Paperboard or cardboard

Abstract

A paperboard and a cardboard comprising at least one nonwoven web layer are provided. The nonwoven web layer comprises a plurality of first fibers, a plurality of second fibers, and a binder. The first fibers comprise a water non-dispersible synthetic polymer and have a different configuration and/or composition than the second fibers. The first fibers have a length of less than 25 millimeters and a minimum transverse dimension of less than 5 microns. The nonwoven web layer comprises at least 1 weight percent of the first fibers, at least 10 weight percent of the second fibers, and at least 1 weight percent of the binder. The paperboard and cardboard can incorporate a large amount of post consumer recycled fibers and still exhibit high strength and durability. Also disclosed is a process for producing the first fibers and the multicomponent fibers from which they are derived.

1 . A paperboard or a cardboard comprising at least one nonwoven web layer, wherein said nonwoven web layer comprises a plurality of first fibers, a plurality of second fibers, and a binder, wherein said first fibers comprise a water non-dispersible synthetic polymer, wherein said second fibers are cellulosic fiber pulp, lycocell fibers, or rayon fibers, wherein said first fibers have a length of less than 25 millimeters and a minimum transverse dimension of less than 5, wherein said first fibers make up at least 1 weight percent and not more than 10 weight percent of said nonwoven web layer, wherein said second fibers make up at least 20 weight percent of said nonwoven web layer, wherein said binder makes up at least 1 weight percent and not more than 40 weight percent of said nonwoven web layer, wherein said nonwoven web layer has a tensile strength (TAPPI T494) of at least 0.1 kg/15 mm and a basis weight (TAPPI 410) of at least 150 grams per square meter. 
     
     
         2 . The paperboard or cardboard of  claim 1 , a Mullen burst strength (TAPPI 403) of at least 0.5, 1, 5, 10, 25, 50 pounds per square inch. 
     
     
         3 . The paperboard or cardboardpaperboard or cardboard of  claim 1 , wherein said first fibers make up at least 1, 3, or 5 weight percent and/or not more than 20, 15, 10, or 5 weight percent of said nonwoven web layer. 
     
     
         4 . The paperboard or cardboard of  claim 1 , wherein said second fibers make up at least 20, 30, or 40 weight percent and/or not more than 99, 98, or 95 weight percent of said nonwoven web layer. 
     
     
         5 . The paperboard or cardboard of  claim 1 , wherein said binder makes up at least 1, 2, or 4 weight percent and/or not more than 40, 30, or 20 weight percent of said nonwoven web layer. 
     
     
         6 . The paperboard or cardboard of  claim 1 , wherein said nonwoven web layer further comprises a coating selected from the group consisting of a decorative coating, a printing ink, a barrier coating, an adhesive coating, and a heat seal coating. 
     
     
         7 . The paperboard or cardboard of  claim 1 , wherein the total amount of synthetic fibers in said nonwoven web is not more than 20, 15, 10, 5, 2, or 1 weight percent of said nonwoven web layer. 
     
     
         8 . The paperboard or cardboard of  claim 1 , wherein said first fibers have a length of less than 25, 10, 5, or 2 millimeters. 
     
     
         9 . The paperboard or cardboard of  claim 1 , wherein said first fibers have a minimum transverse dimension of less than 5, 4, or 3 microns. 
     
     
         10 . The paperboard or cardboard of  claim 1 , wherein said first fibers are derived from a multicomponent fiber. 
     
     
         11 . The paperboard or cardboard of  claim 1 , wherein said first fibers are formed by removing a water dispersible polymer from a multicomponent fiber comprising a plurality of said first fibers. 
     
     
         12 . The paperboard or cardboard of  claim 11 , wherein said first fibers are formed by cutting said multicomponent fiber to the length of said first fibers prior to removing said water dispersible polymer. 
     
     
         13 . The paperboard or cardboard of  claim 11 , wherein said water dispersible polymer is a sulfopolyester. 
     
     
         14 . The paperboard or cardboard of  claim 1 , wherein said first and second fibers have different compositions. 
     
     
         15 . The paperboard or cardboard of  claim 1 , wherein said first fibers comprise at least one polymer selected from the group consisting of polyesters, polyamides, polyolefins, polylactides, polycaprolactone, polyurethane, polyvinyl chloride, and combinations thereof. 
     
     
         16 . The paperboard or cardboard of  claim 1 , wherein at least 25, 50, 75, or 90 weight percent of said second fibers are post consumer recycled fibers 
     
     
         17 . The paperboard or cardboard of  claim 1 , wherein said binder is selected from the group consisting of synthetic resin binders, phenolic binders, and combinations thereof. 
     
     
         18 . The paperboard or cardboard of  claim 1 , wherein said binder comprises a synthetic resin selected from the group consisting of sulfopolyesters, acrylic copolymers, vinyl copolymers, polyurethanes, and combinations thereof. 
     
     
         19 . The paperboard or cardboard of  claim 1 , wherein said binder comprises at last one sulfopolyester and wherein said first fibers comprise a thermoplastic polycondensate. 
     
     
         20 . The paperboard or cardboard of  claim 1 , wherein said nonwoven web layer further comprises a coating selected from the group consisting of a decorative coating, a printing ink, a barrier coating, an adhesive coating, and a heat seal coating.