BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates a process for forming a poly coated paper with a copolymer and/or terpolymer coating.
FIG. 2 illustrates a process for forming a poly coated paper with polyethylene monomer and copolymer and/or terpolymer blended into the monomer.
FIG. 3 illustrates a process for forming a coextruded poly coated paper with one layer of copolymer or terpolymer and one layer of polyethylene monomer.
FIG. 4 illustrates the product formed by the process of FIG. 3.
FIG. 5 illustrates a process for forming a coextruded poly coated paper with one layer of copolymer or terpolymer and one layer of polyethylene monomer.
FIG. 6 illustrates the product formed by the process of FIG. 5.
FIG. 7 illustrates a process for forming a coextruded poly coated paper with one layer of copolymer or terpolymer between two layers of polyethylene monomer.
FIG. 8 illustrates the product formed by the process of FIG. 7.
FIG. 9 illustrates a process for forming a co-extruded poly coated paper with one layer of polyethylene monomer between two layers of copolymer and/or terpolymer resin.
FIG. 10 illustrates the product formed by the process of FIG. 9.
DETAILED DESCRIPTION OF THE INVENTION
In an embodiment of the present invention, the low density polyethylene resin is a monomer utilizing ethylene feed stock. The copolymer and terpolymer resins are made by combining butene, hexene and/or octene feedstock with ethylene feedstock.
In one embodiment shown in FIG. 1, the copolymer and terpolymer resins are applied to the paper surface. The copolymer and/or terpolymer 10 are fed into an extruder die 30 where it becomes extrudate 40. The extrudate 40 is coated on the paper 20 between the backing roll 50 and the chill roll 60 to form a poly coated paper with copolymer and/or terpolymer coating 70.
In a further embodiment shown in FIG. 2, low-density monomer polyethylene resin 80 is mixed with copolymer and/or terpolymer resins 10 before or as being fed into an extruder die 30. The low-density polyethylene monomer and copolymer and/or terpolymer resin becomes extrudate 40. The extrudate 40 is applied to the paper surface 20 between the backing roll 50 and the chill roll 60. This creates a poly coated paper with polyethylene monomer and copolymer or terpolymer blended into the monomer 90.
In a further embodiment, shown in FIG. 3, the copolymer and/or terpolymer layer 10 which may be blended with polyethylene monomer, is coextruded with a polyethylene monomer layer 80. The copolymer and/or terpolymer layer 10 and the polyethylene monomer layer 80 are fed through a coextruder die 130 to form coextrudate 140 wherein the coextrudate 140 has the copolymer and/or terpolymer 10 facing the paper 120. The co-extrudate 140 is applied to the paper surface 120 between the backing roll 50 and the chill roll 60. This creates a poly coated paper 170 with one layer of copolymer or terpolymer and one layer of polyethylene monomer.
FIG. 4 shows the product made by the process shown in FIG. 3 wherein the co-extruded poly coated paper 170 has one layer of copolymer or terpolymer 180 on top of the paper 120 and one layer of polyethylene monomer 110 on top of layer 180.
In FIG. 5 the copolymer and/or terpolymer layer 10 which may be blended with a polyethylene monomer, is coextruded with a polyethylene monomer layer 80. The copolymer and/or terpolymer layer 10 and the polyethylene monomer layer 80 are fed through a coextruder die 130 to form coextrudate 140 wherein the coextrudate 140 has the polyethylene monomer 80 facing the paper 120. The co-extrudate 140 is applied to the paper surface 120 between the backing roll 50 and the chill roll 60. This creates a poly coated paper 170 with one layer of copolymer or terpolymer and one layer of polyethylene monomer.
FIG. 6 shows product made by the process shown in FIG. 5 wherein the co-extruded poly coated paper 170 has one layer of polyethylene monomer 110 on top of paper layer 120 and layer 180 on top of layer 110.
In FIG. 7 the copolymer and/or terpolymer layer 10 which may be blended with polyethylene monomer, is coextruded with a layer of polyethylene monomer 80 on each side. The copolymer and/or terpolymer layer 10 and the polyethylene monomer layers 80 are fed through a coextruder die 130 to form coextrudate 140 wherein the coextrudate 140 has one of the polyethylene monomer layers 80 facing the paper 120. The co-extrudate 140 is applied to the paper surface 120 between the backing roll 50 and the chill roll 60. This creates a poly coated paper 210 with one layer of copolymer or terpolymer between two layers of polyethylene monomer.
FIG. 8 shows the product made by the process shown in FIG. 7 wherein the co-extruded poly coated paper 120 has one layer of polyethylene monomer 110 on top of paper layer 120 followed by layer 180 having on top of it a second layer 110.
In FIG. 9 the copolymer and/or terpolymer layer 10 which may be blended with polyethylene monomer, is coextruded with a layer of polyethylene monomer 80 on each side. The copolymer and/or terpolymer layer 10 and the polyethylene monomer layers 80 are fed through a coextruder die 130 to form coextrudate 140 wherein the coextrudate 140 has one of the polyethylene monomer layers 80 facing the paper 120. The co-extrudate 140 is applied to the paper surface 120 between the backing roll 50 and the chill roll 60. This creates a poly coated paper 220 with one layer of copolymer or terpolymer between two layers of polyethylene monomer.
FIG. 10 shows the product made by the process shown in FIG. 9 wherein the co-extruded poly coated paper 120 has one layer of polyethylene monomer 110 on top of paper layer 120 followed by layer 180 having on top of it a second layer 110.
By utilizing these copolymer and/or terpolymer resins the present invention achieves a substantial improvement in the tear strength of the ream wrapper. Below are results using the same 50# Canfor paper as above and 14 pounds of combined copolymer or terpolymer resin and low density polyethylene monomer which shows the significant strength gain versus the traditional low density polyethylene shown above.
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Machine
Cross
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Direction
Direction
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Tear
Tear
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50# Canfor Paper
122
137
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50# Canfor Paper with 14# copolymer
196
240
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and/or terpolymer resin or a blend of
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low density polyethylene monomer resin
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and copolymer or terpolymer resin or a
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coextrusion of low density monomer polyethylene
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resin and copolymer and/or terpolymer resin
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Strength Gain
70
103
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MD Tear test-TAPPI T-414-units grams of force
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CD Tear test-TAPPI T-414-units grams of force
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