Method for making paper product

Patent metadata

Field	Value
Publication number	US-10731296-B2
Application number	US-201916562524-A
Country	US
Kind code	B2
Filing date	Sep 6, 2019
Priority date	Jun 28, 2016
Publication date	Aug 4, 2020
Grant date	Aug 4, 2020

Abstract

A paperboard, sidewall, and disposable cup made from about 70 wt % to about 100 wt % of recycled fiber. The paperboard can include about 70 wt % to about 100 wt % of recycled fiber, based on the total weight of the fiber. The paperboard can have a board thickness of about 14 mil to about 20 mil, an apparent density of less than about 11.5 lbs/3,000 ft2/mil, a CD Taber Stiffness of about 50 g*cm or more, and a MD/CD Taber Stiffness ratio of 1.0 to 3.0, and can be used to make recycled cups having sufficient strength and rigidity properties that rival cups made from virgin fibers.

First claim

What is claimed is:

1. A method for making a paperboard, comprising:
introducing a pulp stock onto a meshed surface, the pulp stock comprising water and fiber, wherein the fiber comprises about 70 wt % to about 100 wt % of recycled fiber;
pressing the pulp stock to remove at least a portion of the water through the meshed surface;
forming a ply of the pressed fibers; and
drying the ply of pressed fibers to provide a paperboard having a board thickness of about 14 mil to about 22 mil; an apparent density of less than about 15 lbs/3,000 ft 2 /mil; a CD Taber Stiffness of about 50 g*cm or more; and a MD/CD Taber Stiffness ratio of 1.0 to 3.0.

2. The method of claim 1 , further comprising applying a vacuum to pull water from the pulp stock.

3. The method of claim 1 , further comprising applying a coating at least partially on a first side of the paperboard, wherein the surface coating comprises clay, starch, sizing, or a mixture thereof.

4. The method of claim 3 , wherein the coating is applied by extrusion coating, co-extrusion coating, lamination, or any combination thereof.

5. The method of claim 1 , wherein the recycled fiber is substantially derived from old corrugated containers.

6. The method of claim 1 , wherein at least 25% of the recycled fiber is post-consumer recycled fiber.

7. The method of claim 1 , wherein the paperboard comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber.

8. The method of claim 1 , wherein the apparent density is less than about 13 lbs/3,000 ft 2 /mil.

9. The method of claim 1 , wherein the apparent density is less than about 11.5 lbs/3,000 ft 2 /mil.

10. The method of claim 1 , wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more.

11. The method of claim 1 , wherein the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5.

12. The method of claim 1 , wherein the disposable consumer products are plates.

13. The method of claim 1 , wherein the disposable consumer products are bowls.

14. The method of claim 1 , wherein the disposable consumer products are cups.

15. A method for making a disposable paper product, comprising:
introducing a pulp stock onto a meshed surface, the pulp stock comprising water and fiber, wherein the fiber comprises about 70 wt % to about 100 wt % of recycled fiber;
pressing the pulp stock to remove at least a portion of the water through the meshed surface;
forming a ply of the pressed fibers;
drying the ply of pressed fibers to provide a paperboard having a board thickness of about 14 mil to about 22 mil; an apparent density of less than about 15 lbs/3,000 ft 2 /mil; a CD Taber Stiffness of about 50 g*cm or more; and a MD/CD Taber Stiffness ratio of 1.0 to 3.0;
cutting the paperboard to provide a paperboard substrate; and
forming a paper product from the paperboard substrate.

16. The method of claim 15 , further comprising applying a layer of low density polyethylene at least partially on at least one side of the paperboard before forming into the paper product.

17. The method of claim 15 , further comprising applying a layer of oil resistant material at least partially on at least one side of the paperboard before forming into the paper product.

18. The method of claim 17 , wherein the oil resistant material comprises low density polyethylene (LDPE) or an acrylic emulsion polymer.

19. The method of claim 17 , wherein the oil resistant material comprises an acrylic emulsion polymer.

20. The method of claim 15 , wherein the recycled fiber is substantially derived from old corrugated containers.

21. The method of claim 15 , wherein at least 25% of the recycled fiber is post-consumer recycled fiber.

22. The method of claim 15 , wherein the paperboard comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber.

23. The method of claim 15 , wherein the apparent density is less than about 13 lbs/3,000 ft 2 /mil.

24. The method of claim 15 , wherein the cross direction (CD) Taber Stiffness is 75 g-cm or more, and the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5.

25. The method of claim 15 , wherein the paper product is a plate.

26. The method of claim 15 , wherein the paper product is a bowl.

27. The method of claim 15 , wherein the paper product is a cup.

28. A method for making a disposable paper product, comprising:
introducing a pulp stock onto a meshed surface, the pulp stock comprising water and fiber, wherein the fiber comprises about 70 wt % to about 100 wt % of recycled fiber;
pressing the pulp stock to remove at least a portion of the water through the meshed surface;
forming a ply of the pressed fibers;
drying the ply of pressed fibers to provide a paperboard having a board thickness of about 14 mil to about 22 mil; an apparent density of less than about 15 lbs/3,000 ft 2 /mil; a CD Taber Stiffness of about 50 g*cm or more; and a MD/CD Taber Stiffness ratio of 1.0 to 3.0;
applying a first coating at least partially on at least one side of the paperboard;
applying a second coating at least partially on at least one side of the paperboard;
cutting the coated paperboard to provide a coated paperboard blank; and
forming a paper product from the coated paperboard blank.

29. The method of claim 28 , wherein the first coating comprises one or more polyolefins, one or more clays, or one or more waxes.

30. The method of claim 28 , wherein the second coating comprises one or more polyolefins, one or more clays, or one or more waxes.

31. The method of claim 28 , wherein the first coating and the second coating are the same or different, and wherein the first and second coatings are applied directly to the paperboard or one over the other.

32. The method of claim 28 , wherein the recycled fiber is substantially derived from old corrugated containers.

33. The method of claim 28 , wherein at least 25% of the recycled fiber is post-consumer recycled fiber.

34. The method of claim 28 , wherein the coated paperboard blank comprises 75 wt % to 90 wt % of the recycled fiber and less than 25 wt % of virgin fiber.

35. The method of claim 28 , wherein the apparent density is less than about 12 lbs/3,000 ft 2 /mil, the cross direction (CD) Taber Stiffness is 75 g-cm or more, and the MD/CD Taber Stiffness ratio is about 1.0 to about 2.5.

36. The method of claim 28 , wherein the paper product is a plate.

37. The method of claim 28 , wherein the paper product is a bowl.

38. The method of claim 28 , wherein the paper product is a cup.

Assignees

• Gpcp Ip Holdings Llc

Inventors

• Knauf Gary Harold
• Pounder Joseph

Classifications

• B65D85/816

  into which liquid is added {and the resulting preparation is retained}, e.g. cups preloaded with powder or dehydrated food · CPC title

• B65D81/3865

  drinking cups or like containers · CPC title

• D21H19/84

  on both sides of the substrate · CPC title

• D21H11/14 Primary

  Secondary fibres (working-up waste paper D21C5/02) · CPC title

• B65D3/06

  essentially conical or frusto-conical · CPC title