Kaolin Clay Systems for Surface Enhancement

Recyclable multilayer films for Bag-in-Box packaging that replace metallized films and reduce polymer incompatibility for improved recyclability. The films use natural additives like green tea extract and nanoclays to enhance barrier properties instead of multiple polymers. This allows producing recyclable Bag-in-Box bags for wine and beverages with reduced environmental impact compared to metallized bags. The bags have an outer layer with nanoclays and an inner layer with natural antioxidant masterbatch instead of multiple polymer layers.

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A paperboard for packaging liquid and/or frozen food that provides good moisture barrier properties without the need for separate coating steps. The paperboard has a dispersion coating on one side containing latex and pigments like clay and calcium carbonate. The dispersion coating forms a barrier against moisture ingress and improves optical properties compared to traditional extrusion coated barriers. The dispersion coating is applied directly onto the untreated paperboard without intermediate drying steps. This allows the moisture content of the paperboard to remain similar before and after coating, preventing cracking.

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Packaging material for retortable packages that can withstand sterilization by heat and steam. The material has a coated paperboard layer with a pigment coating containing calcium carbonate, clay, binder, and zirconium crosslinker. This coating allows printing decorations that retain quality after sterilization compared to uncoated paperboard. The pigment composition with calcium carbonate and clay provides a stable, printable base for the retortable packaging.

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Cardboard for packaging liquid and frozen foods that provides a barrier to moisture while still allowing good print quality. The cardboard has a dispersion barrier layer on one side, formed by applying a dispersion coating directly onto the untreated cardboard surface. The dispersion coating contains pigments like clay and calcium carbonate that provide barrier properties and optical effects. The dispersion coating is dried to form a barrier layer on the cardboard surface without cracking. This allows the cardboard to be printed on the coated side without issues. The dispersion coating provides a barrier against moisture from condensation while still allowing good printability.

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Laminated sheet and food packaging container with improved hiding properties by optimizing the particle size distribution of the inorganic powder used in the inner layer. The laminated sheet has at least three layers, with an inner layer containing an inorganic powder and thermoplastic resin. The particle size distribution of the inorganic powder should have D20 of 2.0-3.4 μm, D50 of 4.8-7.6 μm, and D70 of 7.7-11.6 μm. This prevents variations in hiding power when using high content of inorganic powder. The container is formed from the laminated sheet by vacuum forming.

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Paperboard for packaging liquid and frozen foods that provides a barrier against moisture resulting from condensation while maintaining good optical properties and printability. The barrier is achieved by applying a dispersion coating on the exterior side of the paperboard containing latex (30-50%) and clay (50-70%) pigments. This dispersion barrier replaces traditional polymer coatings on the exterior side for a simplified and more sustainable packaging solution.

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Coating formulations for paper and paperboard with improved hiding power and coverage. The coatings contain modified clay pigments with higher shape factors compared to conventional clays. The modified clays have plate-like shapes that pack less densely, allowing more space between particles and increasing the volume of the coating for a given weight. This results in better hiding power and coverage compared to standard clay coatings. The modified clay shape factors are calculated based on particle size distributions.

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Laminated packaging sheet for food containers with improved appearance and mechanical properties. The inner layer contains polyethylene, polypropylene, inorganic powder, and lauric acid diethanolamide. The outer layers have polyethylene and polypropylene. The inner layer has a ratio of 90-50% resin to 10-50% inorganic powder, and the outer layers are 20-50% resin each. The lauric acid diethanolamide and inorganic powder enhance appearance without reducing mechanical properties. The thicker outer layers maintain appearance while protecting the inner layer. The sheet is suitable for vacuum forming into food containers.

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Packaging materials for food that are harmless to humans and the environment by adding biodegradable and photodegradable materials to synthetic resins like polyethylene. The materials include clay minerals like mica, biodegradable polymers like polylactic acid, and photodegradable materials like cobalt fatty acids. The composition also contains plasticizers, inorganic fillers like calcium carbonate, and plant extracts. This enables the packaging to decompose naturally instead of polluting.

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Tipping wrapper for cigarettes that provides shiny appearance, good lip release, and prevents ink abrasion while being non-combustible. The tipping wrapper has a base layer with low porosity (<1.5 C.U.) containing fillers like TiO2. The outer surface is pigmented with a mixture of CaCO3 and a non-combustible filler like clay. This pigmented layer has a high grammage (2.0 gsm) and smoothness (400 sec) to prevent sticking and ink abrasion. The pigmented surface gives shiny appearance without needing silver ink or calandering. The non-combustible filler replaces TiO2 for health concerns.

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Composite packaging material for shipping and transportation applications that is durable, low cost, attractive, and environmentally friendly. The composite material has two layers: a fiber-containing layer for machinability and a mineral-containing layer for strength. The layers are bonded together. The mineral layer is made with earth minerals like talc, diatomaceous earth, mica, or clay mixed with binders like polymers. This provides burst and tear resistance. The fiber layer adds machinability for forming final packaging shapes. The composite structure can be molded into boxes or cards for shipping and transportation uses. The composite balances strength, printability, machinability, and environmentally friendly materials.

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Coating compositions for paperboard that have higher bulk volume and better hiding power compared to conventional coatings. The coating compositions contain kaolin clay with a specific particle size distribution to increase packing density and reduce compaction. The clay has fewer fines (less than 30% <1 μm particles) and a higher sediment void volume (>48%) compared to standard clay. This modified clay provides looser packing and higher bulk volume when used as a pigment in coatings.

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Coating paperboard with a low packing density clay to improve the properties of the coated paperboard. The clay used has a specific particle size distribution with a low proportion of fine particles. This clay has a particle size distribution where less than 30% of the particles are smaller than a certain diameter. By using this clay in coatings applied to paperboard, it allows reducing the coating weight and thickness compared to standard clay coatings without sacrificing properties like whiteness or opacity. The lower packing density clay provides better hiding power and reduces the amount of coating needed.

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Cardboard for packaging liquid and frozen foods with improved barrier properties and printability compared to conventional coatings. The cardboard has a dispersion barrier coating applied directly onto the printing side instead of traditional extrusion coatings. The dispersion coating uses aqueous dispersions of pigments like clay and calcium carbonate to create a solid, non-porous film. This provides a barrier against moisture and liquid penetration while maintaining printability. The dispersion coating can be applied using roller and rod coaters. The dispersion coating layers can contain crosslinkers to improve barrier properties.

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A paperboard for packaging liquid and/or frozen food that provides a barrier against moisture while having good optical properties for printing. The paperboard has a dispersion coated barrier layer on one side made by applying a latex dispersion containing clay or calcium carbonate pigment. This layer forms the printing surface. The coated paperboard can be produced by applying the dispersion directly to the substrate and drying it. The coating composition has latex at 30-40% and pigment at 50-70% by weight. This provides a barrier against moisture without the limitations of extrusion coating. The paperboard can also have a polymer layer on the other side for additional barrier properties.

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Multilayer sheet, tray, and packaging with excellent water vapor and oxygen barrier properties, sealing capability, and moldability. The multilayer structure has outer surface layers without fillers, a middle water vapor barrier layer with fillers, and an oxygen barrier layer. The water vapor barrier layer has fillers like talc, mica, or layered silicates. The fillers have aspect ratios of 5-200 and plate-like or scalelike shapes. The multilayer sheet has low water vapor (0.3 g/m²/day) and oxygen (0.35 cc/m²/day) permeation, and good sealing. The middle barrier layer is 37.5-90% of total thickness. The outer layers have glossiness of 10-40 at 60°. The multilayer sheet is moldable

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Water-dispersible coating composition for paper that provides improved moisture resistance and blocking properties for eco-friendly food packaging paper. The coating composition contains an acrylic polymer resin and a pigment with specific particle size limitations. The pigment choices are clay, talc, and calcium carbonate. The pigment particles should have a size of 4 nm to 1800 nm. Smaller than 4 nm isn't practical due to cost and larger than 1800 nm has issues with uniform mixing and barrier performance. The pigment particles are blended with the acrylic polymer resin using it as a binder. The coating composition is applied to paper to make food packaging paper with improved moisture resistance, water resistance, oil resistance, and recyclability compared to traditional coatings.

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Eco-friendly coating for food packaging paper that is reusable without generating harmful substances. The coating improves durability and reusability of food packaging paper without using harmful plastics like polyethylene. The coating is made from a water-soluble resin, plasticized cellulose derivative, slip agent, dispersant, and smectite clay particles. The cellulose derivative is plasticized to improve flexibility. The slip agent prevents sticking. The dispersant helps the particles mix. The smectite clay particles provide weatherability. The coating enables multiple reuses without agglomeration and pollution issues compared to plastic coatings.

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Kraft paper with improved strength and printability for packaging liquids like pillows, as well as a multilayer material and a manufacturing method to make it. The kraft paper has a specific grammage range of 65-85 g/m2 and is made from at least 50% kraft pulp. The paper has higher strength and lower fiber consumption compared to standard kraft paper. To improve print quality, hydrophobic sizing, starch, and clay can be added. The paper is produced by calendaring to reduce surface roughness. The multilayer material uses this improved kraft paper as a layer sandwiched between coatings. This provides a packaging material with enhanced strength, printability, and liquid resistance compared to standard kraft paper.

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Coated paperboard with improved opacity and printability by using a low fine particle kaolin clay with specific particle size distribution and packing density. The clay contains less than 30% of particles below 1 micron diameter, measured by Sedigraph analysis. This clay has a sediment void volume greater than 48% indicating low packing density. This modified clay coating provides better opacity and printability on paperboard compared to standard clays.

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