AU2016203734B2 - Paper sheet and a process for the manufacture thereof - Google Patents
Paper sheet and a process for the manufacture thereof Download PDFInfo
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- AU2016203734B2 AU2016203734B2 AU2016203734A AU2016203734A AU2016203734B2 AU 2016203734 B2 AU2016203734 B2 AU 2016203734B2 AU 2016203734 A AU2016203734 A AU 2016203734A AU 2016203734 A AU2016203734 A AU 2016203734A AU 2016203734 B2 AU2016203734 B2 AU 2016203734B2
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Abstract
The present invention relates to a paper sheet and a process for
making the paper sheet in which the paper sheet includes nano
particles.
7809702_1 (GHMatters) P103274.AU 3/06/16
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Description
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The present invention relates to a paper sheet and a process of
making the paper sheet. In particular, the present invention
relates to a paper sheet having improved performance, such as
any one or a combination of improved bending stiffness, or
improved creep resistance to buckling under cyclic or high
humidity conditions.
The bending stiffness and creep resistance of a sheet of paper
is dependent on a number of factors including the weight (or
grammage of the paper), the type of fibres used and the amount
of starch added to the sheet. For example, the paper sheets
used to produce paper based packaging typically have a starch
content in the range from 5 to 10%wt. Both chemically modified
and unmodified starches can be used to improve the stiffness and
strength of paper.
Depending on the product being produced, silicon or compositions
containing silicon acting as sizing agents may also be added to
increase the hydrophobicity of the paper. The starch material
together with the sizing agents help to give the necessary
stiffness.
Once the paper sheet has been fully formed and dried, the sheet
may also be treated in a coating process to enhance the visual
appearance of the sheet, or to laminate the sheet to other
materials. For instance, polymeric films and metallised foils
have been laminated to the sheet, and in other instances clay
has been applied to the outer face of the sheet to form a smooth
high gloss surface. The clay may also contribute significantly
to the weight of the sheet.
17375687_1 (GHMatters) P103274.AU 1/02/21
In essence, the clay coating forms a layer in a laminate structure in which the clay coating essentially forms the outer surface of the sheet.
The present invention is based on the realisation that nano particles can be incorporated in the sheet which can: i) increase the stiffness of the sheet; ii) improve creep resistance of the sheet particularly in cyclic or high humidity environments, and iii) increase hydrophobicity or the moisture barrier property of the sheet.
In one embodiment of the invention relates to a paper sheet including a base material and clay nano-particles bonded to the base material, wherein the base material includes at least two of fibrous material, cellulosic material or starch material, and the clay nano-particles are bonded to the base material to form a paper sheet having improved creep resistance and ring crush strength compared to a paper sheet having no nano-particles. In one example, the base material may include starch material.
In another example, the base material may include cellulosic material.
In another example, the base material may include fibrous material.
Another embodiment of the invention relates to a paper sheet including nano-particles that can bond to any one or a combination of: starch of the paper sheet, cellulose of the paper sheet, and fibre of the paper sheet.
The bond between the nano-particles and the starch, the cellulose, or the fibre may be in the form of physical bonding, but is ideally a chemical bond.
Without wanting to be limited by theory, it is believed that the nano-particles may occupy spaces or voids in the sheet and/or starch coating and thereby define a tortuous path by which
17375687_1 (GHMatters) P103274.AU 1/02/21 moisture is required to take in order to reach the inner core of the sheet. As a result, one the properties changed is that the sheet may exhibit an increase in the hydrophobicity or the moisture barrier property of the sheet. In addition, the nano particles can occupy spaces that would otherwise be voids. Occupying the voids can limit the mobility of the matrix of starch, cellulose and fibre of the paper sheet. It is believed that restricting the matrix mobility on this scale can increase the stiffness and creep resistance of the paper sheet.
Throughout this specification, the term "paper sheet" may refer to any fibrous or cellulosic containing material and embraces material including a single ply, multiple plies and other laminated structures. The term "paper sheet" therefore embraces corrugated medium that has been corrugated, corrugated medium prior to being corrugated, namely a flat planar sheet, and paper layers joined together, and optionally joined to non-paper materials such as polymeric film, metallic foil, coatings of wax and so forth.
The nano-particles may include any one or a combination of clay nano-particles and cellulose nano-particles.
Cellulose nano-particles or derivatives thereof including: nanocrystalline cellulose, cellulose nanocrystals, cellulose whiskers, nanofubrillated cellulose, cellulose nanofibrils, microfibrillated cellulose, carboxymethylated cellulose, microcrystalline cellulose, and cellulose filaments. Examples of other nano-particles that may be present in the paper sheet include graphite or graphene platelets, carbon nanotubes, and ZnO or TiO 2 nano-particles.
In one embodiment, the nano-particles may be in the form of clay nano-particles only.
Irrespective of whether the clay nano-particles are in combination with other nano-particles or not, ideally, the clay nano-particles are present in the paper sheet at a weight in the range of 2.0 to 20.Ogsm, and suitably 4.0 to 10gsm.
17375687_1 (GHMatters) P103274.AU 1/02/21
In another embodiment, the nano-particles may be in the form of cellulose nano-particles only.
In yet another embodiment, the nano-particles may include clay nano-particles in combination with the other nano-particles while cellulose nano-particles are absent.
In yet another embodiment, the nano-particles may include cellulose nano-particles in combination with other nano particles while clay nano-particles are absent.
The nano-particles may have a size in the range of equal to, or less than 500nm, and even more suitably the nano-particles may have a size in the range of equal to or less than 100nm.
The nano-particles may have any suitable shape.
In one embodiment, the nano-particles may be platelets. The platelets may have a thickness in the range of 1 to 5nm, and suitably approximately 1nm, and a diameter in the range of 0.1 to 101m.
In one embodiment, the platelets may be clay platelets. The clay nano-particles may have a platelet shape and may have the size ranges mentioned above.
Any combination of clay nano-particles, cellulose nano-particles and starch may be included in the paper sheet. For instance, the nano-particles may include from 0% to 100% clay nano particles and from 100% to 0% cellulose nano-particles, and any mix in between. By way of example, the weight ratio of clay nanoparticles and cellulose nanoparticles may be in the ranges of 10 to 90 : 90 to 10 respectively. Specifically, the weight ratio of clay nanoparticles to cellulose nanoparticles may be any one of 50:50, 40:60, 30:70, 20:80, 60:40, 70:30 and 80:20 respectively.
The nano-particles, and especially clay nano-particles, provide the synergistic benefit of increased cyclic or high humidity creep resistance, stiffness and possibly the fail strength by forming bonds to starch and/or cellulose, and improving the
17375687_1 (GHMatters) P103274.AU 1/02/21 moisture barrier property. In other words, the presence of nano-particles in the paper sheet can show a noticeable improvement in paper creep performance in moist or humid environments.
The nano-particles may chemically bond to the starch added to
the sheet, for example, by hydrogen bonding.
In one embodiment, the nano-particles may be absent from the, or
each, outer face of the paper sheet. In another embodiment,
the nano-particles may be present on the, or each, outer face of
the paper sheet.
The nano-particles may be distributed thought out the paper
sheet. Moreover, the nano-particles may be distributed evenly,
or uniformly in the paper sheet.
When the paper sheet has one ply layer only or multiple ply
layers, the nano-particles may be distributed throughout the or
each layer. In one embodiment, the nano-particles may be
present in at least one outer ply layer of the paper sheet and
absent from an inner ply layer of the paper sheet. For
instance, the nano-particles may be present in only one of two
outer ply layers.
In another embodiment, the nano-particles may be present in an
inner ply layer and absent from at least one of the outer ply
layers, and suitably both of the outer ply layers.
The nano-particles may be incorporated into one or more than one
of the ply layers of the paper sheet during the formation of the
paper sheet. For example, the nano-particles may be added to a
paper pulp slurry feed to the headbox of a papermaking machine
so that the nano-particles are distributed throughout the ply
layer of the headbox. The nano-particles can be added as a wet
slurry or in pre-mixed and dried powered form. The nano
particles may migrate from the ply layer having the nano
particles distributed therein to the ply layer in which the
nano-particles are not distributed therein.
17375687_1 (GHMatters) P103274.AU 1/02/21
The nano-particles may be applied to the outer faces of the
sheet. It is possible that the nano-particles have been applied
to one or both of the outer faces of the sheet.
The nano-particles may be applied to a face of the ply layer
that is discharged from a paper machine head box. For instance,
the nano-particles may be sprayed onto the ply layer on the wire
at the wet end of the paper machine and another ply layer laid
on top. The nano-particles may migrate to some extent inwardly
from the outer face.
For example, the nano-particle may migrate nearly entirely
through each ply layer, but may also migrate only to a smaller
extent, for example, up to 50% of the thickness of the ply
layers, or only up to 30% of the thickness of the ply layers.
For example, although the nano-particles may have been applied
to a surface of the one of the ply layers, for example, while
the ply layer contains a high water content at the wet end of
the paper making machine, or incorporated into the ply layer by
being added to the slurry from which the ply layer is made, the
nano-particles can migrate away from the interface between the
ply layers.
The nano-particles may increase the strength of the bond between
the fibres, cellulose and starch within the paper sheet,
including within each of the ply layers, and if multiple ply
layers are present, between the ply layers.
Enhancing the bond between the ply layers and within the ply
layers may enhance the performance characteristics of the paper
sheet. For example increasing the bond between the ply layers
and within the ply layers may increase the ultimate loading
point at which the sheet fails. In some situations, the
enhanced bond may increase shear stiffness and bending stiffness
of the paper sheet. It will be appreciated however, that an
increase in shear stiffness and bending stiffness does not
necessitate an increase in the ultimate loading point.
Moreover, it is possible that increasing the shear and/or
17375687_1 (GHMatters) P103274.AU 1/02/21 bending stiffness may in fact have no effect on the ultimate loading point, increase the ultimate loading point, or reduce the ultimate loading point.
The nano-particles may be applied to the paper sheet after the
paper sheet has been formed. For example the nano-particles may
be applied at some stage of a dry end of a paper machine, such
as in a sizing press. In another example the nano-particles may
be applied at some stage after production from a paper machine,
for example, in a coating process.
The nano-particles may penetrate up to 100 microns from the
outer face of the paper sheet during a coating process. The
degree of penetration can be controlled to some extent during
coating depending on coating viscosity, nip pressure, web
moisture, etc. Bending and printing properties can be enhanced
if the nano-particles are located predominantly near the surface
(as would be suitable for linerboards). While shear properties
are enhanced if the nano-particles penetrate to near the centre
of the sheet (as would be suitable for corrugating mediums).
The paper sheet may be a corrugated medium having crests and
troughs.
One of the benefits of the present invention is that the nano
particles increase creep resistance of the paper sheet compared
to the paper sheet having no nano-particles.
Another benefit of the present invention is that the paper sheet
can be made from a reduced amount of virgin fibres, for example,
the paper sheet may be made entirely of recycled fibre while
maintaining the same or having an improved creep resistance
compared to an equivalent paper sheet made from virgin fibres.
It will be appreciated that the term virgin fibres refers to not
previously used in paper fibres.
Generally speaking, papers containing recycled fibres, compared
to virgin fibre have an inherent increased rate of creep, and
therefore, in situations where creep needs to be controlled,
higher cost virgin fibres are required. One benefit is that
17375687_1 (GHMatters) P103274.AU 1/02/21 paper made from solely or predominately from recycled fibres can be used because the nano-particles help to reduce creep. Creep, refers to the undesirable property of paper based packing to deform and weaken over time under load, particularly in humid or cycling humidity environments.
For example, when made from predominantly recycled fibres, the
paper sheet may include:
i) in one embodiment from 50% to 100% recycled fibres,
ii) in another embodiment from 70 to 100% recycled
fibres;
iii) in yet another embodiment from 80 to 100% recycled
fibres; and
iv) still yet another embodiment from 90 to 100% recycled
fibres.
The present invention also relates to a process of manufacturing
a paper sheet, the process including the steps of:
forming the paper sheet including one or more than one ply
layer comprising a base material including two or more of
fibrous material, cellulosic material or starch material;
forming a mixture including clay nano-particles; and
adding the mixture to the paper sheet, such that the mixture is
bonded to the base material to form a paper sheet having
improved creep resistance and ring crush strength compared to a
paper sheet having no nano-particles.
Forming the paper sheet may include mixing a paper pulp slurry
containing the paper fibre, and delivering the slurry onto a
travelling wire at the wet end of a paper making machine.
The nano-particles may be incorporated into the paper sheet by
being added to the paper slurry that forms one or more of the
ply layers.
The step of incorporating the nano-particles into the paper
sheet may include any one or a combination of the following.
17375687_1 (GHMatters) P103274.AU 1/02/21 i) Applying the nano-particles to the paper sheet after the ply layers have been joined together. For example, the ply layers may be dried in a drier and the nano particles applied to the paper sheet in size press. In another example, the nano-particles may be applied by meter press roll. According to either example, the nano-particles can migrate into the paper sheet. The nano-particles may be applied to the paper as a dispersion that is formed by suspending the nano particles in water, for example, separating the sheets of the nano-particles in the high shear mixer or agitator. The dispersion may also include additional agents for treating the web prior to drying. The additional agents include any one or a combination of sizing agents such as silicon, colouring agents such as whitening agents, starch and so forth.
ii) Adding the nano-particles in a paper pulp slurry feed to
the headbox of a papermaking machine so that the nano
particles is distributed through the ply layer of the
headbox. The nano-particles can be added as a wet
slurry, or in pre-mixed and dried powered form.
iii) Applying the nano-particles to a face of the ply layer
that is discharged from a paper machine head box. For
instances, the nano-particles may be sprayed onto face
of one or more ply layers on a wire at the wet end of
the paper machine and another ply layer laid thereover
top.
The process of the present invention may include any one or a
combination of the features of the paper sheet described herein.
Similarly, the paper sheet may include any one or a combination
of the features of the process described herein.
17375687_1 (GHMatters) P103274.AU 1/02/21
A preferred embodiment will now be described with reference to
the accompanying Figures, of which:
Figure 1 is a schematic perspective view of a paper sheet;
Figures 2a, 2b and 2c are alternative schematic cross-sectional
views of the section shown in the dashed circle in Figure 1;
Figure 3 is a schematic illustration of a process of making a
paper sheet in which the process includes forming two ply
layers, in which nano-particles are incorporated in the ply
layers, and/or applied to a surface of one of the ply layers of
the paper sheet;
Figures 4a and 4b are schematic illustrations of two processes
for applying the nano-particles to the surface of the paper
sheet, in which Figures 4a and 4b is representative of the
process steps represented by block 20 of Figure 3; and
Figure 5a is a graph illustrating the improved performance of
the single sheet of 100gsm paper that has been treated with
starch and clay nano-particles at a weight of approximately
4.5gsm;
Figure 5b is a graph illustrating the improved performance of a
sandwich of the two 100gsm sheets of paper in which starch and
nano-clay has been applied at a weight of approximately 9gsm
between the sheets; and
Figure 5c is a graph illustrating the improved performance of a
single sheet of 135gsm paper that has been treated with starch
and nano-clay at a weight of approximately 4.5 gsm.
With reference to the Figures, Figure 1 illustrates a paper
sheet 15 and nano-particles, preferably either one or a
combination of clay nano-particles and cellulosic nano
particles. It will be appreciated that the paper sheet 15 may
be of any form, including for example, corrugated medium, liner
boards for cartons, liner boards for corrugated board and liner
boards for plaster board.
17375687_1 (GHMatters) P103274.AU 1/02/21
Figures 2a, 2b and 2c are schematic cross-section views of the
paper sheet 15 in the dashed circle in Figure 1 in which the
dots 13 represent the nano-particles 13 in the paper sheet 15.
The nano-particles 13 may be present at various sections in the
thickness of the paper sheet 15 from an outer surface, to inner
sections, and to the interface between ply layers 11 and 12 of
the paper sheet 15. Figure 2a illustrates the situation in
which the nano-particles 13 are present at the interface between
the ply layers 11 and 12 and have migrated to some extent
through the ply layers 11 and 12. Figure 2b illustrates the
situation in which the nano-particles 13 are incorporated
throughout the ply layers 11 and 12 of the paper sheet 15.
Figure 2c illustrates the situation in which the nano-particles
13 are present on the outer face of the paper sheet 13 and may
have migrated to some extent inwardly.
The nano-particles 13 suitably including either one or a
combination of cellulose nano-particles and clay nano
particles, having a size in the range of equal to, or less than
500nm, and suitably equal to, or less than 100nm.
The nano-particles 13 may have a platelet shape having a
thickness in the range of the 1 to 5nm, and suitably
approximately 1 nm, and a diameter in the range of 1 to 10tm.
Clay nano-particles can bond, for example by physical or
chemical bonding, to the starch and/or cellulose of the ply
layers and increase the stiffness of the paper sheet 15.
Examples of other nano-particles 13 that may be included in the
paper sheet 15 include one or combination of graphite or
graphene platelets, carbon nanotubes (fibers/whiskers), ZnO and
TiO 2 nano-particles.
This will produce two practical advantages. The nano-particles
13 can occupy voids between the starch molecules, cellulose and
the fibre of the paper sheet, thereby reducing the mobility of
the matrix structure of the paper sheet 15, making the sheet 15
17375687_1 (GHMatters) P103274.AU 1/02/21 stiffer than equivalent paper sheet 15 without the nano particles 13.
In addition to making the paper sheet 15 stiffer, the nano
particles 13 infill voids in the matrix structure of the paper
sheet 15, increasing the hydrophobicity of the paper sheet 15.
In turn, the paper sheet 15 will have an increased stiffness and
better creep resistant properties in cyclic and high humidity
conditions.
The manner in which the nano-particles 13 can be included in the
paper sheet 15 can be achieved by several means. Figure 3 is a
schematic illustration of the process for making the paper sheet
15 in which the process includes forming the ply layers 11 and
12 by delivering sequentially, two suspensions 11s and 12s of
paper fibre (paper pulp slurry) onto a wire 17 at the wet end of
paper making machine so that the ply layers 11 and 12 are
overlaid in a stagewise manner.
The nano-particles 13 can be added to the suspensions 11s and
12s, for example, in upstream mixing vessels 21 in which the
suspensions 11s and 12s are prepared. It is also possible that
the nano-particles 13 can be added directly to the headboxes 18.
By including the nano-particles 13 in the suspensions 11s and
12s, the nano-particles 13 will be distributed throughout the
entire thickness of one or more of the ply layers 11 and 12
delivered from the respective headbox 18.
Figure 3 also illustrates a first ply layer 12 delivered from a
first headbox 18 onto the wire 17, and the nano-particles 13 are
applied to the upper face of the first ply layer 12 prior to the
second ply layer 11 being delivered onto the first ply layer 12.
The nano-particles 13 may be sprayed onto the upper face of the
first ply layer 12 by a sprayer 19. Thereafter the ply layers
11 and 12 are joined together in a joining step 14. The joining
step 14 may include dewatering and drying the paper sheet 15 in
a drier.
17375687_1 (GHMatters) P103274.AU 1/02/21
The nano-particles 13 can be added to the paper sheet 15 by
means of either one or a combination of: i) adding the nano
particles 13 to the suspensions 11s and 12s in the mixing
vessels 21 or the head boxes 18, or ii) applying a solution
containing the nano-particles 13 to the surface of one of more
of the ply layers 11 and 12 using, for example, sprayer 19.
Although Figure 3 illustrates the sprayer 19 located for
applying the nano-particles 13 to ply layer 12, it will be
appreciated that the sprayer 19 could be arranged to spray the
inner face of the ply layer 11. It is also possible that other
sprayers could be arranged to apply a solution containing the
nano-particles 13 to other faces of ply layers 11 and 12.
As shown in Figure 3, the process may include applying the nano
particles 13 to the outer face of the paper sheet in step 20,
which is described in detail below with reference to Figure 4.
Following step 20 the paper sheet 15 can be rolled into a roll
21 for storage.
Figures 4a and 4b illustrate process steps for treating the
surface of the paper sheet 15 with the nano-particles 13.
Moreover the processes illustrated in Figures 4a and 4b can be
used with, and in addition to the process illustrated in Figure
3. It is possible that the nano-particles may not be included
in in suspension 11s and 12s, or applied to the surface of the
ply layers 11 and 12 via sprayer 19 in accordance with Figure 3,
but rather, the nano-particles may be applied solely to the
outside face of the paper sheet 15 according to the processes
shown in Figure 4a and 4b.
The processes of Figures 4a and 4b include forming an aqueous
solution of the nano-particles. The solution may be formed by
dispersing the nano-particles 13 supplied in a powder/aggregate
form in a high shear mixing tank 25. From the mixing tank 25,
the dispersion is supplied to a pool 27. The process
illustrated in Figures 4a and 4b can be carried out alternately
or in combination.
17375687_1 (GHMatters) P103274.AU 1/02/21
Figure 4a illustrates the pool 27 formed in a size press
comprising two engaging rollers 26 with the paper sheet 15 being
conveyed through the nip of the rollers 26. The pool 27 may
also include other agents such as starch, sizing agents,
brightness enhancers and so forth. After being conveyed through
the size press, the paper sheets 15 can be dried in an after
drier 28 and rolled.
Figure 4b illustrates the pool 27 being arranged to feed a meter
roller 30 having grooves or indentations on the surface of the
metered roller 30. The grooves receive the solution and apply
the solution containing the nano-particles 13 to the paper sheet
15. A transfer roller 31 may convey the solution from the pool
27 to metered roller 30. A backing roller 32 may be used to
ensure adequate contact between the paper sheet 15 and the meter
roller 30.
Figure 5a is a graph illustrating the improved performance of
the single sheet of 100gsm paper that has been treated with
starch and nano-clay at a weight of approximately 4.5gsm (i.e.,
apporximately 4.5wt%). To provide a control, untreated paper is
first tested according to a ring crush strength test (RCS) and a
high humidity load carrying capacity test (HHLCC).
The RCS test method involves a compression force being exerted
on a sample of paper held in a ring form in a sample holder that
is placed between two platens of a compression machine in which
platen is driven toward a rigid platen at a uniform speed until
the sample collapses. The sample is pre-conditioned in a
controlled environment having a 50% relative humidity at 23 0 C.
The HHLCC test method is the same as the RCS test method
described above, save for the additional following steps:
i) The sample is exposed to a changing environment in which
the humidity changes stepwise between 50% relative
humidity and 90% relative humidity over a three hour
cycle.
17375687_1 (GHMatters) P103274.AU 1/02/21 ii) A constant load is applied and the time taken for the sample to collapse is measured (i.e. creep test).
iii) Step ii) is repeated for a series of different loads.
iv) The load required to survive one full three-hour
relative humidity cycle is estimated using a plot
comprising the ex-intercept of log-load(N) versus log
life(at number of relative humidity cycles).
v) The load is used as a measure of Cree performance in a
site click high humidity environment.
As can be seen in figure 5a, the RCS of a single 100gs a paper
sheet increased by approximately 8% and the HHLCC of the same
paper sheet increased by approximately 13%. This is considered
to be a considerable improvement.
Figure 5b is a graph illustrating the improved performance of a
sandwich of the two 100gsm sheets of paper in which starch and
clay nano-particles have been applied at a weight of
approximately 9gsm between the sheets (i.e., approximately
4.5wt%). The RCS of the sandwich does not increase
significantly; however, the HHLCC of the same sample of paper
increases by approximately 13%.
Figure 5c is a graph illustrating the improved performance of a
single sheet of 135gsm paper that has been treated with starch
and clay nano-particles at a weight of approximately 4.5 gsm
(i.e., approximately 3.3wt%). The RCS of the single sheet
increases by proximally 5%, and the HH else of the same sample
increases by approximately 4%.
In other words, the addition of clay nano-particles and starch
can increase creep resistance of the paper sheet compared to the
paper sheet having no nano-particles by up to 115%, and suitably
up to 113%, and even more suitably in the range of 105 to 110%
when the starch and nano-particles together are applied in an
amount in the range of 3 to 5 wt%.
17375687_1 (GHMatters) P103274.AU 1/02/21
In other words, the addition of the addition of clay nano
particles and starch can increase the ring crush strength of the
paper sheet compared to the paper sheet having no nano-particles
by up to 108%, and even more suitably in the range of 103 to
105% when the starch and nano-particles together are applied in
an amount in the range of 3 to 5 wt%.
Set out below in Table 1 is a set of data showing the
performance increases from combinations including: i) starch and
clay nanoparticles, and ii) starch, clay nanoparticles and
cellulose nanoparticles.
Table 1
Paper Control Starch and Starch, clay
Composition (Starch clay nanoparticles and
additive nanoparticles cellulose
Only) nanoparticles
Pulp Fibre % 95 92 85
Starch % 5 5 5
Clay 0 3 5
nanoparticles %
cellulose 0 5 5
nanoparticles%
Ring Crush 100 range from range from 112 to
Strength* % 104 to 110, 125,
(relative to typcially 108 typically 120 control)
High Humidity 100 range from range from 112 to
Load Carrying 105 to 115, 125,
Capacity * %typcially 113 typically 120
(relative to
control)
17375687_1 (GHMatters) P103274.AU 1/02/21
One of the benefits of the present invention is that the
performance characteristics, such as ultimate load strength,
shear stiffness and bending stiffness can be improved by the
nano-particles. This means that the paper sheet may contain a
higher percentage of the recycled fibres, yet have the
characteristics akin to a product made from virgin fibre.
Moreover, the nano-particles can improve the performance of the
paper sheet, particular in terms of the stiffness and creep
resistance in high or cyclic humid conditions.
It will be understood to persons skilled in the art of the
invention that many modifications may be made to embodiments
described above without departing from the spirit and scope of
the invention.
In the claims which follow and in the preceding description of
the invention, except where the context requires otherwise due
to express language or necessary implication, the word
"comprise" or variations such as "comprises" or "comprising" is
used in an inclusive sense, i.e. to specify the presence of the
stated features but not to preclude the presence or addition of
further features in various embodiments of the invention.
17375687_1 (GHMatters) P103274.AU 1/02/21
Claims (25)
1. A paper sheet including a base material and clay nano
particles bonded to the base material, wherein the base material
includes at least two of fibrous material, cellulosic material
or starch material, and the clay nano-particles are bonded to
the base material to form a paper sheet having improved creep
resistance and ring crush strength compared to a paper sheet
having no nano-particles.
2. The paper sheet according to claim 1, wherein the nano
particles is a combination of clay nano-particles and cellulose
nano-particles.
3. The paper sheet according to claim 2, wherein the clay nano
particles are present in the paper sheet at a weight in the
range of 2.0 to 20.Cgsm.
4. The paper sheet according to either claim 2 or 3, wherein the
cellulose nano-particles are present in the paper sheet at a
weight in the range of 2.0 to 20.Ogsm.
5. The paper sheet according to any one of the preceding claims,
wherein the clay nano-particles have a size in the range of
equal to, or less than 500nm.
6. The paper sheet according to any one of the preceding claims,
wherein the clay nano-particles are platelets having a thickness
in the range of 0.5 to 5.Onm and a diameter in the range of 0.1
to 10.0ptm.
7. The paper sheet according to any one of the preceding claims,
wherein the paper sheet includes starch, clay nano-particles and
cellulose nano-particles, in which the weight ratio of clay
nano-particles to cellulose nano-particles is in the range of 10
to 90 : 90 to 10 respectively.
8. The paper sheet according to any one of the preceding claims,
wherein the clay nano-particles are absent from at least one
outer face of the paper sheet.
17375687_1 (GHMatters) P103274.AU 1/02/21
9. The paper sheet according to any one of the preceding claims,
wherein the clay nano-particles are present on at least one
outer face of the paper sheet.
10. The paper sheet according to any one of the preceding
claims, wherein the clay nano-particles are distributed
throughout the paper sheet.
11. The paper sheet according to any one of the preceding
claims, wherein the paper sheet has at least two ply layers and
the clay nano-particles are present in only one of the ply
layers.
12. The paper sheet according to any one of the preceding
claims, wherein the paper sheet has at least one outer ply layer
and at least one inner ply layer, and the clay nano-particles
are absent from an inner ply layer of the paper sheet.
13. The paper sheet according to any one of the preceding
claims, wherein the addition of clay nano-particles and starch
increases creep resistance of the paper sheet compared to the
paper sheet having no nano-particles by up to 115%.
14. The paper sheet according to any one of the preceding
claims, wherein the addition of clay nano-particles and starch
increases the ring crush strength of the paper sheet compared to
the paper sheet having no nano-particles by up to 108%.
15. The paper sheet according to any one of the preceding
claims, wherein the paper sheet includes a combination of
starch, cellulose nano-particles and clay nanoparticles range
the high humidity load carrying capacity ranges 112 to 125%
relative to the paper sheet having starch only.
16. The paper sheet according to any one of the preceding
claims, wherein the paper sheet includes a combination of
starch, cellulose nano-particles and clay nanoparticles range
the ring crush strength range from 112 to 125%.
17. The paper sheet according to any one of the preceding
claims, wherein the paper sheet may include from 50% to 100%
17375687_1 (GHMatters) P103274.AU 1/02/21 recycled fibres yet retain the same creep resistance as the paper sheet made from virgin fibres.
18. A process of manufacturing a paper sheet, the process
including the steps of:
forming the paper sheet including one or more than one ply
layer comprising a base material including two or more of
fibrous material, cellulosic material or starch material;
forming a mixture including clay nano-particles; and
adding the mixture to the paper sheet, such that the
mixture is bonded to the base material to form a paper sheet
having improved creep resistance and ring crush strength
compared to a paper sheet having no nano-particles.
19. The process according to claim 18, wherein the mixture
includes starch.
20. The process according to either claim 18 or 19, wherein
forming the paper sheet includes mixing fibrous material,
cellulosic material or starch material so as to form a paper
pulp slurry and delivering the slurry onto a travelling wire at
the wet end of a paper making machine, and adding the clay nano
particles to the paper pulp slurry includes adding the clay
nano-particles into the pulp slurry.
21. The process according to any one of claims 18 to 20, wherein
the clay nano-particles are added to a paper pulp slurry feed to
a headbox of a papermaking machine so that the clay nano
particles are distributed through a ply layer that is delivered
by the headbox onto the travelling wire.
22. The process according to any one of claims 18 to 21, wherein
the clay nano-particles are contained in a liquid that is
sprayed onto face of one or more ply layers on a wire at the wet
end of the paper machine.
17375687_1 (GHMatters) P103274.AU 1/02/21
23. The process according to any one of claims 18 to 22, wherein incorporating the clay nano-particles into the paper pulp slurry includes applying the clay nano-particles to the paper sheet after ply layers of the paper sheet have been joined together.
24. The process according to any one of claims 18 to 23, wherein the clay nano-particles are applied to the paper sheet in a size press.
25. The process according to any one of claims 18 to 23, wherein the clay nano-particles are applied to the paper sheet by meter press roll.
17375687_1 (GHMatters) P103274.AU 1/02/21
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2015902153 | 2015-06-03 | ||
| AU2015902153A AU2015902153A0 (en) | 2015-06-03 | Paper sheet and a process for the manufacture thereof | |
| AU2016901174A AU2016901174A0 (en) | 2016-03-30 | Paper sheet and a process for the manufacture thereof | |
| AU2016901174 | 2016-03-30 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| AU2016203734A1 AU2016203734A1 (en) | 2016-12-22 |
| AU2016203734B2 true AU2016203734B2 (en) | 2021-03-04 |
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ID=57584288
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2016203734A Active AU2016203734B2 (en) | 2015-06-03 | 2016-06-03 | Paper sheet and a process for the manufacture thereof |
Country Status (1)
| Country | Link |
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| AU (1) | AU2016203734B2 (en) |
Families Citing this family (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU2016203734B2 (en) * | 2015-06-03 | 2021-03-04 | Opal Packaging Australia Pty Ltd | Paper sheet and a process for the manufacture thereof |
| WO2017165919A1 (en) * | 2016-03-30 | 2017-10-05 | Orora Packaging Australia Pty Ltd | Paper sheet, corrugated paper and a process for the manufacture thereof |
| CN108286208A (en) * | 2018-01-26 | 2018-07-17 | 刘成旭 | A method of improving paper strength using nano combined intercalation material |
| SE542093C2 (en) | 2018-02-27 | 2020-02-25 | Stora Enso Oyj | Method for production of a paper, board or non-woven product comprising a first ply |
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| WO2000029673A1 (en) * | 1998-11-12 | 2000-05-25 | Paper Technology Foundation, Inc. | Partially impregnated lignocellulosic materials |
| WO2005052256A2 (en) * | 2003-11-21 | 2005-06-09 | Bercen Incorporated | Paper making process and starch compositions comprising a crosslinking agent for use in same |
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| AU2016203734A1 (en) * | 2015-06-03 | 2016-12-22 | Opal Packaging Australia Pty Ltd | Paper sheet and a process for the manufacture thereof |
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- 2016-06-03 AU AU2016203734A patent/AU2016203734B2/en active Active
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| US4948448A (en) * | 1987-11-27 | 1990-08-14 | Lacani Ab | Method of manufacturing moisture resistant corrugated fiberboard |
| WO2000029673A1 (en) * | 1998-11-12 | 2000-05-25 | Paper Technology Foundation, Inc. | Partially impregnated lignocellulosic materials |
| WO2005052256A2 (en) * | 2003-11-21 | 2005-06-09 | Bercen Incorporated | Paper making process and starch compositions comprising a crosslinking agent for use in same |
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| AU2016203734A1 (en) * | 2015-06-03 | 2016-12-22 | Opal Packaging Australia Pty Ltd | Paper sheet and a process for the manufacture thereof |
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| Publication number | Publication date |
|---|---|
| NZ720850A (en) | 2024-02-23 |
| AU2016203734A1 (en) | 2016-12-22 |
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Owner name: OPAL PACKAGING AUSTRALIA PTY LTD Free format text: FORMER APPLICANT(S): ORORA PACKAGING AUSTRALIA PTY LTD |
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