Patent EA-001353-B1 (EA)
Title: Poly-coated paper composites
Inventor: MEDOFF MARSHALL
IPC: B32B9/00
Filed: 1998-08-27
Abstract: 1. A composite comprising resin reinforced with at least about 2% polycoated paper that has been sheared to the extent that the internal fibers are substantially exposed. 2. The composite of claim 1, wherein at least about 5% by weight of the poly-coated paper is texturized. 3. The composite of claim 1, wherein the poly-coated paper comprises polyethylene and paper. 4. The composite of claim 3, wherein the poly-coated paper further comprises aluminum. 5. The composite of claim 1, wherein the resin is a thermoplastic resin. 6. The composite of claim 5, wherein the thermoplastic resin is polyethylene. 7. The composite of claim 5, wherein the thermoplastic resin is polypropylene. 8. The composite of claim 1, wherein the composite comprises about 50% to about 70% by weight poly-coated paper and about 30% to about 50% by weight resin. 9. The composite of claim 1, wherein the composite further comprises lignocellulosic fiber. 10. The composite of claim 1, wherein the composite further comprises cellulosic fiber. 11. A composite comprising polyethylene reinforced with at least about 2% poly-coated paper, wherein at least about 50% by weight of the poly-coated paper has been sheared to the extent that the internal fibers are substantially exposed. 12. A composite comprising resin reinforced with at least about 2% poly-coated paper, wherein the poly-coated paper has been sheared to the extent that the internal fibers are substantial exposed, and wherein the composite has a flexural strength of at least 210,9 kg/cm<2>. 13. The composite of claim 12, wherein the composite has a flexural strength of at least 421,8 kg/cm<2>. 14. The composite of claim 12, wherein the composite has a flexural strength of at least 730 kg/cm<2>. 15. A composite comprising resin reinforced with at least about 2% poly-coated paper, wherein the poly-coated paper has been sheared to the extent that the internal fibers are substantial exposed, and wherein the composite has a tensile strength of at least 210,9 kg/cm<2>. 16. The composite of claim 15, wherein the composite has a tensile strength of at least 351,5 kg/cm<2>. 17. The composite of claim 15, wherein the composite has a tensile strength of at least 421,8 kg/cm<2>. 18. A process for manufacturing a composite comprising shearing poly-coated paper to the extent that its internal fibers are substantially exposed to form texturized poly-coated paper, and combining the texturized poly-coated paper with a resin. 19. The process of claim 18, wherein the resin is a thermoplastic resin. 20. The process of claim 18, wherein the step of shearing the poly-coated paper comprises shearing with a rotary knife cutter. 21. The method for forming texturized fiber material comprising shearing poly-coated paper to the extent that its internal fibers are substantially exposed to form the texturized fiber material. 22. The method of any claim 18 to 21, wherein the poly-coated paper comprises polyethylene and paper. 23. The method of claim 22, wherein the poly-coated paper comprises one or more aluminum layers. 24 The method of any claim 18 to 21, wherein least about 50% of the exposed internal fibers have a length/diameter ratio of at least 10. 25. The method of any claim 18 to 23, wherein at least about 50% of the exposed internal fibers have a length/diameter ratio of at least 25. 26. The method of any claim 18 to 23, wherein at least about 50% of the exposed internal fibers have a length/diameter ratio of at least 50. 27. The texturized fiber material comprising poly-coated paper having the internal fibers where said poly-coated paper is sheared to the extent that its internal fibers are substantially exposed. 28. The composite of any claim 1 to 5 and 8 to 17, wherein the polymer is selected from the group comprising polyethylene, polypropylene, polystyrene, polycarbonate, thermoplastic polyesters, polyethers, thermoplastic polyurethan, polyvinylchloride and polyamide. 29. The composite of any claim 1 to 17 and 28, wherein at least about 50% of the exposed internal fibers have a length/diameter ratio of at least 10. 30. The composite of any claim 1 to 17 and 28, wherein at least about 50% of the exposed internal fibers have a length/diameter ratio of at least 25. 31. The composite of any claim 1 to 17 and 28, wherein at least about 50% of the exposed internal fibers have a length/diameter ratio of at least 50. 32. The composite of any claim 1 to 17 and 28, wherein at least about 70% of the exposed internal fibers have a length/diameter ratio of at least 50.