Extensible high puncture-resistant recyclable paper-based packaging structures

Abstract

Recyclable, paper-based packaging structures and articles comprise extensible or semi-extensible paper layer with an anisotropy ratio in the range of 0.67 to 1.5 and a polymer extrusion coating layer. Methods for forming same are also provided. The structures and articles have a puncture resistance of 3 lbf or greater. Recyclable, paper-based packaging structures and articles and methods are formed using a polymer extrusion coating layer disposed on one side of an extensible or semi-extensible paper layer having an anisotropy ratio in the range of 0.67 to 1.5. A second polymer extrusion coating layer is disposed on a second side of the paper substrate layer. Advantageously, the paper substrates have a puncture resistance in the range of 3 lbf to 13.5 lbf.

What is claimed is: 
     
         1 . A paper-based recyclable packaging structure for use in applications with high product weight, the structure comprising:
 a paper layer having a first surface and a second surface opposite the first surface, the paper layer comprising paper having an anisotropy ratio in the range of 0.67 to 1.5; and   a first polymer extrusion coating layer disposed on the second surface of the paper layer, wherein a paper fiber content of the paper-based structure is in the range of 60% by weight to 99% by weight.   
     
     
         2 . The paper-based recyclable packaging structure of  claim 1 , wherein the paper layer has a puncture resistance in the range of from 3 lbf to 13.5 lbf. 
     
     
         3 . The paper-based recyclable packaging structure of  claim 1 , wherein the first polymer extrusion coating layer is selected from the group consisting of polyethylene, polypropylene, polyolefin blends, polyolefin copolymers, low-density polyethylene, very low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, linear medium density polyethylene, high-density polyethylene, metallocene polyethylene, metallocene linear low-density polyethylene, polyolefin plastomer, cast polypropylene, ethylene-propylene copolymer, monoaxially-oriented polyolefins, biaxially-oriented polyolefins, ionomer resins, SURLYN™, ethylene-vinyl acetate copolymer, ethylene methyl acrylate copolymer, ethylene acrylic acid copolymer, ethylene-methyl methacrylate copolymer, polyvinyl alcohol, or any combination thereof. 
     
     
         4 . The paper-based recyclable packaging structure of  claim 1 , wherein the first polymer extrusion coating layer is a coextrusion coating comprising first and second polymer layers, a first barrier layer disposed between the first and second polymer layers, an optional first tie layer disposed between the first polymer layer and the first barrier layer and an optional second tie layer disposed between the first barrier layer and the second polymer layer. 
     
     
         5 . The paper-based recyclable packaging structure of  claim 4 , wherein the first and second polymer layers comprise a polyolefin selected from the group consisting of polyethylene, polypropylene, and blends and copolymers thereof, and wherein the first barrier layer is selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), nylon, nylon 6, nylon 66, nylon 6/66, polyvinyl alcohol (PVOH), and any combination thereof. 
     
     
         6 . The paper-based recyclable packaging structure of  claim 1 , further comprising a second polymer extrusion coating layer disposed on the first surface of the paper layer. 
     
     
         7 . The paper-based recyclable packaging structure of  claim 6 , wherein the second polymer extrusion coating layer is selected from the group consisting of polyethylene, polypropylene, polyolefin blends, polyolefin copolymers, low-density polyethylene, very low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, linear medium density polyethylene, high-density polyethylene, metallocene polyethylene, metallocene linear low-density polyethylene, polyolefin plastomer, cast polypropylene, ethylene-propylene copolymer, monoaxially-oriented polyolefins, biaxially-oriented polyolefins, ionomer resins, SURLYN™, ethylene-vinyl acetate copolymer, ethylene methyl acrylate copolymer, ethylene acrylic acid copolymer, ethylene-methyl methacrylate copolymer, polyvinyl alcohol, and any combination thereof. 
     
     
         8 . The paper-based recyclable packaging structure of  claim 6 , wherein the second polymer extrusion coating layer is a coextrusion coating comprising third and fourth polymer layers, a second barrier layer intermediate the third and fourth polymer layers, and an optional third tie layer disposed between the third polymer layer and the second barrier layer and an optional fourth tie layer disposed between the second barrier layer and the fourth polymer layer. 
     
     
         9 . The paper-based recyclable packaging structure of  claim 8 , wherein the third and fourth polymer layers comprise a polyolefin selected from the group consisting of polyethylene, polypropylene, and blends and copolymers thereof, and wherein the second barrier layer is selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), nylon, nylon 6, nylon 66, nylon 6/66, polyvinyl alcohol (PVOH), and any combination thereof. 
     
     
         10 . The paper-based recyclable packaging structure of  claim 1 , wherein the paper layer has a basis weight in a range of from about 25 lb to about 70 pounds per ream. 
     
     
         11 . A packaging article formed from the paper-based recyclable packaging structure of  claim 1 . 
     
     
         12 . A method for producing a paper-based recyclable packaging structure, the method comprising the steps of:
 providing a paper layer having a first surface and a second surface with an anisotropy ratio in the range of 0.67 to 1.5; and   providing a first polymer extrusion coating layer disposed on the second surface of the paper layer;   wherein the paper layer comprises a paper fiber content such that the paper-based recyclable structure product of the method comprises a structure fiber content in the range of 60% by weight to 99% by weight.   
     
     
         13 . The method of  claim 12 , wherein the paper layer is formed of an extensible of semi extensible paper material having a puncture resistance in the range of from 3 lbf to 13.5 lbf. 
     
     
         14 . The method of  claim 12 , wherein the paper layer has a basis weight in a range of from about 25 lb to about 70 pounds per ream. 
     
     
         15 . The method of  claim 12 , wherein the first polymer extrusion coating layer is selected from the group consisting of polyethylene, polypropylene, polyolefin blends, polyolefin copolymers, low-density polyethylene, very low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, linear medium density polyethylene, high-density polyethylene, metallocene polyethylene, metallocene linear low-density polyethylene, polyolefin plastomer, cast polypropylene, ethylene-propylene copolymer, monoaxially-oriented polyolefins, biaxially-oriented polyolefins, ionomer resins, SURLYN™, ethylene-vinyl acetate copolymer, ethylene methyl acrylate copolymer, ethylene acrylic acid copolymer, ethylene-methyl methacrylate copolymer, polyvinyl alcohol, and any combination thereof. 
     
     
         16 . The method of  claim 12 , wherein the first polymer extrusion coating layer is a coextrusion coating layer comprising first and second polymer layers, a first barrier layer disposed intermediate the first and second polymer layers, an optional first tie layer disposed between the first polymer layer and the first barrier layer and an optional second tie layer disposed between the first barrier layer and the second polymer layer. 
     
     
         17 . The method of  claim 16 , wherein the first and second polymer layers comprise a polyolefin selected from the group consisting of polyethylene, polypropylene, and blends and copolymers thereof, and wherein the first barrier layer is selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), nylon, nylon 6, nylon 66, nylon 6/66, polyvinyl alcohol (PVOH), and any combination thereof. 
     
     
         18 . The method of  claim 12 , further comprising the steps of providing a second polymer extrusion coating layer on the second surface of the paper layer via extrusion coating. 
     
     
         19 . The method of  claim 18 , wherein the second polymer extrusion coating layer is selected from the group consisting of polyethylene, polypropylene, polyolefin blends, polyolefin copolymers, low-density polyethylene, very low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, linear medium density polyethylene, high-density polyethylene, metallocene polyethylene, metallocene linear low-density polyethylene, polyolefin plastomer, cast polypropylene, ethylene-propylene copolymer, monoaxially-oriented polyolefins, biaxially-oriented polyolefins, ionomer resins, SURLYN™, ethylene-vinyl acetate copolymer, ethylene methyl acrylate copolymer, ethylene acrylic acid copolymer, ethylene-methyl methacrylate copolymer, polyvinyl alcohol, and any combination thereof. 
     
     
         20 . The method of  claim 18 , wherein the second polymer extrusion coating layer is a coextrusion coating layer comprising third and fourth polymer layers, a second barrier layer disposed intermediate the third and fourth polymer layers, an optional third tie layer disposed between the third polymer layer and the second barrier layer and an optional fourth tie layer disposed between the second barrier layer and the fourth polymer layer. 
     
     
         21 . The method of  claim 20 , wherein the third and fourth polymer layers comprise a polyolefin selected from the group consisting of polyethylene, polypropylene, and blends and copolymers thereof, and wherein the second barrier layer is selected from the group consisting of ethylene-vinyl alcohol copolymer (EVOH), polyamide (PA), nylon, nylon 6, nylon 66, nylon 6/66, polyvinyl alcohol (PVOH), and any combination thereof. 
     
     
         22 . The method of  claim 12 , further comprising forming a packaging article from the paper-based recyclable packaging structure. 
     
     
         23 . The method of  claim 22 , wherein the packaging article is a bag configured to support a high product weight.