International Paper Company

Polyweave International, LLC

John R Boylan

James A Goettmann

Stephen H Monroe

Peter J Angelini

Guy D'Anna

A high-opacity cellulose-free synthetic paper is formed from a wet-laid nonwoven web of thermoplastic fibers, all or most of which fibers are made of a predetermined polymeric material. The wet-laid web is dried to remove excess water, drying being carried cut at temperatures below the melting temperature of the predetermined polymeric material. The dried nonwoven web is saturated on at least one side with a pigmented binder forming a continuous coating thereon. The binder is cured at temperatures below the melting temperature of the predetermined polymeric material.

Recyclable polymeric synthetic paper and method for its manufacture

A gloss coating composition comprising radiation curable oligomers and monomers, and photosensitizers in a homogeneous mixture having a viscosity in the range of 4500 to 8000 cps; wherein the presence of the photosensitizers causes polymerization of the radiation curable oligomers and monomers when exposed to an ultraviolet light source. The coating composition is applied to at least one surface of a substrate and exposed to an ultraviolet light source resulting in curing of the composition onto the substrate surface without substantial penetration into the substrate surface forming a gloss coated substrate.

High gloss ultraviolet curable coating for porous substrates

An in-mold label material is a nonwoven mat of fibers having one side fused with the outer surface of a polymeric container and the other side coated with a pigment-containing latex suitable for printing thereon. The label paper is manufactured from commercially available fibers combined in water into a homogeneous mixture and then formed into a mat employing a wet-lay process. For use with polyethylene containers, the label may be a web consisting of 88-100% polyethylene fibers and 0-15% polyvinyl alcohol fibers or 70-100% polyethylene fibers, 0-15% polyvinyl alcohol fibers and 0-30% polypropylene fibers. For use with polyester containers, the label may be a web consisting of 50-90% polyester staple fibers, 10-40% bicomponent polyester/co-polyester, core/sheath binder fibers and 0-10% polyvinyl alcohol binder fibers thermally bonded together. The nonwoven web of fibers has a pigmented coating. After the material has been cut into labels, the labels may be applied to the blow-molded containers in-mold without the use of an adhesive material using a conventional in-mold labeling technique or post-mold using adhesive.

Recyclable polymeric label paper

High gloss ultraviolet curable coating

A nonwoven composite web consists of 15 to 50 wt. % of first polyester fibers having a length of 5 mm to 3/4 inch and a denier of 0.3 to 3, 5 to 50 wt. % of second polyester fibers having a length of 5 mm to 1-1/2 inches and a denier of 3 to 15, and 10 to 40 wt. % of binder fibers comprising thermoplastic binder material having a melting temperature which is less than the first and second melting temperatures respectively. The first and second polyester fibers are bonded to each other at least in part by solidification of the thermoplastic binder material after subjecting the web to temperatures in excess of the melting temperature of the binder material but not in excess of the melting temperature of either the first or second polyester fibers. In particular, the web is thermally bonded by calendaring at a temperature of in the range of 360.degree. to 410.degree. F. and at a pressure in the range of 40 to 70 psi. Preferably the binder fibers comprise bicomponent fibers having a co-polyester sheath and a polyester core.

Printable, high-strength, tear-resistant nonwoven material and related

A nonwoven composite web consists of 15 to 50 wt. % of first polyester fibers having a first length, a first denier and a first melting temperature; 15 to 50 wt. % of second polyester fibers having a second length, a second denier and a second melting temperature; 15 to 50 wt. % of third polyester fibers having a third length, a third denier and a third melting temperature; 10 to 35 wt. % of polypropylene fibers; and 1 to 25 wt. % of cellulose fibers. The first, second and third lengths are no less than 1/2 inch, the first, second and third denier are no less than 1.5, and the third melting temperature is less than the first and second melting temperatures respectively. The first and second polyester fibers, the polypropylene fibers and the cellulose fibers are bonded to each other at least in part by solidification of the third polyester fibers after subjecting the web to temperatures in excess of the third melting temperature but not in excess of the first and second melting temperatures. In particular, the web is thermally bonded by calendaring at a temperature of approximately 385.degree. F. The web can be manufactured to have high opacity by adding titanium dioxide and silicone-acrylic latex to the composition. The titanium dioxide and latex are agglomerated and the resulting agglomerates are thermally bonded to the fiber matrix.

Growing community of inventors

Newtown, PA, United States of America

John R Boylan