摘要：
A composite structure comprises a fiber-containing layer, such as a layer of paperboard or other layer having fibers from natural and/or synthetic sources, and a mineral-containing layer covering the fiber-containing layer. The mineral-containing layer is substantially continuously bonded to the fiber-containing layer along the surface of the fiber-containing layer and provide a printing surface. The fiber-containing layer and mineral-containing layer can be shaped, sized, and manufactured such that the composite structure formed therefrom is capable of being machined to form a storage article. The composite structure further has tensile strength and other characteristics that allow it to be readily machined into desired storage article forms, such as box, carton, and other forms.
权利要求：
WHAT IS CLAIMED IS:
1. A printable and machinable composite structure of from about 2 to 1000 mils (0.051 mm to 25.4 mm) thick, the structure by weight equal to or less than about 525 lbs/1000 sq. ft. (22.15 kg/m ) basis weight containing less than 25% polymers, and containing natural mineral content comprising:
a fiber-containing layer formed from natural fibers from about 1.3 mil to 900 mil thickness (0.033 to 22.86 mm), the layer being solid and having opposing flat contact surfaces, wherein the fiber-containing layer has a basis weight of from about 20 to 800 g/m2 and tensile strength of from about 20 to about 1200 MD and about 25 to 1500 CD; and
an organic mineral-containing layer formed of minerals with a polymer bonding agent forming a mineral composite layer, wherein a mineral containing layer comprises a basis weight of about 15 to 500 lbs/1000 sq. ft. (0.63 to 21.08 kg/m2);
wherein the mineral-containing layer is substantially and continuously bonded, without requiring stretching, across the entire contact surface of the fiber-containing layer;
wherein at least one outer facing surface of the mineral-containing layer comprises a bonding agent content from about 15% or more the weight of the layer;
wherein the composite structure contains organic mineral content on at least one surface layer;
wherein the composite structure comprises one outer facing mineral containing layer with at least 15% by weight bonding agent, said bonding agent comprising a selection of polymers, co-polymers, homo-polymers, and monomers such that the composite per ASTM D228-02 #10 and ASTM D 6125-97 (2002) has a more pliable surface than a 100% natural fiber structure;
wherein the composite structure comprises one outer facing mineral containing layer with at least 15% by weight bonding agent, said bonding agent comprising a selection of polymers, co-polymers, homo-polymers, and monomers such that the composite has a more water resistant surface than 100% natural fiber; structure;
wherein the composite structure comprises at least one outer facing mineral containing layer that is printable using common printing techniques; and
wherein the composite structure comprises at least 40% natural fibers; and
wherein at least one surface-facing mineral containing layer comprises on or about at least 1% by weight of the composite.
2. The composite structure according to claim 1 wherein the composite structure further comprises woven and non-woven webbing reinforcement, for example “scrim,” as one or more layers.
3. The composite structure according to either claim 1 or 2 wherein the mineral-containing layer comprises a pliable mineral composite containing an amount of a thermo-formable bonding agent sufficient so that a storage article containing the mineralcontaining layer may be formed into a selected shape via thermo-forming, pressure forming, or vacuum forming.
4. The composite structure according to any preceding claim wherein the fiber-containing layer is poly coated.
5. The composite structure according to any preceding claim wherein one or more surfaces are clay coated.
6. The composite structure according to any preceding claim wherein one or more surfaces are coated with water or solvent based heat seal coatings.
7. The composite structure according to any preceding claim wherein one or more layers are formed into a corrugated shape.
8. The composite structure according to any preceding claim wherein the mineral-containing layer comprises sustainable polymer content of at least one of the group consisting of bio-polymers; for example, starch, wheat, com, and others.
9. The composite structure according to any preceding claim wherein the fiber-containing layer comprises at least one of the group consisting of bleached Kraft board, unbleached Kraft board, recycled folding boxboard, folding box board, coated recycled board, and uncoated recycled board.
10. The composite structure according to any preceding claim wherein the fiber-containing layer comprises a basis weight of from about 5 to about 800 lbs/1000 sq. ft., (0.42 to about 33.7 kg/m2), a thickness of from about 4.0 mils to about 45 mils (0.10 to about 1.14 mm), and a tensile strength of from about 75 to about 1200 MD and about 25 to about 900 CD.
11. The composite structure according to any preceding claim comprising a basis weight of from about 648 to about 2640 g/m , a thickness of from about 45 mils to about 80 mils, (1.14 to 2.03 mm) and a tensile strength of from about 375 to about 2700 MD and about 648 to about 2640 CD.
12. A composite structure according to any preceding claim containing by weight less than 25% polymers and containing at least 5% natural mineral content, the composite structure comprising:
a fiber-containing layer formed from natural fibers in calipers between around 1.5 mils and 990 mils (0.04 and 25.15 mm), the layer being solid or semi-solid and having opposing flat contact surfaces that may or may not require calendaring, wherein the fiber-containing layer has a basis weight of from about 10 to about 610 lbs/1000 sq. ft., (0.46 to about 28.1 kg/m2) and a tensile strength of from about 20 to about 1200 MD and about 25 to about 1500 CD; and
a mineral-containing layer containing an interspersed or non-interspersed polymer bonding agent, comprising a basis weight of about 35 g/m to about 1500 g/m , blended or unblended within the composite, with said mineral-containing layer comprising at least 2% by weight of the entire composite structure, a density from about 0.30 g/cm to 1.5 g/cm , with calipers between 1.3 mil and 50.0 mil (0.033 and 1.27 mm) and containing organic minerals;
wherein the mineral-containing layer is substantially and continuously bonded, with our without requiring stretching, across the entire contact surface of the fibercontaining layer
13. A composite structure according to any preceding claim containing polymers and natural mineral content, the composite structure comprising:
a fiber-containing layer formed from natural fibers in calipers between around 1.5 mils and 990 mils (0.038 and 25.15 mm) and the layer being solid or semi-solid and having opposing flat contact surfaces that may or may not require calendaring,
2 wherein the fiber-containing layer has a basis weight of from about 20 to 1500 g/m , and a tensile strength of from about 20 to about 1200 MD and about 25 to about 1500 CD; and
a mineral-containing layer containing an interspersed or non-interspersed polymer bonding agent, comprising a basis weight of about 5 Ib./lOOO sq. ft. to about 915 lbs/1000 sq. ft. (0.21 to about 39 kg/m ), blended or unblended within the composite, with said mineral-containing layer comprising at least 1% by weight of the entire composite structure, a density from about 0.30 g/cm to 1.5 g/cm , with calipers between 1.3 mil and 50.0 mil, (0.033 and 1.27 mm) and containing organic minerals;
wherein the mineral-containing layer is adhered to the surface of the fibercontaining layer.
14. A recycled paper-containing composite structure having at least one polymer-containing layer printable using common flexographic and offset printing techniques, said composite containing less than 70% polymers, with a caliper of about at least 0.203 mm and an MD tensile strength less than 3700, the composite structure comprising:
a fiber-containing layer having recycled content, the fiber-containing layer formed in calipers between about 0.0381 mm to about 25.146 mm, the layer having opposing flat contact surfaces, wherein the fiber-containing layer has a basis weight of from about 20 g/m to 1500 g/m , and a tensile strength of from about 20 CD to about 1200 MD and about 25 MD to about 1500 CD; and
a polymer-containing layer comprising a basis weight of from about 30 g/m to about 1500 g/m , a density from about 0.30 g/cm to about 1.5 g/cm , with calipers between 0.033 mm to about 1.27 mm with said polymer-containing layer comprising at least 2% by weight of the entire composite structure;
wherein the polymer-containing layer is adapted to be adhered across the entire contact surface of the fiber-containing layer; and
wherein the composite structure has at least one polymer-containing layer that is printable using common flexographic and offset printing techniques, and said composite structure containing less than 70% polymers.
15. A printable and machinable composite structure by weight containing less than 25% polymers and containing at least one polymer-containing surface layer, the composite structure comprising:
at least one fiber-containing layer formed from natural fibers in thicknesses less than 25.146 mm, the layer having opposing surfaces, wherein the fiber-containing layer has a basis weight from about 40 g/m to 1500 g/m
at least one polymer-containing layer with a minimum density from about 0.40 g/cm , with said polymer-containing layer comprising from about 2% or more by weight of the entire composite structure;
wherein a polymer-containing layer is adhered across the contact surface of at least one fiber-containing layer;
wherein the polymer-containing layer comprises at least 2% natural minerals;
wherein the composite structure contains by weight over 40% fibers; and wherein the composite structure contains at least one outer fiber layer.
16. A machinable and printable recycled fiber-containing composite structure having at least one fiber-containing layer printable using common printing techniques, said composite structure containing less than 25% polymers and at least 40% by weight of fibers, the composite structure comprising:
a fiber-containing layer having opposing flat contact surfaces, wherein the fiber-containing layer has a basis weight from about 40 g/m to 1500 g/m ; and
a polymer-containing layer having a minimum density about 0.40 g/cm , with said polymer-containing layer comprising on or about at least 2% by weight of the entire composite structure;
wherein the polymer-containing layer is adapted to be adhered across the entire contact surface of at least one fiber-containing layer;
wherein at least one fiber containing layer comprises on or about 50% or more recycled content and at least 25% by weight of the entire composite; and
wherein the composite structure has at least one fiber-containing layer that is adapted to be printable using common printing techniques, the polymer-containing layer making surface contact with at least one fiber-containing layer.