Mouldable fibrous sheet and a production method thereof

Patent metadata

Field	Value
Publication number	US-12146007-B2
Application number	US-201917299986-A
Country	US
Kind code	B2
Filing date	Dec 4, 2019
Priority date	Dec 5, 2018
Publication date	Nov 19, 2024
Grant date	Nov 19, 2024

Abstract

The present invention relates to a web of fibrous cellulosic material derived from wood pulp, said web being suitable for three-dimensional moulding to form a packaging product, wherein the web comprises >40 wt % of soft wood chemical pulp and at least one strength enhancement agent, wherein the web has a grammage less than 400 g/m 2 , and wherein the cellulose fibers of said soft wood chemical pulp comprise a fiber curl of >9%.

First claim

The invention claimed is:

1. A web of fibrous cellulosic material derived from wood pulp, said web being suitable for three-dimensional moulding to form a packaging product, wherein the web comprises:
>40 wt % of soft wood chemical pulp comprising cellulose fibers, and
at least one strength enhancement agent,
wherein the web has a grammage less than 400 g/m 2 , and
wherein the cellulose fibers of said soft wood chemical pulp comprises a fiber curl of >9%,
wherein said strength enhancement agent comprises a natural binder agent in the form of a starch, at an amount of 10-75 kg/tn.

2. The web according to claim 1 , wherein the web comprises a density between 600-875 kg/m 3 .

3. The web according to claim 1 , further comprising:
between 0.3-10% by weight of microfibrillated cellulose, based on a total fiber weight of the web.

4. The web according to claim 1 , wherein said starch is selected from a group consisting of: native starch, cooked starch, cationic starch, native chemically modified starch, physically modified polymer grafted starch, enzyme modified starch, anionic starch, amphoteric starch, crosslinked starch, pre-gelled starch, and swelled starch.

5. The web according to claim 1 , wherein said web has been subjected to hydrophobic sizing.

6. The web according to claim 1 , wherein the web comprises a geometrical mean tensile strength index of >50 Nm/g.

7. The web according to claim 1 , wherein the web comprises a geometrical mean stretch, referring to a percentage elongation of the web before rupture, of >4% as measured by standard tensile test ISO 1924-2 with a span length of 20 mm and a test speed of 2 mm/minute.

8. The web according to claim 1 , wherein the web comprises a stretch, referring to a percentage elongation of the web before rupture, in the cross direction (CD), of >6.5% as measured by standard tensile test ISO 1924-2 with a span length of 20 mm and a test speed of 2 mm/minute.

9. A multiply laminate material comprising:
at least two layers,
wherein one layer of the least two layers is a web according to claim 1 .

10. The multiply laminate material according to claim 9 , further comprising:
at least one barrier layer forming a barrier against liquid, gas, aroma, or grease, oil and/or fat.

11. A method for producing a molded, three-dimensional fiber-based product, comprising at least the steps of:
providing a fibrous cellulosic web material according to claim 1 ;
providing a forming tool with at least one three-dimensional mold; and
using the forming tool for forming a three-dimensional product out of the fiber-based material.

12. The method according to claim 11 , wherein said forming is selected from a group consisting of: vacuum forming, thermoforming, cold forming, pressing, or hydroforming.

13. A three-dimensional, fiber-based product obtained by the method according to claim 11 .

14. A three-dimensional, fiber-based product comprising:
a laminate with multiple layers,
whereof at least one layer of said multiple layers is made of the web of fibrous cellulosic material according to claim 1 .

15. The web according to claim 1 , wherein the web comprises a three-dimensional packaging product.

Assignees

• Stora Enso Oyj

Inventors

• Heiskanen Isto
• Hiltunen Mari
• Ruohoniemi Nina
• Lammi Titta
• Ribu Ville
• Lindfors Tim
• Räsänen Jari

Classifications

• C08B31/00

  Preparation of derivatives of starch (derivatives of amylose C08B33/00; derivatives of amylopectin C08B35/00) · CPC title

• C08B30/10

  Working-up residues from the starch extraction {, e.g. potato peel or steeping water}, including pressing water from the starch-extracted material · CPC title

• B29K2003/00

  Use of starch or derivatives as moulding material · CPC title

• B29K2001/00

  Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material · CPC title

• B29C64/118

  using filamentary material being melted, e.g. fused deposition modelling [FDM] · CPC title