Patent Description:
Food sold in fast food restaurants is often wrapped in a low basis weight paper product. The wrapping paper is often treated with a coating to provide wet strength, such as a silicone, or a fluorocarbon, or a wax, and further is often laminated to a thin aluminum foil. The aluminum foil serves several purposes. First, aluminum has a low thermal emissivity, and so the foil layer provides thermal insulation. Second, the foil adds some resiliency to the paper when subjected to hot moisture and lipids, such as vegetable and animal fats, dairy products etc..

While cheap to produce, manufacture, and effective at insulating, such laminated foil paper products also have many disadvantages. Aluminum foil (<NUM>) is persistent in the environment as it does not decompose, contributing to long term landfills, (<NUM>) is frequently litter that is unsightly and may cause obstruction in the guts of smaller animals when ingested, (<NUM>) is not recyclable or repulpable, causing problems if accidentally introduced into a repulping mill, (<NUM>) does not burn if the material is incinerated and (<NUM>) has been linked to certain neurodegenerative diseases in humans when ingested.

For similar reasons, some paper beverage cups are also difficult to recycle. They are coated with a low molecular weight polyethylene, which causes problems when introduced into the pulp.

What is needed is a highly thermally insulating paper structure that provides one or more of the following benefits: (<NUM>) is non-toxic and safe for use with food, (<NUM>) is thin and can be supplied to restaurants in roll or sheet format, (<NUM>) insulates hot food from cooling, (<NUM>) is recyclable by municipal recycling services without separation or segregation from other papers in the waste stream, (<NUM>) is biodegradable or biodestructable and therefore ephemeral when released into the environment (<NUM>) is able to maintain integrity with condensation formation after wrapping hot food, and (<NUM>) is resistant to the penetration of oils and fats.

The present invention is directed to insulated paper products as defined in claims <NUM>-<NUM> that (<NUM>) insulate food positioned therein and/or surrounded thereby, (<NUM>) are biodegradable or biodestructable, recyclable, repulpable, and (<NUM>) can be printed and decorated, and (<NUM>) are food contact safe. The disclosed insulated paper products utilize a coating that acts in a similar manner to a laminated aluminum foil. Insulating materials included within the coating are coated onto a variety of paper products.

In another embodiment, the present invention is directed to a repulpable storage container comprising the insulated paper product of the present invention as defined in claim <NUM>.

The present document further describes methods of making insulated paper products. A method of making an insulating wrapping paper product may comprise: forming a paper sheet comprising one or more layers on a fourdrinier wire, then coating the formed paper layer with a coating with a low thermal conductivity and/or a low thermal emissivity onto the paper layer. A method of making an insulating wrapping paper product may further comprise coating the formed paper layer with a moisture barrier and/or a grease resistant layer at the size press, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity.

For example, a method of making an insulating wrapping paper product may comprise: forming a paper sheet comprising one or more layers, then coating the formed paper layer with a moisture barrier and/or a grease resistant layer on one side, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity on the opposite side.

In another example, a method of making an insulating wrapping paper product may comprise: forming a paper sheet comprising one or more layers, then coating the formed paper layer with a moisture barrier and/or a grease resistant layer on one side, and then coating a thin layer of a coating with a low thermal conductivity and/or a low thermal emissivity on the same side.

The present invention is even further directed to methods of using insulated paper products as defined in claim <NUM>. The method of using an insulated paper product comprises: insulating an object (e.g., food, medicine, pharmaceuticals, ice, flowers, etc.) via any one of the herein-described insulated paper products.

These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments and the appended claims.

The present invention is further described with reference to the appended figure, wherein:.

The present invention is directed to insulated paper products as defined in claims <NUM>-<NUM> comprising fibers <NUM> (e.g., wood pulp fibers <NUM>) and insulating material <NUM>. Although shown in all figures, each paper layer <NUM> comprises fibers <NUM> (e.g., wood pulp fibers <NUM>) with or without other paper layer additives including, but not limited to, an insulating material <NUM>. Some definitions of fibers, paper, and packaging, as well as product specification and fiber sources, are provided below.

As used herein, the term "paper" is used to identify a type of non-woven material in which fibers are randomly oriented in all directions. Fibers principally made from cellulose are poured as a slurry on a mesh screen. As the paper is formed, the fibers come into contact with each other, and physically bond with neighboring fibers via a variety of interactions, including hydrogen bonding. The fibers originally come from plants including trees, although synthetic and mineral fibers, or other types of fibers, may optionally be included. Often, the paper also contains recycled fiber. Wood may be sourced from direct harvesting of trees from forest land, or from lumber industry byproducts (such as sawdust).

Paper fibers may include the fibrous portions from many parts, including softwoods (such as those plants with needles instead of leaves, for example, loblolly pine) and hardwoods. Other plants that yield useful paper fibers include but are not limited to bamboo, sugar cane, wheat straw, reed grass, mischanthus grass, coconut fiber, hemp fiber, cotton fiber, jute, palm, reeds, and papyrus. Cellulose fibers in many plants are bound together with lignin.

In the case of virgin (non-recycled) fiber, much of the lignin is removed during the pulping process. Recycled paper may include fibers from corrugated, fiber board, writing paper, pressboard, card, newspaper, tissue paper, specialty papers, linerboard, containerboard, boxboard, PE-lined paperboard, carton material, cup stock, or foodboard.

When made from trees, the pulping process involves methods to separate the individual cellulosic fibers into a slurry, as well as remove some or all of the lignin. Pulping methods may include a) thermomechanical pulping, which involves the use of steam and sheer forces generated between a spinning and a stationary plate, b) chemical pulping, which uses strong chemicals to break down the pulp by dissolving the lignin, and/or c) the semi-chem process, which uses a combination of mechanical and chemical methods. Most often, fluted medium board (e.g., fluted medium board <NUM>) is made using semi-chem process pulp and/or recycled paper fiber. Other types of pulp include solid bleached sulfate pulp, chipboard, and kraft.

Paper (and paper layer <NUM>), as used herein, may broadly include any material that includes <NUM>% or more cellulose fibers (discussed further below). Other additives, including insulating material <NUM>, other particles/additives/components that impart grease resistant and/or water resistant, as well as other particles/additives/components to impart strength. Non-paper (and non-paper layer <NUM>) is anything containing less than <NUM>% of cellulose fibers (discussed further below).

As used herein, the term insulating material, such as insulating material <NUM>, is used to describe inorganic or organic materials that provide some degree of insulation. The term insulating material, as in insulating material <NUM>, does not include air alone or any other gas alone, although air and/or another gas could be trapped within one or more inorganic or organic insulating material <NUM>.

Paper products <NUM>/<NUM>'/<NUM>, comprising fibers <NUM> (e.g., wood pulp fibers <NUM>) and insulating material <NUM>, can either be made flat (e.g., insulated paper products <NUM>/<NUM>') using a screen to make flat materials, or alternatively be molded, vacuum formed, or thermoformed from a pulp suspension to form essentially three-dimensional (non-flat) objects (e.g., molded or otherwise formed containers <NUM> shown in <FIG>). Such three-dimensional paper products include certain packaging, for instance, egg crates and egg cartons, packaging that protects the corners of products shipped in the mail, biodegradable compost containers, biodegradable plant pots, disposable urinals and bed pans used in hospitals, disposable cat little boxes, and the like. Additives, including insulating material <NUM>, may be included within and/or on the paper products <NUM>/<NUM>'/<NUM> to impart thermal insulation properties, strength under moist or wet conditions, impart water repellency or water proofing, impart grease absorption resistance, increase strength, improve the color, improve printability, or other aesthetic aspects.

Additives, including insulating material <NUM>, may be added to the paper pulp prior to casting on the paper wire or otherwise molding the pulp with additives into a product <NUM>/<NUM>'/<NUM>. Alternatively, additives, including insulating material <NUM>, may be added at the size press, or after the steam can dryers. Additives, including insulating material <NUM>, can also be added to a clay coating (e.g., coating <NUM>) often applied to liner board (e.g., liner board <NUM>/<NUM>) to make clay coated kraftback, or clay coated newsback.

According to the invention, the insulating material is present in a thermally insulating coating as defined in claim <NUM>.

Paper packaging (e.g., containers <NUM> shown in <FIG>), formed from the insulated paper products <NUM>/<NUM>'/<NUM>" of the present invention, may include a wide variety of formats, including: regular slotted container (RSC), overlap slotted container, full overlap slotted container, special center slotted container, Bag-in-Box, center special overlap slotted container, center special full-overlap slotted container, snap- or <NUM>-<NUM>-<NUM>-bottom box with tuck top, snap- or <NUM>-<NUM>-<NUM>-bottom box with RSC top, Full Bottom File Box, Hamper Style, Ft. Wayne Bottom or Anderson Lock Bottom, Bellows Style top and Bottom Container, Integral Divider Container, RSC with Internal Divider or Self Divider Box, Full-telescope Design-style Box, Full-telescope Half-slotted Box, Partial-Telescope Design-style Box, Partial-telescope half-slotted box, Design-Style Box with cover, Half-slotted Box with cover, Octagonal Double Cover Container, Double cover box, Interlocking Double-Cover box, double-thickness score-line box, one-piece folder, two-piece folder, three-piece folder, fiver panel folder, one piece folder with air cell/end buffers (used to protect e.g. books), wrap-around blank, tuck folder, one piece telescope, double-slide box, number <NUM> or <NUM> bliss box, recessed end box, self-erecting box, pre-glued auto bottom with RSC top flaps, four corner tray, self-erecting six-corner tray, flange box, Arthur lock bottom, valentine lock container, reverse valentine lock container.

Medium board used in the insulated paper products <NUM>/<NUM>'/<NUM>" of the present invention may be fluted with flutes of different dimensions. See, for example, exemplary fluted medium board <NUM> shown in <FIG>). The Fiber Box Handbook defines flutes and flute dimensions as: A, B, C, E, F, G, K, N, as well as R/S/T/D. The liner and medium papers may also be tested and rated by different burst grade: <NUM>-<NUM> SW, <NUM>-<NUM> ECT, <NUM>-<NUM> DW, <NUM>-<NUM> ECT DW, <NUM>-<NUM> TW, <NUM>-<NUM> ECT TW. The carton or box (e.g., box <NUM>) may then be folded into the following industry known styles: reverse tuck, snap lock, automatic bottom, straight tuck, tuck top snaplock bottom, tuck top automatic bottom, seal end, beers, mailing envelopes, folder, and simplex.

Generally, an insulated paper product may comprise a single paper layer with insulating material dispersed therein or coated thereon, or may comprise two or more paper layers in combination with insulating material, wherein the insulating material is within one or more of the paper layers of the insulated paper product and/or is present as a component within the insulated paper product (e.g., as a separate layer from the paper layers and/or as a filler within a layer or component of the insulated paper product). See, for example, exemplary insulated paper products <NUM>/<NUM>'/<NUM>" in <FIG>. According to the invention, the insulating material is present in a thermally insulating coating as defined in claim <NUM>.

The insulated paper products of the present invention may further comprise one or additional layers other than the one or more paper layers and layers of insulating material. Suitable additional layers may include, but are not limited to, a coating that provides reduced emissivity of the insulated paper product, a coating that provides a desired color and/or surface texture for the insulated paper product, and a coating that provide enhanced water-repellency (e.g., waterproofing properties) to the insulated paper product. See, for example, exemplary insulated paper products <NUM>/<NUM>'/<NUM>" in <FIG>.

In exemplary insulated paper product <NUM>/<NUM>'/<NUM>" shown in <FIG>, a corrugated cardboard structure <NUM>/<NUM>'/<NUM>" comprises two liner boards <NUM>/<NUM> bonded to a fluted medium board <NUM>. One (or both) of the liner boards <NUM>/<NUM> may be coated (e.g., clay coated) with coating layer <NUM> for aesthetics. The fluted medium <NUM> may have a range of flute dimensions, which are classified by the industry as A-flute through F-Flute. Each liner board <NUM>/<NUM> may be made from one ply of paper <NUM>/<NUM>', or it may comprise two or more plies <NUM>/<NUM>'. Other types of board that could be used in combination with the above-described insulated paper products <NUM>/<NUM>'/<NUM>" discussed above: pressboard - pressed fiber board; honeycomb board - e.g., two liner boards <NUM>/<NUM> with a honeycomb spacer in between.

In exemplary insulated paper product <NUM>/<NUM>'/<NUM>" shown in <FIG>, a corrugated cardboard structure <NUM>/<NUM>'/<NUM>" comprises two liner boards <NUM>/<NUM> bonded to a fluted medium board <NUM>, and demonstrates several opportunities for incorporation of insulating additives <NUM> into the structure of corrugated cardboard <NUM>/<NUM>'/<NUM>". First, insulating additives <NUM> have been added to the furnish of the fluted medium <NUM>. Second, the flutes have been further isolated from heat transfer via conduction by incorporating insulating additives <NUM> into the starch adhesive <NUM> that bonds each flute (e.g., of fluted medium <NUM>) to the liner boards <NUM>/<NUM>. Third, the liner board <NUM> is coated with insulating additives <NUM> via a coating <NUM>. Fourth, to slow radiative heat transfer, a low emissivity coating <NUM> is overcoated on the outside of the corrugated cardboard structure <NUM>/<NUM>'/<NUM>" (e.g., a box <NUM>). Such a coating <NUM> will reflect vs. absorb radiative heat and infra-red radiation.

In exemplary insulated paper product <NUM>/<NUM>'/<NUM>" shown in <FIG>, another corrugated cardboard structure <NUM>/<NUM>'/<NUM>" comprises two liner boards <NUM>/<NUM> bonded to a fluted medium board <NUM>, and again demonstrates several opportunities for incorporation of insulating additives <NUM> into the corrugated cardboard structure <NUM>/<NUM>'/<NUM>". First, insulating additives <NUM> have been added to the furnish of the fluted medium board <NUM>, however, in such a way that the insulating material <NUM> has preferentially segregated to one face (e.g., the upper face as shown) of the medium fluted board <NUM> over the other (e.g., the lower face as shown). Second, the flutes (of the medium fluted board <NUM>) have been further isolated from heat transfer via conduction by incorporating insulating additives <NUM> into the starch adhesive <NUM> that bonds each flute of the medium fluted board <NUM> to the liner boards <NUM>/<NUM>. Third, another coating <NUM> containing insulating additives <NUM> has been incorporated in the valleys <NUM> of the flutes. Fourth, one of the liner boards <NUM>/<NUM> contains insulating additives <NUM> distributed in a non-uniform manner (e.g., such as in first liner board <NUM> as shown). Fifth, to slow radiative heat transfer, a low emissivity coating <NUM> is overcoated on the outside faces of both liner boards <NUM>/<NUM>. Such a coating <NUM> will reflect vs. absorb radiative heat and infra-red radiation. Emissivity relates to both a surface's ability to absorb and radiate heat. Thus, a low emissivity coating will also show reduced heat loss through radiative cooling.

In exemplary insulated paper product <NUM>/<NUM>'/<NUM>" shown in <FIG>, another corrugated cardboard structure <NUM>/<NUM>'/<NUM>" comprises two liner boards <NUM>/<NUM> bonded to a fluted medium board <NUM>, and again demonstrates several opportunities for incorporation of insulating additives <NUM> into the insulated paper product <NUM>/<NUM>'/<NUM>". First, insulating additives <NUM> have been added to the furnish of the fluted medium board <NUM> in such a way that the insulating materials <NUM> are distributed evenly throughout the thickness of the one or more paper layers <NUM>/<NUM>'. Second, the flutes of the fluted medium board <NUM> have been further isolated from heat transfer via conduction by incorporating insulating additives <NUM> into the starch adhesive <NUM> that bonds each flute of the fluted medium board <NUM> to the liner boards <NUM>/<NUM>. Third, another coating <NUM> containing insulating additives <NUM> has been coated onto one of the liner board <NUM>. Fourth, the second liner board <NUM> contains insulating additives <NUM> distributed in a non-uniform manner. Fifth, to slow radiative heat transfer, a low emissivity coating <NUM> is overcoated on the outside faces of one of the liner boards <NUM>. Such a coating <NUM> will reflect vs. absorb radiative heat and infra-red radiation. It will also show reduced heat loss through radiative cooling because emissivity relates to both a surfaces ability to absorb and radiate heat.

In addition, any of the insulated paper products of the present invention described herein may be configured into a variety of shapes. For example, in some embodiments, the insulated paper product is in the form of an insulated cup or mug that may be used to house a hot beverage such as coffee. Such insulated paper products may be used instead of STYROFOAM® cups, eliminating the disposal and environmental problems associated with STYROFOAM® cups. In other embodiments, the insulated paper product is in the form of insulated packaging for temporary storage and transport of items such as food, medicines, etc. Such insulated paper products may be in the form of an insulated box, corrugated or not corrugated, as well as many other packaging items discussed herein. See, for example, exemplary insulated paper products <NUM>/<NUM>'/<NUM>" in <FIG>.

Regardless of configuration and/or shape, the insulated paper products <NUM>/<NUM>'/<NUM>" of the present invention provide a degree of insulation due to coating compositions that reduce heat transfer.

The present document further describes methods of making and using the herein disclosed and described coated insulated paper products. The insulated paper products may be made using papermaking equipment and techniques so as to produce one or more paper layers. As discussed herein, the methods of making the insulated paper products of the present invention involve the strategic placement of one or more insulating materials within a given insulated paper product and/or the strategic placement of one or more optional coatings on the insulated paper product so as to provide superior insulating properties, as well as other properties to the insulated paper product. Exemplary method steps and procedures for forming insulated paper products of the present invention are shown/described in <FIG> and <FIG>.

<FIG> depict an exemplary process of forming paper sheets <NUM>. As shown in <FIG>, pulp (furnish) is pumped into a header box <NUM>. The fiber content of the furnish is approximately <NUM>-<NUM> wt% at this stage. A gate <NUM> allows furnish to flow out onto the moving forming wire (a fine mesh conveyor. The forming wire <NUM> may be <NUM>-<NUM> feet long. Initially, water drains via gravity, however, further down, vacuum boxes <NUM> beneath the wire <NUM> assist water removal, increasing the fiber content to around <NUM>-<NUM> wt%.

As shown in <FIG>, the material (~<NUM>-<NUM> wt% fiber) is then fed through one or more felt presses <NUM>, which "blot" the precursor paper (i.e., precursor to paper layer <NUM>), removing more water, and increasing the fiber content to around <NUM>-<NUM> wt%. If starch or another additive or coating is to be applied, then that may be done at the size press <NUM> prior to drying. Many different materials may be added at the size press <NUM> prior to the dryers, including starch, sizes, waxes, coatings to impart wet strength, materials to impart water resistance, and materials that impart grease proofing.

As shown in <FIG>, drying may be affected in a number of ways, including running over steam cans <NUM>, or entering a long hot air-drying tunnel (not shown). After passing through calendar rolls <NUM> and prior to winding, the paper <NUM> may be between <NUM> to <NUM>% moisture content.

<FIG> depicts details of an exemplary linerboard <NUM> suitable for use in forming an insulated paper product <NUM>/<NUM>'/<NUM>" of the present invention or a component (e.g., a layer or outer linerboard) of an insulated paper product <NUM>/<NUM>'/<NUM>" of the present invention. As shown in <FIG>, exemplary linerboard <NUM> comprises two sheets of paper <NUM> laminated to one another. Exemplary linerboard <NUM> further comprises a first clay coating <NUM> directly on an outer surface <NUM> of one of the paper layers <NUM>, and an outermost second white clay coating <NUM> so as to provide a printable surface/layer <NUM> for exemplary linerboard <NUM>. First clay coating <NUM> evens out the valleys and troughs of the rough paper <NUM>, leaving a smooth surface for additional coatings and for high-quality printing.

The methods of using the insulated paper products <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention may comprise insulating food, medicines, etc. from hot or cold environments. In some embodiments, the method may simply comprise placing an item (e.g., food, medicines, etc.) within an insulated paper product <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention (e.g., putting hot coffee in a cup of the present invention). In other embodiments, the method may comprise placing an item (e.g., food, medicines, etc.) within an insulated paper product <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention (e.g., a bag or a box), and sealing the insulated paper product <NUM>/<NUM>/<NUM>'/<NUM>" for transport.

As discussed herein, methods of using the insulated paper products <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention may involve insulating an item (e.g., food, medicines, etc.) from hot or cold environments, wherein the item (e.g., food, medicines, etc.) is placed or packaged within an insulated paper product <NUM>/<NUM>/<NUM>'/<NUM>" that has a conventional shape, such as a cup or box. In other words, the insulated paper products <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention take the place or conventional items such as cups and boxes so as to provide one or more advantages as discussed above. As discussed herein, the insulated paper products <NUM>/<NUM>/<NUM>'/<NUM>" of the present invention may have a variety of shapes and configurations similar to many conventional items such as cups and boxes.

During use, the insulated paper products <NUM>/<NUM>/<NUM>'/<NUM>"/<NUM> of the present invention desirably provide/have one or more of the following features/properties in addition to providing insulating properties:.

Rovene VSR-<NUM> is an acrylic latex binder with pH in the range of <NUM>-<NUM>, and around <NUM>% solids content. The polymer contained in Rovene VSR-<NUM> has a Tg of around <NUM>, and so a heat treatment is needed to coalesce the dried polymer particles to form a film.

Rovene <NUM> (Mallard Creek Polymers, NC) is a carboxylated styrene-butadiene copolymer emulsion with a polymer Tg around -<NUM>, so no post-dry heating is required to form a film. The product contains around <NUM>% solids, and the emulsion has a pH of around <NUM>. Rovene <NUM> is a styrene-acrylic copolymer emulsion with a high Tg (><NUM>), and so a post-heat treatment is required. Rovene <NUM> is modified vinyl acetate copolymer emulsion with a polymer Tg of <NUM>. This binder has release properties, allowing adhesive materials to be peeled from the coating surface.

Tykote <NUM> (Mallard Creek Polymers) is an approximately <NUM>% solids pH <NUM>-<NUM> acrylic polymer emulsion, with a polymer Tg of <NUM>. This binder is claimed to have flexibility combined with moisture vapor barrier properties.

The present invention is further described by the following additional embodiments, examples, and claims. It should be understood that any feature and/or component described herein may be present alone or in combination with any other feature and/or component or combination of features and/or components described herein to form the here-in described paper layer <NUM> and/or insulated paper product <NUM>/<NUM>' and/or corrugated paper product <NUM>" and/or storage container <NUM> of the present invention. Examples that are not in accordance with the appended claims are described for illustrative purposes only.

A repulpable insulated paper product <NUM> as defined in claim <NUM> comprises: one or more paper layers <NUM>; and an insulating coating <NUM> on at least one outer surface <NUM>/<NUM> of said one or more paper layers <NUM>, said thermally insulating coating <NUM> comprising (i) from about <NUM> weight percent (wt%) to about <NUM> wt% of one or more insulating materials <NUM> comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, sericite, powdered silicon, silver-coated glass bubbles, aluminum oxide, hollow polymeric microsphere pigments, or any mixture or combination thereof, and (ii) from about <NUM> wt% to about <NUM> wt% of a binder comprising (A) a latex binder selected from polymers synthesized using emulsion polymerization including poly(vinyl acetate), poly(acrylonitrile), poly(acrylates), poly(methacrylates), poly(butadiene), poly(styrene), poly(acrylic acid), and various copolymers of these polymers; or (B) a latex binder comprising a polymer or co-polymer of one or more monomers selected from styrene, butadiene, acrylic acid, acrylate, methacrylate, and vinyl acetate. The coating forms a continuous coating that completely covers the at least one outer surface; reflects heat; and reduces transfer of heat through the repulpable insulated paper product As discussed herein, each paper layer <NUM> may further comprise one or more additives, the one or more additives including, but are not limited to, flocculants and retention aids such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers; additives to provide water resistance (e.g., wax, synthetic latexes and resins); or any combination thereof. In some embodiments, the insulating coating <NUM> comprises one or more insulating materials <NUM> comprising bismuth oxychloride, mica, zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, sericite, or any mixture or combination thereof. In some embodiments, the insulating coating <NUM> comprises one or more insulating materials <NUM> comprising bismuth oxychloride, mica, zinc oxide, or any mixture or combination thereof.

In the insulated paper product <NUM>, the one or more paper layers <NUM> may comprise a single paper layer <NUM>.

Alternatively, the one or more paper layers <NUM> may compriss two or more paper layers <NUM>.

The insulating coating <NUM> may comprise one or more insulating materials <NUM> comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, sericite, or any mixture or combination thereof.

In particular,the insulating coating <NUM> may comprise one or more insulating materials <NUM> comprising bismuth oxychloride, mica, zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof.

The insulating coating <NUM> comprises from about <NUM> weight percent (wt%) to about <NUM> wt% of the one or more insulating materials <NUM> and from about <NUM> wt% to about <NUM> wt% of the binder. It should be understood that the insulating coating <NUM> may comprise (i) any value between about <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., <NUM> wt%, or any range of values between about <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., from about <NUM> wt% to <NUM> wt%, of the one or more insulating materials <NUM>, and (ii) any value between about <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., <NUM> wt%, or any range of values between about <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., from about <NUM> wt% to <NUM> wt%, of the binder. The binders are as defined in claim <NUM> under items (A) and (B).

The insulating coating <NUM> may comprise from about <NUM> wt% to about <NUM> wt% of the one or more insulating materials <NUM> and from about <NUM> wt% to about <NUM> wt% of the binder.

In particular, the insulating coating <NUM> may comprise from about <NUM> wt% to about <NUM> wt% of the one or more insulating materials <NUM> and from about <NUM> wt% to about <NUM> wt% of the binder. According to the invention, the binder comprises a latex binder (A) or (B). A binder of item (B) is a latex binder comprising a polymer or co-polymer of one or more monomers selected from styrene, butadiene, acrylic acid, acrylate, methacrylate, and vinyl acetate.

Each insulating coating <NUM> may independently comprise one or more coating layers <NUM> with each coating layer <NUM> comprising said insulating material <NUM> and said binder.

At least one insulating coating <NUM> may comprise two or more coating layers <NUM> with each coating layer <NUM> comprising said insulating material <NUM> and said binder.

In particular embodiments, said two or more coating layers <NUM> comprise (i) a first coating applied onto the one or more paper layers <NUM> and comprising zinc oxide, aluminum-doped zinc oxide, or any mixture or combination thereof, and (ii) a second coating applied onto the first coating and comprising bismuth oxychloride, bismuth oxychloride-coated mica, or any mixture or combination thereof.

The insulated paper product <NUM> of the invention may further comprise a treatment to impart water or grease resistance to the insulated paper product <NUM>.

The treatment may comprise adding one or more treatment additives to one or more of the one or more paper layers <NUM>.

The treatment may comprise adding one or more treatment additives to the insulating coating <NUM>. Further, the treatment may comprise adding a water or grease resistance layer comprising one or more treatment additives onto the insulated paper product <NUM>.

In particular, the insulating coating <NUM> may be applied over the water or grease resistance layer.

In particular embodiments, the water or grease resistance layer is applied onto an outer surface of the insulated paper product <NUM> opposite the insulating coating <NUM>.

The one or more treatment additives may comprise a wax emulsion, a latex binder, Epotal S440 (BASF) (i.e., a styrene acrylic based copolymer emulsion), Rhoplex P-<NUM> (Dow) (i.e., a styrene acrylic copolymer emulsion binder), Diofan B204 (Solvay) (i.e., a poly(vinylidene chloride) (PVDC) latex), Barrier-Grip 9471A (IGI) (i.e., a blend including a styrene acrylic copolymer emulsion, a poly(ethylene) wax and clay), Daran SL143 (Owensboro) (i.e., a poly(vinylidene chloride) (PVDC) latex), or any combination thereof.

According to a particular aspect of the invention, the insulated paper product <NUM> has an overall basis weight of less than about <NUM> grams per square meter (gsm). It should be understood that the insulated paper product <NUM> may have any overall basis weight between about <NUM> gsm and <NUM> gsm, in increments of <NUM> gsm, e.g., <NUM> gsm, or any range of values between about <NUM> gsm and <NUM> gsm, in increments of <NUM> gsm, e.g., from <NUM> gsm to <NUM> gsm.

In particular embodiments, the insulated paper product <NUM> has an overall basis weight ranging from about <NUM> gsm to about <NUM> gsm.

The insulated paper product <NUM> may comprise a void-containing insulated paper product <NUM>".

In particular embodiments, the void-containing insulated paper product <NUM>" comprises voids <NUM> within at least one paper layer <NUM>, the voids <NUM> being encapsulated by a material other than paper (e.g., a paper layer <NUM> containing hollow beads/particles (not shown)).

The void-containing insulated paper product <NUM>" may comprise voids <NUM> within at least one paper layer <NUM>, the voids <NUM> being encapsulated by paper (e.g., a paper layer <NUM> containing air pockets <NUM> therein, possibly formed via a molding process or a process in which a void-forming material is removed from the paper layer <NUM>). See, <FIG>.

The void-containing insulated paper product <NUM>" may comprise a corrugated paper product <NUM>".

According to a particular aspect of the invention, the integral paper product <NUM>' comprises (i) a first linerboard layer <NUM> comprising one or more first paper layers <NUM>/<NUM>/<NUM>', (ii) a second linerboard layer <NUM> comprising one or more second paper layers <NUM>/<NUM>/<NUM>', and (iii) (a) a fluted paper layer <NUM> comprising one or more fluted paper layers <NUM>/<NUM>/<NUM>' or (b) a honeycomb layer (not shown) positioned between the first linerboard layer <NUM> and the second linerboard layer <NUM>, and (I) each of (i) said first linerboard layer <NUM>, (ii) said second linerboard layer <NUM>, and (iii) (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) may independently comprise insulating material <NUM> therein or thereon, and (II) said insulating coating <NUM> is present on (i) an outer surface of said first linerboard layer <NUM>, (ii) an outer surface of said second linerboard layer <NUM>, or (iii) both (i) and (ii). An insulated paper product <NUM> according to claim <NUM> comprises a corrugated integral paper product <NUM>", said corrugated integral paper product <NUM>" comprising: a first linerboard layer <NUM> comprising one or more first paper layers <NUM>/<NUM>/<NUM>', a second linerboard layer <NUM> comprising one or more second paper layers <NUM>/<NUM>/<NUM>', and (a) a fluted paper layer <NUM> comprising one or more fluted paper layers <NUM>/<NUM>/<NUM>' or (b) a honeycomb layer (not shown) positioned between the first linerboard layer <NUM> and the second linerboard layer <NUM>, wherein one or more of (i) said first linerboard layer <NUM>, (ii) said second linerboard layer <NUM>, and (iii) (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) each independently comprise optional insulating material <NUM> therein or thereon; and a smooth, heat-reflecting, thermally insulating coating <NUM> on (i) an outer surface of said first linerboard layer <NUM>, (ii) an outer surface of said second linerboard layer <NUM>, or (iii) both (i) and (ii). According to a particular embodiment of the invention, (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) provides pockets of air <NUM> between said first linerboard layer <NUM> and said second linerboard layer <NUM>.

Said pockets of air <NUM> may represent from about <NUM> to <NUM> volume percent of a total volume occupied by (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown)(i.e., a total volume between innermost opposing surfaces <NUM>/<NUM> of said first linerboard layer <NUM> and said second linerboard layer <NUM>). See, for example, <FIG>.

The insulated paper product <NUM> of of the above embodiments may further comprise an adhesive <NUM> that bonds portions of (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) to portions of said first linerboard layer <NUM> and said second linerboard layer <NUM>. Suitable materials for adhesive <NUM> include, but are not limited to, starch adhesives, synthetic latex adhesives such as poly(vinyl acetate), natural rubber latex, modified starches, hydrocolloids such as hydroxypropylcellulose, carboxymethylcellulose, and other water-soluble polymers such as poly(vinyl alcohol). A cross-linking agent may also be added to the adhesive to avoid potential swelling of the adhesive and weakening of the bonds when wet. Flocculants and retention aids may also be included such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers. As discussed herein, in some embodiments, adhesive <NUM> is at least partially filled with one or more of the herein disclosed insulating materials <NUM>.

In a particular embodiment, said adhesive <NUM> has insulating material <NUM> dispersed therein.

Each of (i) said first linerboard layer <NUM>, (ii) said second linerboard layer <NUM>, and (iii) (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) may independently comprise the insulated paper product <NUM> described above.

Alternatively, each of (i) said first linerboard layer <NUM>, (ii) said second linerboard layer <NUM>, and (iii) (a) said fluted paper layer <NUM> or (b) said honeycomb layer (not shown) is substantially free of insulating material <NUM>.

Alternatively, the integral paper product <NUM>' may comprise said fluted paper layer <NUM>. Alternatively, the integral paper product <NUM>' comprises said honeycomb layer (not shown).

According to a particular aspect of the invention, the insulated paper product <NUM>' further comprises one or more additional non-paper layers <NUM>/<NUM>. As used herein, the term "non-paper layer" is used to describe a layer that contains less than <NUM> wt% paper pulp or cellulosic fiber, and typically contains <NUM> wt% to less than <NUM> wt% paper pulp or cellulosic fiber. Conversely, as used herein, the term "paper layer" (such as each paper layer <NUM>) is used to describe a layer that contains <NUM> wt% or more paper pulp or cellulosic fiber, and typically contains greater than <NUM> wt% up to <NUM> wt% paper pulp or cellulosic fiber (or any value between <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., <NUM> wt%, or any range of values between <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., from <NUM> wt% to <NUM> wt%).

The one or more additional non-paper layers <NUM>/<NUM> may comprise a gypsum layer, a clay-containing layer, a polymer coating, a pigment-containing layer, a fabric layer (e.g., a nonwoven, woven or knit fabric layer), a fiber-reinforcement layer (e.g., a layer of unidirectional fibers), a second layer of insulating material <NUM>, a metal film layer, a foam layer, or any combination thereof. One or more of the additional non-paper layers <NUM>/<NUM> may be added to the insulated paper product <NUM> in order to provide a desire property such as lower (or higher) emissivity, lower (or higher) thermal conductivity, enhanced water-repellency, an aesthetically pleasing color and/or texture, or any combination thereof.

The one or more additional non-paper layers <NUM>/<NUM> may comprise a gypsum layer (not shown).

The one or more additional non-paper layers <NUM>/<NUM> may comprise a clay-containing layer <NUM>, a coating <NUM> that provides a lower or higher emissivity of the insulated paper product <NUM>, a pigment-containing layer <NUM>, or any combination thereof. See, <FIG>.

The one or more non-paper layers <NUM>/<NUM> may comprise at least two non-paper layers <NUM>/<NUM>.

In a particular aspect of the invention, at least one paper layer <NUM> of the one or more non-paper layers <NUM> comprise a paper insulating material <NUM>.

In particular, the paper insulating material <NUM> may comprise perlite, perlite coated with copper ions, expanded perlite, perlite hollow microspheres (such as available from Richard Baker Harrison Ltd. , UK, or CenoStar Corporation (US), or Sil-Cel® microcellular aluminum silicate filler particles made by creating a structure of multicellular spherical bubbles comprising perlite, available from Silbrico (US), Sil-Cel® microspheres are available in a range of particle sizes, and may be coated or uncoated, or Dicaperl HP-<NUM> perlite microspheres, as sold by Dicalite (US), or flaked or milled perlite (such as Dicaperl LD1006, cryogenic grades of perlite, Dicaperl HP-<NUM>, HP-<NUM>, and HP100-<NUM> grades, also sold by Dicalite), porous volcanic materials (such as pumice), vermiculite (including MicroLite® vermiculite dispersions, available from Dicalite), hollow expanded vermiculite, glass foams (such as Owens Corning), recycled glass foams (such as manufactured by GrowStone Inc. ), cellular glass insulation materials, cenospheres (such as available from CenoStar Corp. ), glass bubbles (such as available from <NUM> under the trade designations iM30K, iM16k, and K20, as well as Q-Cel glass), ceramic microspheres, plastic microspheres, and synthetic hollow microspheres (such as available from Kish Company Inc. ), silica aerogels (such as those available from Aspen Aerogels, and those that may be incorporated into paints and coatings under the Enova® and Lumira® brand from Cabot), microporous polyolefin-based aerogels (such as disclosed in <CIT>. ), organic aerogels such as those disclosed in <CIT> which comprise thiol-epoxy based aerogels, xerogels (i.e., collapsed aerogels), seagels (i.e., microfoams made from agar and alginates), foamed starch, foamed paper pulp, agar, foamed agar, alginates, foamed alginates, bismuth oxychloride, metalized ceramics, metalized fibers, cadmium yellow pigment (cadmium disulfide), or any combination thereof. Examples of commercially available insulating materials <NUM> include, but are not limited to, FOAMGLAS® products commercially available from Owens Corning (Pittsburg PA); and Growstone products commercially available from Growstone, LLC, a subsidiary of Earthstone International Inc. (Santa Fe, NM). Recycled glass suitable for use as insulating materials <NUM> is typically crushed to a finely divided powder and mixed with a blowing agent, e.g., carbon or limestone. It is then passed into a furnace hot enough to begin to melt the glass. As the glass powder particles begin to fuse, the blowing agent gives off a gas or vapor, forming bubbles inside the glass. This generates a porous, mostly closed cell glass foam, with high thermal and sound insulation properties. Vermiculite may also be used as a suitable insulating material <NUM>. Vermiculite is a hydrous phyllosilicate mineral that undergoes significant expansion when heated. Exfoliation occurs when the mineral is heated sufficiently, and the effect is routinely produced in commercial furnaces. Vermiculite is formed by weathering or hydrothermal alteration of biotite or phlogopite.

In particular embodiments, the paper insulating material <NUM> comprises perlite (e.g., in the paper <NUM>, the adhesive <NUM>, the coating <NUM>, and/or the emissivity coating <NUM>), aerogel (e.g., in the paper <NUM> and/or the adhesive <NUM>), glass bubbles (e.g., in the adhesive <NUM> and/or the coating <NUM>), activated carbon (e.g., in the paper <NUM>, the adhesive <NUM>, the coating <NUM>, and/or the emissivity coating <NUM>), or any combination thereof.

According to a particular aspect of the invention, the insulating material <NUM> comprises particles having an average particle size of less than about <NUM> microns (µm) (or any average particle size greater than about <NUM> to less than about <NUM>, in increments of <NUM>, e.g., <NUM>, or any range of average particle size less than about <NUM>, in increments of <NUM>, e.g., from about <NUM> to about <NUM>). For example, perlite particles typically have an average particle size ranging from about <NUM> to about <NUM>, aerogel particles typically have an average particle size ranging from about <NUM> to about <NUM>, and glass bubble particles typically have an average particle size ranging from about <NUM> to about <NUM>.

The insulating material <NUM> may comprise particles having a multi-modal particle size distribution.

According to a particular aspect of the invention, any paper layer <NUM> that contains insulating material <NUM> comprises from <NUM> weight percent (wt%) to <NUM> wt% fibers <NUM>, and from about <NUM> wt% to about <NUM> wt% insulating material <NUM>, based on a total weight of the paper layer <NUM>. It should be understood that a given paper layer <NUM> that contains insulating material <NUM> can have (a) any weight percent of fibers <NUM> between <NUM> wt% and <NUM> wt% (i.e., in increments of <NUM> wt%, e.g., <NUM> wt%, or any range of values between <NUM> wt% and <NUM> wt%, in increments of <NUM> wt%, e.g., from <NUM> wt% to <NUM> wt%).

Any paper layer <NUM> that contains insulating material <NUM> may comprise from <NUM> wt% to <NUM> wt% fibers <NUM>, and from about <NUM> wt% to about <NUM> wt% insulating material <NUM>, based on a total weight of the paper layer <NUM>.

According to a particular aspect of the invention, the insulating material <NUM> has a material density of less than <NUM> gram per cubic centimeter (g/cm<NUM>), more typically, less than <NUM>/cm<NUM>. It should be understood that the insulating material <NUM> can have any material density less than <NUM>/cm<NUM> such as from greater than <NUM>/cm<NUM> to about <NUM>/cm<NUM> (or any value between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>).

According to a particular aspect of the invention, at least one layer <NUM> of said one or more paper layers <NUM> has a layer density of less than <NUM>/cm<NUM>. It should be understood that the at least one layer <NUM> can have any layer density less than <NUM>/cm<NUM> such as from greater than <NUM>/cm<NUM> to about <NUM>/cm<NUM> (or any value between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>). It should be further understood that any number of layers <NUM> of said one or more paper layers <NUM> may have an independent layer density, each of which is less than <NUM>/cm<NUM> (or any value between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM> and <NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>).

According to a particular aspect of the invention, the insulated paper product <NUM> is molded to form a three-dimensional object (e.g., a cup <NUM> or container <NUM>).

A repulpable storage container <NUM> according to claim <NUM> comprises the insulated paper product <NUM> of any one of embodiments described above. See, <FIG>.

The storage container <NUM> may comprise a storage volume <NUM> at least partially surrounded by one or more container walls <NUM>.

The storage volume <NUM> can be completely surrounded by or surroundable (i.e., the storage container <NUM> can be configured to surround the storage volume <NUM>) by one or more container walls <NUM>.

The one or more container walls <NUM> can comprise the insulated paper product <NUM> of any one of the above embodiments.

The one or more container walls <NUM> may comprise a gypsum layer, a clay-containing layer, a polymer coating, a pigment-containing layer, a bismuth oxychloride-containing layer, a mica containing layer, an aerogel containing layer, a fabric layer (e.g., a nonwoven, woven or knit fabric layer), a fiber-reinforcement layer (e.g., a layer of unidirectional fibers), a layer of insulating material <NUM>, a metal film layer, a foam layer, a layer of air, a coating that lowers an emissivity of the one or more container walls (e.g., such as mica, bismuth oxychloride, zinc oxide, zinc sulfide, kaolin clay, or cadmium sulfide), a coating that lowers a thermal conductivity of the one or more container walls, a coating that enhances a water-repellency of the one or more container walls such as a wax, or a fluorocarbon, or a reactive cross-linking agent such as an epoxy or a urethane, or a silicone-based coating, or one or more coatings mentioned in <CIT>, or any combination thereof.

The storage container <NUM> may comprise an insulating wrapper for a food item.

In particular embodiments, the container <NUM> comprises a cup <NUM>, a mug, a flask, or a thermos <NUM>. As shown in <FIG>, the storage container <NUM> may be a hot beverage cup <NUM>, which could replace both STYROFOAM® cups, as well as lined paper cups along with the insulating paper ring currently provided to prevent burning fingers of the person holding the cup.

In other embodiments, the container <NUM> comprises a clam shell type box packaging <NUM> for hot food <NUM>. Such a container may be made via molding pulp using a vacuum forming machine. See, for example, <FIG>.

In still further embodiments, the container <NUM> comprises a salad container <NUM> for chilled food <NUM>. See, for example, <FIG>.

In other embodiments, the container <NUM> comprises a padded envelope <NUM>. See, for example, <FIG>. In other embodiments, the container <NUM> comprises a shipping container <NUM>. See, for example, <FIG>. As shown in <FIG>, exemplary shipping container <NUM> comprises (i) multiple thinner paper layers <NUM>, each of which optionally includes insulating materials <NUM> incorporated therein, optionally with (ii) a non-uniform distribution of material particles <NUM> (which could be insulating material <NUM>), optionally (iii) air <NUM> or an insulative filler material between the layers <NUM>, and (iv) optionally additional coating(s) <NUM> on one or more of the paper layers <NUM>.

The shipping container <NUM> may comprise shipping container walls <NUM> that comprise a closed cell foam <NUM>'. See, for example, FIG. In this embodiment, the closed cell foam <NUM>' may be a biodegradable foam <NUM>', for instance a foamed starch such as GreenCell® sold by KTM Industries Inc. Holt, MI, or a foamed alginate, or pectin, or gelatin, or agar material that has been foamed through one means or another, and optionally chemically cross-linked to a certain extent. As shown in <FIG>, the shipping container <NUM> may include paper layers <NUM> that may optionally include insulating material <NUM>, and may also contain a thermal barrier coating <NUM>. The coating <NUM> could be designed to reduce radiative heat transfer, or it could be designed to reduce conductive heat transfer, or it could be designed to reduce both.

In the storage container <NUM> or the insulated paper product <NUM> described herein, the insulating coating <NUM> can be present on (i) an inner surface <NUM>, (ii) an outer surface <NUM>/<NUM>, or (iii) both (i) and (ii) of the storage container <NUM> or the insulated paper product <NUM>, the insulating coating <NUM> having a low thermal emissivity or thermal barrier property. As used herein, the phrase "a low thermal emissivity" refers to a thermal emissivity of less than <NUM>, as measured using Thermal Emissivity Method #<NUM> Recommended by Flir Systems Inc. (described in the "Example" section below). Suitable materials for use in a given "emissivity coating" include, but are not limited to, bismuth oxychloride, mica flakes, perlite, kaolin, and any combination thereof (e.g., mica flakes partially or completely coated with bismuth oxychloride).

The treatment may comprise a coating <NUM>/<NUM> on (i) an inner surface <NUM>, (ii) an outer surface <NUM>/<NUM>, or (iii) both (i) and (ii) of the storage container <NUM> or the insulated paper product <NUM>, the coating <NUM> comprising one or more materials that increase the water resistance of (i) the inner surface <NUM>, (ii) the outer surface <NUM>/<NUM>, or (iii) both (i) and (ii) of the storage container <NUM> or the insulated paper product <NUM>.

A storage container <NUM> or the insulated paper product <NUM> described herein may further comprise a coating <NUM>/<NUM> on (i) an inner surface <NUM>, (ii) an outer surface <NUM>/<NUM>, or (iii) both (i) and (ii) of the storage container <NUM> or the insulated paper product <NUM>, the coating <NUM>/<NUM> water-proofing (i) the inner surface <NUM>, (ii) the outer surface <NUM>/<NUM>, or (iii) both (i) and (ii) of the storage container <NUM> or the insulated paper product <NUM>. By "waterproofing," it is meant that the outer surface <NUM>/<NUM> of the storage container <NUM> or the insulated paper product <NUM> can be in contact with water for <NUM> hours and maintain its structural integrity.

A method of making the insulated paper product <NUM> described herein may comprise coating the one or more paper layers on at least one side with the insulating coating <NUM>.

Said method may further comprise at least one papermaking step to form the one or more paper layers.

Said method may further comprise a treatment step to impart water or grease resistance to the insulated paper product <NUM>.

The treatment may comprise adding one or more treatment additives to the insulating coating <NUM>. The treatment may comprise adding a water or grease resistance layer comprising one or more treatment additives onto the insulated paper product <NUM>.

The insulating coating <NUM> can be applied over the water or grease resistance layer <NUM>.

The water or grease resistance layer can be applied onto an outer surface of the insulated paper product <NUM> opposite the insulating coating <NUM>.

The one or more treatment additives may comprise a wax emulsion, a latex binder, Epotal S440 (BASF) (i.e., a styrene acrylic based dispersion), Rhoplex P-<NUM> (Dow) (i.e., a styrene acrylic binder), Diofan B204 (Solvay) (i.e., a polyvinylidene chloride (PVDC) latex), Barrier-Grip 9471A (IGI) (i.e., a styrene acrylic/PE wax/clay blend), Daran SL143 (Owensboro) (i.e., a polyvinylidene chloride (PVDC) latex), or any combination thereof.

Said method may further comprise incorporating one or more additives into at least one paper layer <NUM> within the one or more paper layers <NUM>. Suitable additives include, but are not limited to, one or more insulating materials <NUM>, copper ions, waxes, synthetic (e.g., polymeric or glass) fibers, silica, surface modified silica, transition metal surface modified silica, cyclodextrin, sodium bicarbonate, silicones to impart grease and water resistance, metalized ceramic particles, metalized fibers, cationic starches, cationic polymers, such as cationic guar gum, poly(ethylene imine) (e.g., poly(ethylene imine marketed as Polymin P and available from Aldrich Chemical), fillers, sizes, binders, clays including bentonite clay, kaolin clay, and other minerals, calcium carbonate, calcium sulfate, and other materials that may be added to paper products for different reasons, and any combinations thereof. The filler may make the paper more receptive to printing, for instance, or make the paper glossy. Many fillers have a density greater than <NUM>/cm<NUM>. Flocculants and retention aids, may also be included such as high molecular weight poly(acrylamide), poly(ethylene imine), cationic quar gum, and other cationic polymers. Sizes and binders may also be added to help provide strength to papers, and can include starches, hydrocolloids, artificial and natural polymer latexes, such as RHOPLEX® acrylic resins from Dow Chemical and ROVENE® binders from Mallard Creek Polymers (Charlotte NC). Water soluble polymers, such as poly(vinyl alcohol), and poly(acrylic acid) may also be added to the paper. Sometimes, water resistance on the final box is required. Vapor-Guard R5341B or Barrier Grip 9471A (The International Group Inc. , Titusville PA) are useful as barrier coatings that provide a given paper layer <NUM> with a degree of grease and/or water resistance. Said method may further comprise forming at least one fluted paper layer <NUM> within the one or more paper layers <NUM>. See, for example, <FIG>.

The above method may further comprise: applying at least one additional layer onto the insulated paper product <NUM>. The additional layer could be another layer <NUM> of insulating material <NUM>, a coating <NUM>/<NUM> (e.g., a coating <NUM> that increases or decreases an emissivity of a paper layer <NUM>/<NUM>" or an integrated product <NUM>"), a non-paper layer <NUM>, a layer of air <NUM>, or any combination thereof. See, for example, <FIG> and <NUM>.

Said method may further comprise forming a storage container <NUM>.

The storage container <NUM> may comprises the storage container <NUM> described hereinabove.

Said method may further comprise forming at least one paper layer <NUM> within the one or more paper layers <NUM> using recycled insulated paper product <NUM> described hereinabove. For example, one method of making at least one paper layer <NUM> and a container <NUM> formed therefrom comprises forming a corrugated structure <NUM>" with at least one outer ply/liner <NUM>/<NUM> that contains fiber <NUM> and insulating material <NUM>, and a fluted median ply/liner <NUM> without insulating material <NUM>, comprising: suspending cellulose fibers <NUM> in water to make paper pulp <NUM>; forming a fibrous first layer <NUM> from the pulp <NUM>; suspending cellulose fibers <NUM> in water, adding voided materials (e.g., hollow insulating material <NUM>), optionally adding surface active agents, optionally adding a flocculent; forming this layer <NUM> on top of the first layer of pulp <NUM>; suspending cellulose fibers <NUM> in water to make paper pulp <NUM>; forming a fibrous top layer <NUM> on top of the second layer <NUM>; pressing and drying the resultant three-ply insulated paper sheet <NUM>'; optionally coating at least one of the surfaces of the three-ply insulated paper sheet <NUM>' with a coating <NUM> selected from comprising aluminum, silver, mica, sericite, zinc oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth oxychloride coated mica, bismuth vanadate, gypsum, or combinations thereof; passing a paper sheet <NUM> through a corrugator to make a fluted layer <NUM> while adhering two insulated paper sheets <NUM>' as liner boards <NUM>/<NUM> to the fluted layer <NUM> to form corrugated board <NUM>"; optionally adding an additional fluted layer <NUM> and another liner board <NUM>or <NUM> to make a double walled corrugated structure <NUM>", containing three insulated liner boards <NUM>/<NUM> and two fluted layers <NUM>; cutting the double walled corrugated structure <NUM>" into the form/shape of a box <NUM>; and allowing the off-cuts (e.g., scraps from the cutting step) to be sent back to the repulping mill mixed with off-cuts from non-insulating board. Another method of making at least one paper layer <NUM> and a container <NUM> formed therefrom comprises forming a corrugated structure <NUM>" with at least one outer ply/liner <NUM>/<NUM> that contains a paper layer <NUM> and an insulating material layer <NUM>, and a fluted median ply/liner <NUM> without insulating material <NUM>, comprising: suspending cellulose fibers <NUM> in water to make paper pulp <NUM>, and optionally adding a flocculant; forming a fibrous first layer <NUM> from pulp <NUM>; suspending voided materials (e.g., hollow insulating material <NUM>) in water, optionally adding surface active agents, and optionally adding a flocculent and/or a binder; forming this layer <NUM> on top of the first layer <NUM> of pulp <NUM>, through curtain coating, slot-die coating, rod coating, spray application, etc.; suspending cellulose fibers <NUM> in water to make paper pulp <NUM> optionally adding a flocculant; forming a fibrous top layer <NUM> on top of the second layer <NUM>; pressing and drying the resultant insulated paper sheet <NUM>'; optionally coating at least one of the surfaces of the resultant insulated paper sheet <NUM>' with a coating <NUM> comprising aluminum, silver, mica, sericite, zinc oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth oxychloride coated mica, bismuth vanadate, gypsum, or combinations thereof; passing a paper sheet <NUM> through a corrugator to make a fluted layer <NUM> while adhering two insulated paper sheets <NUM>' as liner boards <NUM>/<NUM> to the fluted layer <NUM> to form corrugated board <NUM>"; optionally adding an additional fluted layer <NUM> and another liner board <NUM>or <NUM> to make a double walled corrugated structure <NUM>", containing three insulated liner boards <NUM>/<NUM> and two fluted layers <NUM>; cutting the double walled corrugated structure <NUM>" into the form/shape of a box <NUM>; and allowing the off-cuts (e.g., scraps from the cutting step) to be sent back to the repulping mill mixed with off-cuts from non-insulating board. Yet another method of making at least one paper layer <NUM> and a container <NUM> formed therefrom comprises forming a corrugated structure <NUM>" with at least one outer ply/liner <NUM>/<NUM> that contains fiber <NUM> and insulating material <NUM>, and a fluted median ply/liner <NUM> that comprises insulating material <NUM>, comprising: suspending cellulose fibers <NUM> in water to make paper pulp <NUM>; forming a fibrous first layer <NUM> from the pulp <NUM>; suspending cellulose fibers <NUM> in water, adding voided materials (e.g., hollow insulating material <NUM>), optionally adding surface active agents, optionally adding a flocculent; forming this layer <NUM> on top of the first layer of pulp <NUM>; suspending cellulose fibers <NUM> in water to make paper pulp <NUM>; forming a fibrous top layer <NUM> on top of the second layer <NUM>; pressing and drying the resultant three-ply insulated paper sheet <NUM>'; optionally coating at least one of the surfaces of the three-ply insulated paper sheet <NUM>' with a coating <NUM> selected from comprising aluminum, silver, mica, sericite, zinc oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth oxychloride coated mica, bismuth vanadate, gypsum, or combinations thereof; passing the resultant three-ply insulated paper sheet <NUM>' through a corrugator to make a fluted layer <NUM> while adhering two insulated paper sheets <NUM>' as liner boards <NUM>/<NUM> to the fluted layer <NUM> to form corrugated board <NUM>"; optionally adding an additional fluted layer <NUM> and another liner board 21or <NUM> to make a double walled corrugated structure <NUM>", containing three insulated liner boards <NUM>/<NUM> and two fluted layers <NUM>; cutting the double walled corrugated structure <NUM>" into the form/shape of a box <NUM>; and allowing the off-cuts (e.g., scraps from the cutting step) to be sent back to the repulping mill mixed with off-cuts from non-insulating board. Yet another method of making at least one paper layer <NUM> and a container <NUM> formed therefrom comprises forming a corrugated structure <NUM>" with at least one outer ply/liner <NUM>/<NUM> that contains a paper layer <NUM> and an insulating material layer <NUM>, and a fluted median ply/liner <NUM> with an insulating layer <NUM>, comprising: suspending cellulose fibers <NUM> in water to make paper pulp <NUM>, and optionally adding a flocculant; forming a fibrous first layer <NUM> from pulp <NUM>; suspending voided materials (e.g., hollow insulating material <NUM>) in water, optionally adding surface active agents, and optionally adding a flocculent and/or a binder; forming this layer <NUM> on top of the first layer <NUM> of pulp <NUM>, through curtain coating, slot-die coating, rod coating, spray application, etc.; suspending cellulose fibers <NUM> in water to make paper pulp <NUM> optionally adding a flocculant; forming a fibrous top layer <NUM> on top of the second layer <NUM>; pressing and drying the resultant insulated paper sheet <NUM>'; optionally coating at least one of the surfaces of the resultant insulated paper sheet <NUM>' with a coating <NUM> comprising aluminum, silver, mica, sericite, zinc oxide, zinc sulfide, cadmium sulfide, bismuth oxychloride, bismuth oxychloride coated mica, bismuth vanadate, gypsum, or combinations thereof; passing the insulated paper sheet <NUM>' through a corrugator to make a fluted layer <NUM> while adhering two insulated paper sheets <NUM>' as liner boards <NUM>/<NUM> to the fluted layer <NUM> to form corrugated board <NUM>"; optionally adding an additional fluted layer <NUM> and another liner board <NUM> or <NUM> to make a double walled corrugated structure <NUM>", containing three insulated liner boards <NUM>/<NUM> and two fluted layers <NUM>; cutting the double walled corrugated structure <NUM>" into the form/shape of a box <NUM>; and allowing the off-cuts (e.g., scraps from the cutting step) to be sent back to the repulping mill mixed with off-cuts from non-insulating board.

Said method may further comprise a molding step so as to form a three-dimensional object from the insulated paper product <NUM>.

The molding step may comprise a pressure molding step, a thermoforming step, a vacuum forming step, or any combination thereof.

Each paper layer <NUM> that contains insulating material <NUM> may comprise from <NUM> wt% to <NUM> wt% fibers <NUM>, and from about <NUM> wt% to about <NUM> wt% insulating material <NUM>, based on a total weight of the paper layer <NUM>.

The insulating material <NUM> may have a material density of less than <NUM>/cm<NUM> (or any value between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>). At least one layer <NUM> of the one or more paper layers <NUM> may have a layer density of less than <NUM>/cm<NUM> (or any value between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>). It should be further understood that any number of layers <NUM> of the one or more paper layers <NUM> may have an independent layer density, each of which is less than <NUM>/cm<NUM> (or any value between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>).

The integral paper product <NUM> may have an integral paper product density of less than <NUM>/cm<NUM> (or any value between <NUM>/cm<NUM> and <NUM>, g/cm<NUM> in increments of <NUM>/cm<NUM>, e.g., <NUM>/cm<NUM>, or any range of values between <NUM>/cm<NUM> and <NUM>/cm<NUM>, in increments of <NUM>/cm<NUM>, e.g., from <NUM>/cm<NUM> to <NUM>/cm<NUM>).

A method of using the insulated paper product <NUM> or the storage container <NUM> of the invention as defined in claim <NUM> comprises: insulating an object via the repulpable insulated paper product <NUM> or the storage container <NUM>, wherein the object is a food item, a medicine, or any other item that is desirably kept at a cool temperature (e.g., a temperature below room temperature or a refrigerating temperature) or at an elevated temperature (e.g., a temperature above room temperature or a hot-out-of-the-oven temperature).

In particular embodiments, the object is a food item. in the method of use, the insulated paper product <NUM> may comprise an insulating wrapper for a food item.

In particular embodiments, the method uses the storage container <NUM> and the storage container <NUM> comprises a box <NUM>, a container <NUM> for temporarily housing a liquid (not shown), a cup, a mug, a flask, or a thermos <NUM>, a clam shell <NUM> for hot food <NUM> (See, for example, <FIG>. ), a salad container <NUM> for chilled food <NUM> (See, for example, <FIG>. ), a padded envelope <NUM> (See, for example, <FIG>. ), a shipping container <NUM> (See, for example, <FIG>), a shipping container <NUM> comprising shipping container walls <NUM> that comprise a closed cell foam <NUM>' (See, for example, <FIG>), or any combination thereof. For example, in one method of use, the method comprises a method of maintaining an object at a controlled temperature comprising: heating or chilling an object (e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens) to a predetermined temperature T; packaging the object inside any herein-described storage container <NUM>. The storage container <NUM> of dimensions <NUM>" x <NUM>" x <NUM>" can be capable of keeping a combination of <NUM> cooked pork (or simulant) and <NUM> of frozen water gel packs (conditioned to -<NUM> prior to placing into the container) below <NUM> after <NUM> hours in an external temperature of <NUM>.

The method of use may further comprise transporting the object within the insulated paper product <NUM> or the storage container <NUM>.

The method of use may further comprise shipping the object within the insulated paper product <NUM> or the storage container <NUM>. For example, in one method of use, the method comprises a method of shipping an object at a controlled temperature comprising: chilling an object (e.g., food, medicine, meat, fish, salad, vegetables, flowers, pharmaceuticals, biological specimens) to below a spoiling temperature of the object; packaging the chilled object inside any herein-described storage container <NUM>, along with frozen water gel packs, dry ice, etc.; closing the container; placing the storage container <NUM> into a vehicle (e.g., car, train, bus, airplane, etc.); transporting the package to a predetermined destination; removing the storage container <NUM> from the vehicle; and delivering the storage container <NUM> to either the front door of a residence, or to the loading dock of a distribution center, or the entrance of a restaurant, or the receiving department of a business, wherein the temperature inside the unopened storage container <NUM> remains below the food spoiling temperature for at least <NUM> hours.

The method of use may further comprise repulping the insulated paper product <NUM> and/or the storage container <NUM> after said insulating step, wherein at least <NUM>% of the insulating filler is removed from the pulp during the repulping operation.

The method of use may further comprise incorporating any fibers <NUM> and/or insulating particles <NUM> from a repulped insulated paper product <NUM> and/or a repulped storage container <NUM> into a newly formed insulated paper product <NUM> and/or a newly formed storage container <NUM>.

In addition, it should be understood that although the above-described insulated paper products and methods are described as "comprising" one or more components or steps, the above-described insulated paper products and methods may "comprise," "consists of," or "consist essentially of" the above-described components or steps of the insulated paper products and methods. Consequently, where the present invention, or a portion thereof, has been described with an openended term such as "comprising," it should be readily understood that (unless otherwise stated) the description of the present invention, or the portion thereof, should also be interpreted to describe the present invention, or a portion thereof, using the terms "consisting essentially of" or "consisting of" or variations thereof as discussed below.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," "contains", "containing," "characterized by" or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components. For example, an insulated paper product and/or method that "comprises" a list of elements (e.g., components, layers or steps) is not necessarily limited to only those elements (or components or steps), but may include other elements (or components or steps) not expressly listed or inherent to the insulated paper product and/or method.

As used herein, the transitional phrases "consists of" and "consisting of" exclude any element, step, or component not specified. For example, "consists of" or "consisting of" used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e., impurities within a given component). When the phrase "consists of" or "consisting of" appears in a clause of the body of a claim, rather than immediately following the preamble, the phrase "consists of" or "consisting of" limits only the elements (or components or steps) set forth in that clause; other elements (or components) are not excluded from the claim as a whole.

As used herein, the transitional phrases "consists essentially of" and "consisting essentially of" are used to define an insulated paper product and and/or a method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention. The term "consisting essentially of" occupies a middle ground between "comprising" and "consisting of".

Further, it should be understood that the herein-described insulated paper products and/or methods may comprise, consist essentially of, or consist of any of the herein-described components, layers and features, as shown in the figures with or without any feature(s) not shown in the figures. In other words, in some embodiments, the insulated paper products of the present invention do not have any additional features other than those shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the insulated paper products. In other embodiments, the insulated paper products of the present invention do have one or more additional features that are not shown in the figures.

The present invention is described above and further illustrated below by way of examples, which are not to be construed in any way as imposing limitations upon the scope of the invention defined by the appended claims.

Insulated paper products similar to exemplary insulated paper products <NUM>/<NUM>'/<NUM>"/<NUM> shown and described in <FIG> were prepared.

A polystyrene disposable weigh boat was accurately weighed to <NUM> decimal places (tare mass). Approximately <NUM>-<NUM> gram of liquid was placed in the weigh boat, and promptly weighed to four decimal places (gross-wet mass. ) Subtracting the tare from the gross-wet mass gives the net-wet mass. The weigh boat was carefully tilted and rocked from side to side, allowing the liquid to coat the bottom of the weigh boat evenly, then it was placed in a cupboard for <NUM>-<NUM> hours to evaporate at room temperature. The dry weigh boat was re-weighed to four decimal places (gross-dry mass). Subtracting the tare from the gross-dry mass gives the net-dry mass. <MAT> pH:
All pH measurements were made using universal indicator paper, as supplied by Micro Essential Laboratories Inc. The color of the paper and the chart were compared under indoor fluorescent strip lighting.

A modified version of Leslie's cube was used to screen multiple materials rapidly. The equipment is depicted in <FIG> shows the view from directly above the hotplate <NUM>, viewing the sample <NUM> in visible light. <FIG> shows the thermal view using the Flir E40 thermal camera <NUM>.

One complication with this test is that it highly thermally insulating materials will skew the results, as the method relies upon conduction of heat from the back to reach the same temperature. So, if the flux of heat traveling through is reduced significantly, then the black painted area will be cooling faster (through radiation) than sample area, leading to a slightly misleading result. For this reason, we developed several other tests to screen materials for emissivity.

This test method assumes constant heat flow, and no edge losses or other effects from convection or radiation-based heat transfer (all the heat flows through the sample).

Use the thermal images to compare whether the sample is more or less emissive than the shiny or black painted portions.

The portion of the sample painted black has a high emissivity (approx. <NUM>), and thus shows up red and displays the correct temperature. The polished aluminum material has a low emissivity (approx. <NUM>), and thus shows up blue and displays a lower temperature than the object actually is.

So, for this test, one should be able to say whether the emissivity of the test sample is higher, lower, or roughly equal to the emissivity of the black or silver samples.

<FIG> shows the test apparatus used to quickly visually compare the thermal emissivity of materials directly from the way that they absorb and then re-emit heat radiated from a hot-filament light bulb <NUM>. Samples were mounted onto a shiny metal plate <NUM>. Half of the sample was sprayed with mat black paint, and half was left exposed. All paint and adhesives used were allowed to dry at room temperature for at least <NUM> minutes. The camera <NUM> was switched on, and the spotlight was shone onto the samples from a low angle, so that stray heat radiation reflected away from the thermal camera <NUM>. Immediately, black and high emissivity materials lit up in the thermal camera screen, as the absorbed heat and then re-emitted it back out in all directions - including towards the thermal camera <NUM>.

Materials with low emissivity were generally much darker in color, after illumination for a few seconds.

Thermal emissivity of certain samples was also tested by Thermophysical Properties Research Laboratory, Inc. of West Fayetteville IN using the following test methodology.

The Table Top Emissimetry apparatus measures total normal emissivity over a broad wavelength band. Thin, square samples, <NUM>" on a side are mounted facing downward on an isothermal copper block heated by a resistance heater and surrounded by ceramic insulation. Five type-K thermocouples are mounted on the bottom face of the isothermal plate. Sample temperatures during emissivity measurements are inferred from the closest thermocouple. The samples are exposed to ambient air with convection losses minimized by the face-down orientation of the samples and the small gap to the detector head.

The IR detector is a broadband thermopile with a <NUM> diameter sensitive area and flat spectral response from <NUM> - <NUM> micrometers wavelength. The detector and radiation shield are water cooled and view the sample through a <NUM> aperture <NUM> from the sample surface. The detector is sensitive to radiation from an approximately <NUM> diameter spot on the sample. Stray radiation on the detector is minimized by a flat optical black coating on the inner surface of the shield and both faces of the aperture plate and by cooling the shield and aperture plates. The shield temperature is monitored by two type-K thermocouples embedded in the shield walls. Thermocouple and detector voltages are fed to an analog to digital module and attached to a personal computer. The emissivity ε is calculated by the equation: <MAT> where: <MAT> and V is the detector voltage, T is the temperature measured in Kelvin. The subscripts are as follows:.

In operation, power to the heater is adjusted by a computer controlled Eurotherm temperature controller to achieve a desired plate temperature and the system is allowed to stabilize. The detector is aligned with the sample to be viewed and its output voltage recorded. All samples on the isothermal plate are maintained in a constant radiation and convective heat transfer environment as the X-Y table is moved by the extended insulation block surrounding the detector head. Measurement of an oxidized copper reference standard with ε = <NUM>±<NUM> and a closed aperture measurement are made before and after each sample suite at each temperature. Total hemispherical emissivity is estimated from total normal/total hemispherical relationships developed for metals and insulators. The current temperature range covered is from room temperature to around <NUM>.

This test was devised to measure the amount of heat flowing through a given sample, as if it were placed in direct sunlight on a hot day. While a steady-state test would be ideal, the inventors sought methods to make rapid assessments of thermal properties for further research. While not wishing to be limited by theory, this test combines both emissivity (absorption of radiative heat) and conduction to give a measure of the amount of heat passing through a given sample.

Approximately <NUM> gallons of Atlanta city water was placed into a <NUM>-gallon bucket and sealed with a lid to equilibrate to room temperature for at least <NUM> hours. Expanded polystyrene coolers were purchased from Uline (Pleasant Prairie WI) (part number S21529) Inside dimensions: <NUM>" x <NUM>" x7", wall thickness <NUM>", and outside dimensions <NUM>" x <NUM>" x <NUM>". A <NUM> diameter acrylic circular template was used to draw a circle on one of the <NUM>" x <NUM>" faces of the cooler. The circle was positioned <NUM> from the top of the cooler, and <NUM> from either side, as shown in FIG. The circle was carefully cut out using an electrically heated hot knife (e.g. RoMech Pro Hot Knife Kit 200W Styrofoam cutter, made in China).

Two-part liquid silicone compound was mixed and used to seal the inside of the insulated cooler by painting the inner surfaces. The silicone resin (for example, Diamond Driven Liquid Silicone Compound, available from Amazon. com, or Oomoo <NUM> Silicone Mold Making Rubber available from Amazon, corn, or Smooth-On Ecoflex <NUM>-<NUM> fast platinum cure silicone rubber compound kit, available from Smooth-On through Amazon. com, or RTV Silicone Rubber for Mold Making available from Specialty Resin & Chemical LLC, Dowagiac MI, or similar) was allowed to cure overnight. The following day, excess silicone resin was cut from the exterior of the cooler in the vicinity of the cut circular hole, to ensure bondability between the expanded polystyrene and the sample. Although silicone resins were used, it was also found that epoxy resins could alternately be used to waterproof seal coolers without destroying the expanded polystyrene structure.

Sample preparation: Coatings were made onto <NUM> lb per <NUM> sq ft (<NUM> MSQ or <NUM> gsm) kraft board using meyer rods and dried. Example board is available from Juvo Plus Inc. (Irwindale CA) in the form of "<NUM> pack kraft laser and ink jet printer post cards <NUM> up per page" SKU LJ-WACHG-<NUM>-<NUM>-<NUM>. This paper was selected as it proved to be a more consistent source of kraft fiberboard than obtaining samples of <NUM> lb MSQ liner board from various corrugated board manufacturers. In some tests, the kraft fiberboard was substituted with a sheet of paper containing fillers, or thermal insulation elements or other materials that the inventors wished to assess, such as metallized bubble wrap.

Aluminum foil (e.g. Glad® Heavy Duty Aluminum Foil, distributed by Phoenix Industries Inc Denver CO, and available in grocery stores) was cut into sheets which were sprayed black on the dull side, using matt black spray paint (e.g. Rust-Oleum® Painter's Touch 2X Ultracover Paint + Primer, Rust-Oleum Corporation, Vernon Hills IL) and allowed to dry. The acrylic <NUM> diameter template was then used to mark and cut circular samples of coated kraft board. The back (kraft paper) sides of these were then sprayed with an adhesive such as <NUM>® Super <NUM> ™ Multipurpose Adhesive, made by <NUM> Company (Minneapolis MN) and sold in many craft, office, and hardware stores. The discs were carefully bonded to the shiny side of the painted foil, and placed between paper sheets under several books (about <NUM> pressure) until dry, to maintain flatness of the sample. The foil sheet was trimmed so that approximately <NUM>" to <NUM>" of shiny foil remained surrounded each sample.

<NUM>® Marine Adhesive Sealant Fast Cure <NUM> UV (part # <NUM>) was then used to carefully adhere the black surface of the foil-sample composite to the outside of the cooler, so that the sample was in line with the opening into the cooler. Other sealants could be used provided that they bond to both painted foil and expanded polystyrene, do not destroy expanded polystyrene by partially dissolving it, and that they form a waterproof seal. This was then allowed to cure overnight.

The cooler with the sample window was placed on the test rig built and illustrated in <FIG>. The test rig allows the repeatable location of the test window in front of the 110V 250W tungsten filament heat lamp such as those used in restaurants to keep prepared food hot prior to serving (e.g. Intertek <NUM>, white incandescent tungsten heat lamp). The test rig shown in <FIG> includes adjustment of angle of incidence and distance from the surface of the lamp to the center of the test material. <NUM>,<NUM> of water that had been allowed to equilibrate to room temperature was weighed to the nearest gram (using a Philips® Essence kitchen electronic top pan scale <NUM> increments to <NUM> capacity) and poured into the cooler. The stirrer blade was inserted through the lid, and a digital thermometer probe was also inserted through the lid. A strobe light was used to time the rotation of the stir blade to <NUM> rpm.

The water was stirred for several minutes until the temperature stabilized, at which time it was recorded. A timer was set for <NUM> minutes. The heat lamp was switched on, and the timer started simultaneously. The temperature of the water in the cooler was recorded every <NUM> minutes for one hour.

All tests were conducted in an air-conditioned temperature-controlled environment with an air temperature between <NUM>°F and <NUM>°F. Positive control sample was a kraft disk that also had a layer of aluminum foil laminated to it before adhering it to the shiny side of black painted foil, and a negative control consisted of an uncoated kraft disk mounted onto a similar foil sheet.

The temperature rise (DT) over one hour was used to determine the amount of energy (Joules) flowing through the coated kraft board per unit time (Watts) using the equation: <MAT> where <NUM> is the specific heat capacity of water in J. g-<NUM>; and <NUM> is the mass of the water present in the container.

Rate of energy transfer into the water Watts (ER) through the window is calculated by dividing by the number of seconds in one hour, viz. : <MAT> As the surface area of the disc is known, then the energy flux Watts per square meter can also be calculated (W.

In some experiments, an infrared thermometer (Etekcity Lasergrip 1025D) was also used to measure the outside temperature of the disk, to give an approximation of the temperature difference over the thickness of the sample.

These tests were carried out by SGS Integrated Paper Services Inc. , Appleton WI according to TAPPI T <NUM> om-<NUM> Ash in wood, pulp, paper and paperboard: combustion at <NUM>. Approximately <NUM> of paper was accurately weighed, and then ashed in a muffle furnace at <NUM>. The remaining ash was then re-weighed to determine ash content.

These tests were carried out by SGS Integrated Paper Services Inc. , Appleton WI according to TAPPI T <NUM> om-<NUM> Determination of equilibrium moisture in pulp, paper and paperboard.

Repulpability was tested by SGS Integrated Paper Services Inc. , Appleton WI according to the "<NPL>. Repulpable means the test material that can undergo the operation of re-wetting and fiberizing for subsequent sheet formation, using the process defined in this standard. In the repulpability test, materials are weighed, pulped in a specific manner using laboratory equipment, run through a laboratory disintegrator, and then run through a screen. The amount of rejected material is compared to the material that could be reused as pulp to make board as a % by mass. Two figures are derived: The first is the acceptable recovery of the fiber based upon the mass of material first entered into the test, and the second is the percentage of the recovered fiber that is accepted, not rejected. These figures constitute the "% re-pulpability", and the fiber box association has determined that a pass for both measures of repulpability is ><NUM>%. Other parameters recorded are: a) material fouling the equipment during pulping or forming b) material that does not disintegrate and has to be removed (becomes part of the rejects).

A clip attached to a ¾" thick glass plate is used to hold a stack of photocopy paper and the sheet of paper to be coated. A strip of masking tape was placed along the top of the sheet to be coated, and a paper towel was left hanging off the end. A transfer pipette was used to make a line of coating on the masking tape. This prevented the coating from prematurely soaking into the paper board to be coated. Meyer rods (available from RD Specialties Inc. ) were used to draw the coating down over the sheet. The coating was then dried under ambient conditions.

Before materials can be included in a coating or into the fibrous matrix of paper, materials first have to be wetted out and dispersed. Some materials such as glass have high enough surface free energy that the wet out spontaneously - whereas materials such as perlite and aerogel require surfactants to lower the surface free energy of the water enough to wet out the material.

Surfactants may be non-ionic, cationic, or anionic. They may be high molecular weight polymers or copolymers, or they may be low molecular weight, and able to reach newly created interfaces rapidly. Surfactants for aqueous systems may be characterized by their HLB value. HLB stands for Hydrophilic-Lipophilic Balance, and is a measure of the capability of the particular surfactant to wet out various surfaces of differing surface free energy. Very hydrophobic materials have a low surface free energy, so a matching surfactant should also have a low HLB value. More hydrophilic surfaces - those with multiple polar groups perhaps, require surfactants with higher HLB values.

Microspersion EZ manufactured by Micropowders Inc. of Tarrytown NJ is a non-ionic low molecular weight surfactant with a low HLB. Dawn® liquid dish soap, manufactured by the Procter & Gamble Co (Cincinnati OH) is an example of a low molecular weight anionic surfactant. E-Sperse <NUM> (from Ethos, Greenville SC), Triton BG-<NUM> (Dow) Glucopon <NUM> N (BASF) and Glucopon <NUM> UP (BASF) are additional materials that can wet out certain hydrophobic materials. The Surfynol ® range available from Evonik are ethoxylated acetylenic diols of fairly low molecular weight. They are non-ionic, and low foaming due to the molecular interactions of the acetylenic moiety with the water surface. Surfynol <NUM>, <NUM>, <NUM> are representative examples.

Higher molecular weight materials are useful for stabilizing dispersions of various materials in water. Polymers may be anionic, cationic, or non-ionic - or have a mixture of characteristics. Polymeric dispersants, also known as "grid aids" are often co-polymeric in nature, for instance some of the Joncryl resins from BASF are believed to be methacrylic acid - styrene - butylmethacrylate copolymers, containing anionic ionizable groups. Zetasperse <NUM>, Zetasperse <NUM>, TegoDispers 752W, and TegoDispers 755W are also higher molecular weight dispersing agents with a net negative formal charge when ionized available from Evonik. Disperbyk <NUM>, as well as other Disperbyk products available from BYK Chemie (Wallingford CT) are also polymeric / copolymeric materials that help stabilize dispersions through a) increasing particle surface negative charge (electrokinetic stabilization), and b) by allowing steric stabilization by dint of segments of polymer dissolving into the continuous medium.

Many corrugated cardboard boxes and fiberboard packages are coated with a clay coating. This coating provides a smooth flat ink-receptive surface that allows high quality printing, it covers the brown color of unbleached pulp with white, and gives the packaging a higher quality feel. Often the coating is applied in two layers. The first layer is kaolin clay based, whitened by calcium carbonate. This layer helps smooth the surface by filling in low spots. The second layer also contains titanium dioxide and calcium carbonate. The formulations of clay coatings vary. Usually, they contain kaolin clay, along with a film forming binder, such as an acrylic latex, or sometimes a cornstarch. A polymeric dispersant is usually included to stabilize the clay coating, and a viscosity control agent is usually also included, such as carboxymethyl cellulose, or an hydrophobically associated alkali swellable polymer (HASE polymer. ) Calcium carbonate is also usually included, along with titanium dioxide pigment for whitening. The clay coating offers another opportunity to incorporate insulative elements that reduce conduction and radiative heat transfer.

Powdered materials were sampled and tested to observe emissivity differences through a thermal camera. The emissivity of the powder surface and the powder surface sprayed with black paint were compared. NVD = no visible difference.

These powder sample data gave us several ideas for follow up tests. Curiously, some of the materials gave different results if they are first formulated into a coating (e.g. kaolin and diatomaceous earth). In other cases, low thermal conductivity may have skewed some readings.

Both powdered materials, as well as materials incorporated into coatings coated onto fiberboard were sampled and tested to observe emissivity differences through a thermal camera. The emissivity of the powder surface/coating surface and regular Cardboard were compared when illuminated by an incandescent tungsten spot light. NVD = no visible difference in emissivity vs. cardboard. Coating formulas follow below. NT = not tested.

These data gave us additional ideas to pursue insulating against thermal radiative emission and absorption, in addition to insulating against thermal conduction.

Rhoplex VSR-<NUM> is an acrylic low VOC film forming binder emulsion in water. Commonly used in architectural coatings. Originally sold by Rohm & Haas, now available from Dow Chemical.

Sericite comprised sericite mica surface treated with magnesium myristate or Sericite White sparkle luxury mica colorant pigment powder by H&B Oils Center Co.

Supertherm paint, from Eagle Specialty Coatings, British Columbia, Canada.

Based upon the rapid testing using Emissivity tests <NUM> & <NUM>, several materials were selected for further investigation. In preparation for printing, fiberboard is often coated with a clay coating, which smooths the surface and gives it a white color. A simple clay coat formulation was generated: Kaolin Clay Coating <NUM>-<NUM>:.

Kaolin clay coating <NUM>-<NUM> was coated onto <NUM> gsm (<NUM> lbs/<NUM> sq ft) kraft laser & inkjet printer post cards, available from Juvo Plus Inc Irwinsdale CA, using a # <NUM> Meyer rod and dried in a hot air oven at <NUM>°F for <NUM> mins. Various coatings were selected and coated onto the board, drying the coatings between each application. A representative area was selected, and tested on the test rig illustrated in <FIG>. The distance to the lamp was set to <NUM>", <NUM> grams of water were weighed into the cooler, and the stirrer rotation was set to <NUM> rpm. The water temperature rise over <NUM> hour of lamp exposure was recorded.

These data suggest that we can reduce the amount of energy absorbed by a box, or emitted from the inside surfaces of a box using coatings, by around <NUM>%. While aluminum foil, as well as aluminized bubble wrap are very effective, they can cause problems if introduced into the repulping stream, and in any case are challenging to recycle. Not only could many of these coatings be applied to the interior and or exterior of the box, but could also be used as separate sheets of packaging, as illustrated as the loose sheets in <FIG>.

The inventors were surprised by the results of their own emissivity tests methods <NUM> and <NUM>, as well as the emissivity results provided by the outside laboratory (Thermal Emissivity Test Method #<NUM>). Several coatings have been discovered by the inventors that apparently reduce the transfer of radiant heat energy from an incandescent light bulb (as a proxy to the full-sun illumination of a delivered package) through sheets of paper. The inventors were surprised to find that the emissivity results from the third-party laboratory did not correlate with the heat transfer through the materials measured by the cooler window tests. Clearly, the inventors may have discovered several coatings with non-obvious and unexpected thermal properties.

Approximately <NUM> portions of <NUM> lb liner board (International Paper) was shredded and repulped. Additional materials were added, along with surfactants if necessary for wetting. While not yet optimum formulations, we had found that we could make paper sheets containing insulating elements by adding surfactant, along with a cationic polysaccharide, such as cationic Guar Gum, available from Making Cosmetics Inc. , or a cationic starch sizing, or a synthetic retention aid, such as Polymin P (BASF), also known as poly(ethylene imine), or a high molecular weight poly(acrylamide) available from various sources. Hydrophobically associating polymers may also be incorporated, such as N-alkyl poly(acrylamides. ) We wished to understand the amount of retained insulation in the paper following drying.

The following formulations were made up and cast as paper, dried at room temperature and then sent for ash content and moisture content analysis:.

A mass balance was performed to confirm that a portion of the perlite and a portion of the finer was lost during the drawing and pressing process.

<NUM> lb fiberboard was fed through a paper shredder. <NUM> was weighed and pulped in hot water as usual. The pulp was more dense and more difficult to disperse than the pulp from the <NUM> lb paper. Paper sheets were made using the following formulations:.

As a control (JL <NUM>-<NUM>), the existing method of shipping cold objects was also tested for repulpability. Corrugated cardboard from a BS121007 single walled <NUM>" x <NUM>" x <NUM>" box sections were laminated to an insulated box liner, made from <NUM>/<NUM>" cool-shield bubble & metallized film, available from Uline as model number S-<NUM>. The materials were laminated using <NUM> aerosol spray adhesive.

These data illustrate the validity that the approach of incorporating insulating elements into the paper structure has the potential to produce a repulpable thermally insulating material for packaging.

<NUM> lbs per <NUM> sq. single-ply sheets containing additives were made for additional repulpability tests, consistent with the Fiberboard Association voluntary standard for repulpability. Sheets FA, FD, FE, FF, FG were made using Grade <NUM> bleached pulp secondary fiber (supplied by Donco Recycling Solutions with offices in Chicago IL. ) The target basis weight for each sheet was <NUM> lbs per <NUM> square feet (MSQ). Taking sample FD as an example, to make <NUM> MSQ board with <NUM>% additive, <NUM> lbs of dry pulp is mixed with <NUM> lbs of additive for every <NUM>,<NUM> square feet of paper. Once ash content and moisture were measured, the sheets were then run through the repulping test in duplicate:.

An antique desk-top hand cranked corrugator was purchased. The corrugator indicated <CIT>.

A sheet of TL1 was hung from inside an inverted <NUM>-gallon pail and held over a boiling tea kettle to steam the sheet. The cast iron hand-cranked corrugator was warmed with a hair dryer, and the warm steamed sheet was promptly rippled. This was promptly bonded between two non-corrugated sheets of TL1 to make a rudimentary corrugated structure. Single ply filled sheets were hand pressed in the lab and dried:.

A sheet of EJ was hung from inside an inverted <NUM>-gallon pail and held over a boiling tea kettle to steam the sheet. The cast iron hand-cranked corrugator was warmed with a hair dryer, and the warm steamed sheet was promptly fluted. This was promptly bonded between two non-corrugated sheets of EJ to make a rudimentary corrugated structure. This procedure was repeated using EK sheets for all three layers.

A sheet of TL1, EJ, and EK were each coated with Kaolin clay formulation <NUM>-<NUM>, then dried, and then coated with <NUM>-<NUM> (BiLite (BASF) - bismuth oxychloride coated mica flakes) and dried. More uncoated sheets were steamed and fluted, and similar corrugated structures were produced incorporating one of the coated sheets with the coating side facing out as depicted in <FIG>.

<NUM> diameter disks were cut of each sample, and mounted into a cooler window for thermal testing. Prior to sealing with marine adhesive, the samples were gently pushed into the front of the cooler window so that the face of the composite was flush with the front of the cooler. <NUM> discs of the following were also cut as controls: Aluminized bubble wrap, corrugated C-flute (35lbs. MSQ kraft liners with 23lb medium, Corrugated Supplies Inc. ), corrugated B-flute (35lbs. MSQ kraft liners with 23lb medium, Corrugated Supplies Inc. ), triple wall corrugated B-C flute (35lbs. MSQ kraft liners with 23lb medium, Corrugated Supplies Inc.

Because these samples had significant thickness, temperature rise was monitored over an initial period of time until three consecutive <NUM>-minute temperature readings showed an increase in temperature within +/- <NUM> of each other. Upon attaining consistent temperature increase readings over <NUM> minutes, this was designated as pseudo-steady state. The temperature of the outside lamp-facing surface was also measured using a hand-held pyrometric infra-red thermometer, taking care to try not to allow reflections of the hot lamp from interfering. Usually, a pseudo-steady state situation of incremental temperature increases was established within <NUM> minutes of run time.

These data demonstrate the additive combination of addressing both radiative heat transfer as well as conductive heat transfer.

Stir to disperse. Shake vigorously immediately prior to use.

Approximately <NUM> square feet of <NUM> lbs per <NUM>,<NUM> square feet kraft paper was hung vertically and coated with clay formulation JL3-<NUM>-<NUM> using a <NUM> psi compressed air atomized high-pressure low volume paint spray gun, from about a <NUM>" distance. The coating was applied in multiple passes until a uniform white layer was formed. A similar technique was used to overcoat a thin layer of JL3-<NUM>-<NUM> coating, containing bismuth oxychloride-coated mica and a binder system. The paper was dried using a hair dryer, and allowed to equilibrate overnight. An average of <NUM> dried cut samples of coated and uncoated paper were weighed to determine a total coat weight of <NUM> / m<NUM>.

The paper had improved pigment rub-off compared to earlier formulations using similar materials, presumably, although without wishing to be bound by theory, because the binder concentration was increased and the surfactant package was changed. Interestingly, when the paper was folded or pleated, it made very little noise compared to the uncoated paper. Furthermore, the paper was found to be repulpable when tested.

Claim 1:
A repulpable insulated paper product comprising:
one or more paper layers; and
a smooth, heat-reflecting, thermally insulating coating on at least one outer surface of said one or more paper layers, said smooth, heat-reflecting, thermally insulating coating (a) comprising (i) from about <NUM> weight percent (wt%) to about <NUM> wt% of one or more insulating materials comprising bismuth oxychloride, mica, bismuth oxychloride-coated mica, zinc oxide, aluminum-doped zinc oxide, zinc sulfide, cadmium sulfide, bismuth vanadate, gypsum, sericite, powdered silicon, silver-coated glass bubbles, aluminum oxide, hollow polymeric microsphere pigments, or any mixture or combination thereof, and (ii) from about <NUM> wt% to about <NUM> wt% of a binder comprising (A) a latex binder selected from polymers synthesized using emulsion polymerization including poly(vinyl acetate), poly(acrylonitrile), poly(acrylates), poly(methacrylates), poly(butadiene), poly(styrene), poly(acrylic acid), and various copolymers of these polymers; or (B) a latex binder comprising a polymer or co-polymer of one or more monomers selected from styrene, butadiene, acrylic acid, acrylate, methacrylate, and vinyl acetate; (b) forms a continuous coating that completely covers the at least one outer surface; (c) reflects heat; and (d) reduces transfer of heat through the repulpable insulated paper product,
wherein the repulpable integral paper product is repulpable as determined by the "Voluntary Standard for Repulping and Recycling Corrugated Fiberboard treated to Improve Its Performance in the Presence of Water and Water Vapor Protocol of <NUM>" with <NUM>% or more of recovered fibers from the repulped integral paper product being accepted, not rejected, using this test.