrication efficiency.
[0225] A L&W SE 108 Sample Die Cutter, a fluter, and a L&W
Crust Tester code 248 can be utilized as equipment for the Concora
evaluation.
[0226] The evaluations and comparison of the different
cellulose-based materials are presented in Table 2.
TABLE-US-00002 TABLE 2 Material Basis Wet Dry SCT No. Weight
Strength Strength SCT Index Concora 1 36 8.5 0 19.4 0.545 65 2 36 4
4 21.1 0.596 80 3 36 4 8 22.0 0.621 88 4 40 0 0 19.8 0.508 66 5 40
3-4* 0 21.2 0.530 77 6 45 0 0 23 0.526 71 7 45 3-4* 0 22.9 0.515 82
*Average wet strength added; modified as wet strength
concentrations stabilized in the system.
[0227] As shown in Table 2, the cellulose-based material in
accordance with the present disclosure was superior than the
comparison cellulose-based materials. First, inclusion of a dry
strength chemistry preparation demonstrated an increase in SCT, SCT
Index, and Concora values compared to other cellulose-based
materials that did not include a dry strength chemistry
preparation.
[0228] In the instant example, the cellulose-based material in
accordance with the present disclosure, even when prepared using a
lower basis weight, demonstrated superior or similar SCT, SCT
Index, and Concora values compared to other cellulose-based
materials prepared with a higher basis weight. Thus,
cellulose-based material with a lower basis weight, when prepared
in accordance with the present disclosure, performs better than
comparative cellulose-based material with a higher basis weight.
This improved performance provides an advantage in that
cellulose-based material prepared in accordance with the present
disclosure uses at least 10% less material to generate a product
with desirable characteristics compared to traditional paper-making
procedures.
Example 2
Paper Trial #2 [Mill B]
[0229] An exemplary cellulose-based material in accordance with
certain aspects of the present disclosure is provided in the
instant example. Evaluations in the instant example include
short-span compression strength (SCT), SCT Index, and Concora
values.
[0230] For the instant example, different cellulose-based materials
with a basis weight of 36 were prepared and compared. Preparation
of the different cellulose-based materials included varying the
basis weight of the material, the presence of a wet strength
chemistry preparation, and the presence and amount of a dry
strength chemistry preparation.
[0231] The various cellulose-based materials with a basis weight of
36 were compared to other cellulose-based materials with a basis
weight of 40 or a basis weight of 45. The evaluations of the other
cellulose-based materials (i.e., with a basis weight of 40 or a
basis weight of 45) are based on average production runs at a
similar mill to Paper Trial #2.
[0232] The characteristics of the different cellulose-based
materials are presented in Table 3.
TABLE-US-00003 TABLE 3 Material Basis Wet Strength Dry Strength No.
Weight (dry lbs/ton) (dry lbs/ton) 1 36 3.5 0 2 36 3.5 4 3 40 0 0 4
40 3-4* 0 5 45 0 0 6 45 3-4* 0 *Average wet strength added;
modified as wet strength concentrations stabilized in the
system.
[0233] The process for preparing the cellulose-based materials for
the instant example were similar to those for Example 1. Further,
the methods of evaluating SCT, SCT Index, and Concora values were
identical to those in Example 1.
[0234] The evaluations and comparison of the different
cellulose-based materials are presented in Table 4.
TABLE-US-00004 TABLE 4 Material Basis Wet Dry SCT No. Weight
Strength Strength SCT Index Concora 1 36 3.5 0 19.6 0.554 68 2 36
3.5 4 21.9 0.617 70 3 40 0 0 19.8 0.508 66 4 40 3-4* 0 21.2 0.530
77 5 45 0 0 23 0.526 71 6 45 3-4* 0 22.9 0.515 82 *Average wet
strength added; modified as wet strength concentrations stabilized
in the system.
[0235] As shown in Table 4, the cellulose-based material in
accordance with the present disclosure was superior than the
comparison cellulose-based materials. First, inclusion of a dry
strength chemistry preparation demonstrated an increase in SCT, SCT
Index, and Concora values compared to other cellulose-based
materials that did not include a dry strength chemistry
preparation.
[0236] In the instant example, the cellulose-based material in
accordance with the present disclosure, even when prepared using a
lower basis weight, demonstrated superior or similar SCT, SCT
Index, and Concora values compared to other cellulose-based
materials prepared with a higher basis weight. Thus,
cellulose-based material with a lower basis weight, when prepared
in accordance with the present disclosure, performs better than
comparative cellulose-based material with a higher basis weight.
This improved performance provides an advantage in that
cellulose-based material prepared in accordance with the present
disclosure uses at least 10% less material to generate a product
with desirable characteristics compared to traditional paper-making
procedures.
Example 3
Paper Trial #3 [Mill C]
[0237] An exemplary cellulose-based material in accordance with
certain aspects of the present disclosure is provided in the
instant example. Evaluations in the instant example include
short-span compression strength (SCT), SCT Index, and Concora
values.
[0238] For the instant example, several different cellulose-based
materials with a basis weight of 36 were prepared and compared.
Preparation of the different cellulose-based materials included
varying the basis weight of the material, the presence of a wet
strength chemistry preparation, and the presence and amount of a
dry strength chemistry preparation.
[0239] The various cellulose-based materials with a basis weight of
36 were compared to other cellulose-based materials with a basis
weight of 40 or a basis weight of 45. The evaluations of the other
cellulose-based materials (i.e., with a basis weight of 40 or a
basis weight of 45) are based on average production runs at the
mill for Paper Trial #3.
[0240] The characteristics of the different cellulose-based
materials are presented in Table 5.
TABLE-US-00005 TABLE 5 Material Basis Wet Strength Dry Strength No.
Weight (dry lbs/ton) (dry lbs/ton) 1 36 3.2 0 2 36 3.2 4 3 36 3.2 8
4 40 0 0 5 40 3-4* 0 6 45 0 0 7 45 3-4* 0 *Average wet strength
added; modified as wet strength concentrations stabilized in the
system.
[0241] The process for preparing the cellulose-based materials for
the instant example were similar to those for Example 1. Further,
the methods of evaluating SCT, SCT Index, and Concora values were
identical to those in Example 1.
[0242] The evaluations and comparison of the different
cellulose-based materials are presented in Table 6.
TABLE-US-00006 TABLE 6 Material Basis Wet Dry SCT No. Weight
Strength Strength SCT Index Concora 1 36 3.2 0 19.5 0.559 65 2 36
3.2 4 21.2 0.592 73 3 36 3.2 8 22.5 0.628 76 4 40 0 0 20.4 0.523 74
5 40 3-4* 0 20.6 0.521 78.5 6 45 0 0 23.5 0.533 77 7 45 3-4* 0 24.3
0.546 84 *Average wet strength added; modified as wet strength
concentrations stabilized in the system.
[0243] As shown in Table 6, the cellulose-based material in
accordance with the present disclosure was superior than the
comparison cellulose-based materials. First, inclusion of a dry
strength chemistry preparation demonstrated an increase in SCT, SCT
Index, and Concora values compared to other cellulose-based
materials that did not include a dry strength chemistry
preparation.
[0244] In the instant example, the cellulose-based material in
accordance with the present disclosure, even when prepared using a
lower basis weight, demonstrated superior or similar SCT, SCT
Index, and Concora values compared to other cellulose-based
materials prepared with a higher basis weight. Thus,
cellulose-based material with a lower basis weight, when prepared
in accordance with the present disclosure, performs better than
comparative cellulose-based material with a higher basis weight.
This improved performance provides an advantage in that
cellulose-based material prepared in accordance with the present
disclosure uses at least 10% less material to generate a product
with desirable characteristics compared to traditional paper-making
procedures.
Example 4
Paper Trial #4 [Mill B]
[0245] An exemplary cellulose-based material in accordance with
certain aspects of the present disclosure is provided in the
instant example. Evaluations in the instant example include
short-span compression strength (SCT), SCT Index, and Concora
values.
[0246] For the instant example, several different cellulose-based
materials with a basis weight of 23 were prepared and compared.
Preparation of the different cellulose-based materials included
varying the basis weight of the material, the presence of a wet
strength chemistry preparation, and the presence and amount of a
dry strength chemistry preparation.
[0247] The various cellulose-based materials with a basis weight of
23 were compared to other cellulose-based materials with a basis
weight of 26 or a basis weight of 30. The evaluations of the other
cellulose-based materials (i.e., with a basis weight of 26 or a
basis weight of 30) are based on average production runs at the
mill for Paper Trial #4.
[0248] The characteristics of the different cellulose-based
materials are presented in Table 7.
TABLE-US-00007 TABLE 7 Material Basis Wet Strength Dry Strength No.
Weight (dry lbs/ton) (dry lbs/ton) 1 23 4 0 2 23 4 2 3 23 4 4 4 23
4 8 5 26 0 0 6 30 0 0
[0249] The process for preparing the cellulose-based materials for
the instant example were similar to those for Example 1. Further,
the methods of evaluating SCT, SCT Index, and Concora values were
identical to those in Example 1.
[0250] The evaluations and comparison of the different
cellulose-based materials are presented in Table 8.
TABLE-US-00008 TABLE 8 Material Basis Wet Dry SCT No. Weight
Strength Strength SCT Index Concora 1 23 4 0 13.4 0.561 45 2 23 4 2
14.2 0.592 51 3 23 4 4 13.9 0.580 53 4 23 4 8 16.0 0.661 54 5 26 0
0 12.9 0.520 48 6 30 0 0 15.0 0.521 56
[0251] As shown in Table 8, the cellulose-based material in
accordance with the present disclosure was superior than the
comparison cellulose-based materials. First, inclusion of a dry
strength chemistry preparation demonstrated an increase in SCT, SCT
Index, and Concora values compared to other cellulose-based
materials that did not include a dry strength chemistry
preparation.
[0252] In the instant example, the cellulose-based material in
accordance with the present disclosure, even when prepared using a
lower basis weight, demonstrated superior or similar SCT, SCT
Index, and Concora values compared to other cellulose-based
materials prepared with a higher basis weight. Thus,
cellulose-based material with a lower basis weight, when prepared
in accordance with the present disclosure, performs better than
comparative cellulose-based material with a higher basis weight.
This improved performance provides an advantage in that
cellulose-based material prepared in accordance with the present
disclosure uses at least 10% less material to generate a product
with desirable characteristics compared to traditional paper-making
procedures.
Example 5
Container Trial #1 [Plant D]
[0253] An exemplary container in accordance with certain aspects of
the present disclosure is provided in the instant example.
Evaluations in the instant example include box compression strength
measured at 50% relative humidity (BCT50) and box compression
strength measured at 85% relative humidity (BCT85).
[0254] For the instant example, different containers were prepared
using various cellulose-based materials and then compared.
Preparation of the containers comprised different cellulose-based
materials that varied the basis weight of the material and the
presence and amount of a dry strength chemistry preparation.
[0255] The same liner rolls (56 lb liner) were utilized for each
container from the various mill containers.
[0256] The characteristics of the different containers are
presented in Table 9.
TABLE-US-00009 TABLE 9 Container Basis Wet Strength Dry Strength
No. Identifier Weight (dry lbs/ton) (dry lbs/ton) 1 Reg CG 36 36
3.5 0 [Plant B] 2 CG 2.0 36 36 3.5 4 [Plant B] 3 Reg CG 36 36 3.2 0
[Plant C] 4 CG 2.0 36 36 3.2 4 [Plant C] 5 Reg CG 23 23 4 0 [Plant
B] 6 CG 2.0 23 23 4 4 [Plant B]
[0257] Using the various cellulose-based materials, a Corrugator
can be used to produce corrugated sheets. A Corrugator can range
from about 250 to about 400 feet long with a width range from about
67 inches to about 132 inches. Typical Corrugators can include a
Single Facer section wherein the top liner can be adjoined with
starch to a medium that has been corrugated via corrugating rolls.
Corrugators are known to the skilled artisan and can include, for
example, those manufactured by United, BHS, MHI, Fosber, and the
like.
[0258] The second side liner can then be adhered using starch to
the single face sheet in a "Doublefacer" or "Doublebacker"
apparatus. The resultant combined board sheet can then be cut into
specified widths and can be scored for folding in the
container-making process. A cutoff knife can be used to cut the
container to the desired length. Typically, a Corrugator can
operate at a speed from about 600 to about 1200 feet per minute
(fpm) and can be varied according to the general knowledge in the
art.
[0259] Thereafter, combined board sheets can then be processed
through a primary finishing process, depending on the desired end
use. For instance, a Flexo Folder Gluer finishing process or Die
Cutting equipment could be utilized. A Flexo Folder Gluer can
include a feed section, print section, slotter-scorer, and a folder
gluer section. A die cutter can be, for example, rotary or platen
(flatbed) and produces slotted carton containers that are typically
not glued.
[0260] The cellulose-based materials can be evaluated for BCT50
values according to the procedures of TAPPI T-804 om-06, entitled
"Compression Test of Fiberboard Shipping Containers." The
containers can be conditioned at a temperature of 73.degree. F. and
50% relative humidity for the BCT50 evaluation, as it is important
to provide uniform moisture content for the testing (see T402,
entitled "Standard conditioning and testing atmospheres for paper,
board, pulp hand sheets, and related products").
[0261] First, the containers can be subjected to preconditioning in
a preconditioning chamber. Temperature and humidity preconditioning
can be performed overnight or for at least 2 hours (e.g., liner,
medium, bag, or other cellulose-based materials), at least 7 hours
(e.g., corrugated board, solid fiber, or open containers), at least
14 hours (e.g., sealed containers), or 72 hours (e.g., vapor
resistant (waxed) board and containers).
[0262] Thereafter, containers are removed from the preconditioning
chamber and placed into conditioning. Temperature and humidity
conditioning can be performed overnight or for at least 4 hours
(e.g., liner, medium, bag, or other cellulose-based materials), at
least 8 hours (e.g., corrugated board, solid fiber, or open
containers), at least 16 hours (e.g., sealed containers), or 72
hours (e.g., vapor resistant (waxed) board and containers).
[0263] The BCT50 evaluation can measure the ability of containers,
such as corrugated or solid fiber shipping containers, to resist
external compressive forces. A higher BCT50 value is desirable
because external compressive forces may be encountered in stacking
the containers or in transporting the containers.
[0264] An Emerson Tester Model 6210 and/or an Emerson Model 8510
can be utilized as compression tester equipment for the BCT50
evaluation. The container can be placed at the center of the bottom
platen of the compression tester. Then, a preload can be applied to
the container, for instance 50 pounds on a singlewall container,
100 pounds on a doublewall container, or 500 pounds on bulk bins.
The load can continue to be applied to the container at the rate of
0.5 inches (13+/-2.5 mm) until failure occurs, as evidenced by one
or both of i) falling back from maximum load of 25% or ii)
deflection exceeding 0.75 inches or greater. Thereafter, the
maximum compression and deflection or the compression at the
specified deflection can be recorded for the evaluated
container.
[0265] BCT85 evaluations are conducted in a similar manner as the
BCT50 evaluations, except that the containers can be conditioned at
a temperature of 40.degree. F. and 85% relative humidity prior to
compression testing.
[0266] The evaluations and comparison of the containers prepared
with different cellulose-based materials are presented in Table
10.
TABLE-US-00010 TABLE 10 Container Basis Wet Dry No. Weight Strength
Strength BCT50 BCT85 1 36 3.5 0 1009 549 2 36 3.5 4 1102 642 3 36
3.2 0 1076 586 4 36 3.2 4 1006 636 5 23 4 0 501 317 6 23 4 4 547
345
[0267] As shown in Table 10, the containers in accordance with the
present disclosure were superior than the comparison containers.
Inclusion of a dry strength chemistry preparation in the
cellulose-based materials that prepared the containers demonstrated
an increase in BCT50 and BCT85 values compared to the comparison
containers made with cellulose-based materials that did not include
a dry strength chemistry preparation.
Example 6
Container Trial #2 [Plant A]
[0268] An exemplary container in accordance with certain aspects of
the present disclosure is provided in the instant example.
Evaluations in the instant example include short-span compression
strength (SCT), SCT Index, box compression strength measured at 50%
relative humidity (BCT50) and box compression strength measured at
85% relative humidity (BCT85).
[0269] For the instant example, different containers were prepared
using various cellulose-based materials and then compared.
Preparation of the containers comprised different cellulose-based
materials that varied the basis weight of the material and the
presence and amount of a dry strength chemistry preparation. The
process for preparing the containers for the instant example were
similar to those for Example 5.
[0270] The characteristics of the different containers are
presented in Table 11.
TABLE-US-00011 TABLE 11 Container Basis Wet Strength Dry Strength
No. Weight (dry lbs/ton) (dry lbs/ton) 1 35.63 8.5 0 2 35.40 4 4 3
35.40 4 8
[0271] The evaluations and comparison of the containers prepared
with different cellulose-based materials are presented in Table
12.
TABLE-US-00012 TABLE 12 Container Basis Wet Dry SCT SCT Index BCT %
No. Weight Strength Strength (lbf/in) (SCT/BW) BCT50 BCT85 Loss 1
35.63 8.5 0 19.4 0.54 987.6 753.2 23.7 2 35.40 4 4 21.0 0.59 1037.7
882.2 15.0 3 35.40 4 8 22.0 0.62 1080.9 908.4 16.0
[0272] As shown in Table 12, the containers in accordance with the
present disclosure were superior than the comparison containers.
Inclusion of a dry strength chemistry preparation in the
cellulose-based materials that prepared the containers demonstrated
an increase in SCT and SCT Index values compared to the comparison
containers made with cellulose-based materials that did not include
a dry strength chemistry preparation. Furthermore, inclusion of a
dry strength chemistry preparation in the cellulose-based materials
that prepared the containers demonstrated an increase in BCT50 and
BCT85 values compared to the comparison containers made with
cellulose-based materials that did not include a dry strength
chemistry preparation.
Example 7
Container Trial #3 [Plant C]
[0273] An exemplary container in accordance with certain aspects of
the present disclosure is provided in the instant example.
Evaluations in the instant example include short-span compression
strength (SCT), SCT Index, box compression strength measured at 50%
relative humidity (BCT50), and box compression strength measured at
85% relative humidity (BCT85).
[0274] For the instant example, different containers were prepared
using various cellulose-based materials and then compared.
Preparation of the containers comprised different cellulose-based
materials that varied the basis weight of the material and the
presence and amount of a dry strength chemistry preparation. The
process for preparing the containers for the instant example were
similar to those for Example 5.
[0275] The characteristics of the different containers are
presented in Table 13.
TABLE-US-00013 TABLE 13 Container Basis Wet Strength Dry Strength
No. Weight (dry lbs/ton) (dry lbs/ton) 1 34.4 0 0 2 34.9 3.2 0 3
35.8 3.2 4 4 34.9 3.2 8
[0276] The process for preparing the containers for the instant
example were similar to those for Example 6. Further, the methods
of evaluating SCT, SCT Index, BCT50, and BCT85 values were
identical to those in Example 6.
[0277] The evaluations and comparison of the containers prepared
with different cellulose-based materials are presented in Table
14.
TABLE-US-00014 TABLE 14 Container Basis Wet Dry SCT SCT Index BCT %
No. Weight Strength Strength (lbf/in) (SCT/BW) BCT50 BCT85 Loss 1
34.4 0 0 19.5 0.57 1005.8 567.6 43.6 2 34.9 3.2 0 19.5 0.56 1076.7
586.2 45.6 3 35.8 3.2 4 21.2 0.59 1006.4 636.2 36.8 4 34.9 3.2 8
22.5 0.64 1087.2 679.3 37.5
[0278] As shown in Table 14, the containers in accordance with the
present disclosure were superior than the comparison containers.
Inclusion of a dry strength chemistry preparation in the
cellulose-based materials that prepared the containers demonstrated
an increase in SCT and SCT Index values compared to the comparison
containers made with cellulose-based materials that did not include
a dry strength chemistry preparation. Furthermore, inclusion of a
dry strength chemistry preparation in the cellulose-based materials
that prepared the containers demonstrated an increase in BCT50 and
BCT85 values compared to the comparison containers made with
cellulose-based materials that did not include a dry strength
chemistry preparation.
Example 8
Container Trial #4 [Plant B]
[0279] An exemplary container in accordance with certain aspects of
the present disclosure is provided in the instant example.
Evaluations in the instant example include short-span compression
strength (SCT), SCT Index, box compression strength measured at 50%
relative humidity (BCT50), and box compression strength measured at
85% relative humidity (BCT85).
[0280] For the instant example, different containers were prepared
using various cellulose-based materials and then compared.
Preparation of the containers comprised different cellulose-based
materials that varied the basis weight of the material, the
presence of a wet strength chemistry preparation, and the presence
and amount of a dry strength chemistry preparation. The process for
preparing the containers for the instant example were similar to
those for Example 5.
[0281] The characteristics of the different containers are
presented in Table 15.
TABLE-US-00015 TABLE 15 Container Basis Wet Strength Dry Strength
No. Weight (dry lbs/ton) (dry lbs/ton) 1 35.4 3.5 0 2 35.5 3.5 4 3
23.9 4 0 4 24.0 4 2 5 24.0 4 4 6 24.2 4 8 7 23.6 0 4
[0282] The process for preparing the containers for the instant
example were similar to those for Example 6. Further, the methods
of evaluating SCT, SCT Index, BCT50, and BCT85 values were
identical to those in Example 6.
[0283] The evaluations and comparison of the containers prepared
with different cellulose-based materials are presented in Table
16.
TABLE-US-00016 TABLE 16 % Box Strength Container Basis Wet Dry SCT
SCT Index BCT % Improvement at No. Weight Strength Strength
(lbf/in) (SCT/BW) BCT50 BCT85 Loss High Humidity 1 35.4 3.5 0 19.6
0.55 1009.9 549.3 45.6 2 35.5 3.5 4 21.9 0.62 1101.8 642.3 41.7 3
23.9 4 0 13.4 0.56 501.0 317.2 36.7 0 4 24.0 4 2 14.2 0.59 535.9
333.5 37.8 4.89 5 24.0 4 4 13.9 0.58 546.7 345.0 36.9 8.06 6 24.2 4
8 16.0 0.66 532.9 341.6 35.9 7.14 7 23.6 0 4 13.8 0.58 520.5 327.4
37.1 3.12
[0284] As shown in Table 16, the containers in accordance with the
present disclosure were superior than the comparison containers.
Inclusion of a dry strength chemistry preparation plus a wet
strength preparation in the cellulose-based materials that prepared
the containers demonstrated an increase in SCT and SCT Index values
compared to the comparison containers made with cellulose-based
materials that did not include a dry strength chemistry
preparation. Furthermore, inclusion of a dry strength chemistry
preparation plus a wet strength preparation in the cellulose-based
materials that prepared the containers demonstrated an increase in
BCT50 and BCT85 values compared to the comparison containers made
with cellulose-based materials that did not include a dry strength
chemistry preparation. FIG. 2 depicts that a higher BCT at 85%
relative humidity RH was observed for containers prepared using a
combination of a dry strength chemistry preparation plus a wet
strength preparation in the cellulose-based materials.
[0285] Furthermore, a synergistic effect in strength improvement
was observed for containers prepared using a combination of a dry
strength chemistry preparation plus a wet strength preparation in
the cellulose-based materials. These effects as demonstrated by
Table 16, and as depicted in FIG. 3, were unexpected.
Example 9
Paper Trial #5
[0286] An exemplary cellulose-based material in accordance with
certain aspects of the present disclosure is provided in the
instant example. Evaluations in the instant example include
short-span compression strength (SCT), SCT Index, and Concora
values.
[0287] For the instant example, several different cellulose-based
materials were prepared and compared. Preparation of the different
cellulose-based materials included varying the basis weight of the
material, the presence and amount of a wet strength chemistry
preparation, and the presence and amount of a dry strength
chemistry preparation.
[0288] The characteristics of the different cellulose-based
materials are presented in Table 17.
TABLE-US-00017 TABLE 17 Material Basis Wet Strength Dry Strength
No. Weight (dry lbs/ton) (dry lbs/ton) 1 37.89 0 0 2 37.60 4 0 3
37.83 8 0 4 36.22 0 4 5 36.43 0 6 6 36.61 0 8 7 37.06 8 4 8 37.14 8
8
[0289] The process for preparing the cellulose-based materials for
the instant example were similar to those for Example 1. Further,
the methods of evaluating SCT, SCT Index, and related calculations
were identical to those in Example 1.
[0290] The evaluations and comparison of the different
cellulose-based materials are presented in Table 18.
TABLE-US-00018 TABLE 18 Material Basis Wet Strength Dry Strength
SCT SCT (BW normalized % Strength No. Weight (dry lbs/ton) (dry
lbs/ton) SCT Index to 36 lbs/1000 ft.sup.2) Improvement 1 37.89 0 0
19.28 0.51 18.36 0.00 2 37.60 4 0 19.15 0.51 18.36 0.00 3 37.83 8 0
20.29 0.54 19.44 5.88 4 36.22 0 4 19.32 0.53 19.08 3.92 5 36.43 0 6
18.57 0.51 18.36 0.00 6 36.61 0 8 19.15 0.52 18.72 1.96 7 37.06 8 4
20.68 0.56 20.16 9.80 8 37.14 8 8 21.32 0.57 20.52 11.76
[0291] As shown in Table 18, the cellulose-based material in
accordance with the present disclosure was superior than the
comparison cellulose-based materials. First, inclusion of a dry
strength chemistry preparation plus a wet strength chemistry
preparation demonstrated an increase in SCT and SCT Index compared
to other cellulose-based materials that did not include a dry
strength chemistry preparation. Second, as shown in FIG. 4,
inclusion of a dry strength chemistry preparation plus a wet
strength chemistry preparation demonstrated an increase in SCT when
normalized to 36 lbs/1000 ft.sup.2 compared to other
cellulose-based materials that did not include a dry strength
chemistry preparation.
[0292] Furthermore, a synergistic effect in strength improvement
was observed for containers prepared using a combination of a dry
strength chemistry preparation plus a wet strength preparation in
the cellulose-based materials. These effects as demonstrated by
Table 18, and as depicted in FIG. 5, were unexpected.
* * * * *