Apparatus, systems and methods for making re-pulpable insulated paper products

Abstract

Apparatus, systems, and methods for making insulated paper products are disclosed.

What is claimed is: 
     
         1 . An apparatus for making insulated paper products with an uneven cross-sectional distribution of insulating material therethrough, said apparatus comprising:
 a first paper forming wire moving along a first papermaking path;   a first headbox positioned to deposit a first pulp slurry onto the first paper forming wire;   a first formation plate positioned below the first paper forming wire proximate the first headbox;   at least one first nozzle positioned to deposit first insulating material onto the first paper slurry on the first paper forming wire;   one or more vessels, each vessel being (i) sized to house the first insulating material, and (ii) in fluid communication with the at least one first nozzle;   a second paper forming wire moving along a second papermaking path;   a second headbox positioned to deposit a second pulp slurry onto the second paper forming wire; and   a second formation plate (not shown) positioned below the second paper forming wire proximate the second headbox;   wherein the second paper forming wire is positioned to deposit a second paper ply onto a first paper ply with first insulating material deposited thereon positioned along the first paper forming wire so as to form the insulated paper product with the first paper ply forming a first outer surface of the insulated paper product and the second paper ply forming a second outer surface of the insulated paper product opposite the first outer surface.   
     
     
         2 . The apparatus of  claim 1 , further comprising:
 at least one second nozzle positioned to deposit second insulating material onto the second paper slurry on the second paper forming wire.   
     
     
         3 . The apparatus of  claim 2 , wherein the one or more vessels (i) are sized to house the first insulating material and the second insulating material, and (ii) are in fluid communication with the at least one first nozzle and the at least one second nozzle. 
     
     
         4 . The apparatus of  claim 2 , wherein the one or more vessels comprises (a) a first set of one or more first vessels (i) sized to house the first insulating material, and (ii) in fluid communication with the at least one first nozzle, and (b) a second set of one or more second vessels (i) sized to house the second insulating material, and (ii) in fluid communication with the at least one second nozzle. 
     
     
         5 . The apparatus of  claim 2 , wherein the one or more vessels contain the first insulating material and the second insulating material. 
     
     
         6 . The apparatus of  claim 2 , wherein the one or more vessels contains (i) a mixture of the first insulating material and pulp fiber, (ii) a mixture of the second insulating material and pulp fiber, or (iii) both (i) and (ii). 
     
     
         7 . The apparatus of  claim 2 , wherein the one or more vessels contains (i) a mixture of from about 50.0 weight percent (wt %) to about 98.0 wt % of the first insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, (ii) a mixture of from about 50.0 wt % to about 98.0 wt % of the second insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, or (iii) both (i) and (ii). 
     
     
         8 . The apparatus of  claim 2 , wherein the one or more vessels contains (i) a mixture of from about 90.0 wt % to about 98.0 wt % of the first insulating material and from about 10.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, (ii) a mixture of from about 90.0 wt % to about 98.0 wt % of the second insulating material and from about 10.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, or (iii) both (i) and (ii). 
     
     
         9 . The apparatus of  claim 1 , wherein the at least one first nozzle is capable of depositing a high solids mixture comprising water and from about 50.0 wt % to about 98.0 wt % of the first insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, onto the first paper slurry at a rate of between about 0.5 and about 5.0 US gallons per minute, and generating a dry basis weight of up to about 500 grams per square meter (gsm) of the mixture. 
     
     
         10 . The apparatus of  claim 2 , wherein the at least one second nozzle is capable of depositing a mixture of water and from about 50.0 wt % to about 98.0 wt % of the second insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, onto the second paper slurry at a rate of between about 0.5 and about 5.0 US gallons per minute, and generating a dry basis weight of up to about 500 gsm of the mixture. 
     
     
         11 . The apparatus of  claim 1 , wherein the at least one first nozzle comprises two or more first nozzles. 
     
     
         12 . The apparatus of  claim 11 , wherein the two or more first nozzles are positioned in series with one another along the first paper forming wire. 
     
     
         13 . The apparatus of  claim 2 , wherein the at least one second nozzle comprises two or more second nozzles. 
     
     
         14 . The apparatus of  claim 13 , wherein the two or more second nozzles are positioned in series with one another along the second paper forming wire. 
     
     
         15 . The apparatus of  claim 1 , further comprising:
 one or more spray booms, each spray boom (a) being positioned so as to extend over (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii), and (b) being capable of supporting one or more nozzles.   
     
     
         16 . The apparatus of  claim 1 , further comprising:
 one or more vacuum slots, each vacuum slot (a) being positioned below (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii) and (b) being capable of removing water from a paper slurry positioned on (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii).   
     
     
         17 . The apparatus of  claim 1 , further comprising:
 one or more foils, each foil (a) being positioned below (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii), and (b) being capable of removing water from a paper slurry positioned on (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii).   
     
     
         18 . The apparatus of  claim 1 , further comprising:
 one or more slot coaters, each slot coater (a) being positioned above (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii), and (b) being capable of depositing material onto (i) the first paper forming wire, (ii) the second paper forming wire, or (iii) both (i) and (ii).   
     
     
         19 . The apparatus of  claim 18 , wherein at least one nozzle is positioned downstream along the first paper forming wire from the one or more slot coaters. 
     
     
         20 . The apparatus of  claim 1 , further comprising:
 a process controller capable of bringing the first paper ply and the second paper ply into contact with one another when the first paper ply and the second paper ply are still wet and able to bond to one another.   
     
     
         21 . The apparatus of  claim 1 , further comprising: a process controller capable of bringing the first paper ply and the second paper ply into contact with one another when the first paper ply and the second paper ply each independently comprise from about 70.0 wt % to about 90 wt % water. 
     
     
         22 . A system for making insulated paper products with an uneven cross-sectional distribution of insulating material therethrough, said system comprising:
 the apparatus of  claim 2 ;   pulp fibers; and   first insulating material.   
     
     
         23 . The system of  claim 22 , further comprising: second insulating material. 
     
     
         24 . The system of  claim 23 , further comprising:
 (i) a mixture of from about 50.0 wt % to about 98.0 wt % of first insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, (ii) a mixture of from about 50.0 wt % to about 98.0 wt % of second insulating material and from about 50.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, or (iii) both (i) and (ii).   
     
     
         25 . The system of  claim 24 , further comprising:
 (i) a mixture of from about 90.0 wt % to about 98.0 wt % of first insulating material and from about 10.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, (ii) a mixture of from about 90.0 wt % to about 98.0 wt % of second insulating material and from about 10.0 wt % to about 2.0 wt % of pulp fiber, based on total solids in the mixture, or (iii) both (i) and (ii).   
     
     
         26 . The system of  claim 23 , wherein each of the first insulating material and the second insulating material independently comprises particles (i) having an average particle size of less than about 1000 microns (μm), and (ii) comprising perlite, expanded perlite, perlite hollow microspheres, perlite microspheres, milled expanded perlite, perlite flakes, cenospheres, glass bubbles, glass microbubbles, vermiculite, hollow expanded vermiculite, or any combination thereof. 
     
     
         27 . The system of  claim 26 , wherein said particles consist of perlite, expanded perlite, perlite hollow microspheres, perlite microspheres, milled expanded perlite, perlite flakes, or any combination thereof. 
     
     
         28 . A system for making insulated paper products with an uneven cross-sectional distribution of insulating material therethrough, said system comprising:
 (I) an apparatus comprising:
 a first paper forming wire moving along a first papermaking path; 
 a first headbox positioned to deposit a first pulp slurry onto the first paper forming wire; 
 a first formation plate positioned below the first paper forming wire proximate the first headbox; 
 at least one first nozzle positioned to deposit first insulating material onto the first paper slurry on the first paper forming wire; 
 one or more vessels, each vessel being (i) sized to house the first insulating material, and (ii) in fluid communication with the at least one first nozzle; 
 a second paper forming wire moving along a second papermaking path; 
 a second headbox positioned to deposit a second pulp slurry onto the second paper forming wire; 
 a second formation plate positioned below the second paper forming wire proximate the second headbox; and 
 at least one second nozzle positioned to deposit second insulating material onto the second paper slurry on the second paper forming wire, 
   wherein the second paper forming wire is positioned to deposit a second paper ply onto a first paper ply with first insulating material deposited thereon positioned along the first paper forming wire so as to form the insulated paper product with the first paper ply forming a first outer surface of the insulated paper product and the second paper ply forming a second outer surface of the insulated paper product opposite the first outer surface; and   (II) pulp fiber, first insulating material, and second insulating material.   
     
     
         29 . A method of making an insulated paper product with an uneven cross-sectional distribution of insulating material therethrough, said method comprising:
 forming one or more first paper layers with first insulating material thereon and/or therein on the first paper wire;   forming one or more second paper layers with optional second insulating material thereon and/or therein on the second paper wire; and   combining the one or more first paper layers with first insulating material with the one or more second paper layers with optional second insulating material so as to form the insulated paper product with the one or more first paper layers forming a first outer surface of the insulated paper product and the one or more second paper layers forming a second outer surface of the insulated paper product opposite the first outer surface.