Abstract: Recyclable and repulpable coated paper stock, preferably for use as ream wrap, comprising a substrate coated on at least one surface with a base coat and at least one additional coat over said base coat. Both coats are water based dispersions of a polymer selected from the group consisting of acrylic polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol, ethylene-vinyl acetate, polyvinyl chloride, styrene butadiene copolymers, polyvinylidiene chloride and its copolymers, or starch. The wax free coating forms a pin-hole free continuous film on the substrate which is resistant to water and water vapor. The invention also includes processes for making and recycling the invented coated paper stocks.

Abstract: Recyclable and repulpable coated paper stock, preferably for use as ream wrap, comprising a substrate coated on at least one surface with a base coat and at least one additional coat over said base coat. Both coats are water based dispersions of a polymer selected from the group consisting of acrylic polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol, ethylene-vinyl acetate, polyvinyl chloride, styrene butadiene copolymers, polyvinylidiene chloride and its copolymers, or starch. The wax free coating forms a pin-hole free continuous film on the substrate which is resistant to water and water vapor. The invention also includes processes for making and recycling the invented coated paper stocks.

Abstract: Recyclable and compostable coated paper stock comprising a substrate coated on at least one surface with a primer coat and a top coat both of which are water based dispersions. The primer coat comprises a water based dispersion of a polymer selected from the group comprising acrylic polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol, poly-ethylene vinyl acetate, poly-ethylene vinyl chloride, styrene butadiene copolymers, polyvinylidiene chloride or starch. The top coat comprises a water based dispersion of a polymer selected from the group comprising acrylic polymers, acrylic copolymers, styrene butadiene copolymers or polyvinylidiene chloride. In another embodiment the top coat further includes a wax component comprising 15-90 wt. % of the polymer and 5-85 wt. % of the wax. The substrate is coated with a primer coat prior to the application of the top coat to seal the substrate surface.

Abstract: Recyclable paper stock comprising a substrate coated on at least one surface with a water based emulsion coating. The water based emulsion coating comprises 20-90 dry wt. % of an acrylic-styrene copolymer and 5-70 dry wt. % of a wax. In another embodiment a second water based emulsion coating comprised of an acrylic-styrene copolymer is coated on the substrate surface opposite the initial water based emulsion coating. The substrate may also be coated with a primer coat prior to the application of the water based emulsion coatings to seal the substrate surface. The invention also includes processes for making and using the invented acrylic coated paper stocks.

Abstract: An ultrasonically bonded microwave susceptor material and method for manufacturing this microwave susceptor material. A laminated microwave susceptor material has first and second plies of material ultrasonically bonded together over a part of an area thereof. The first ply of material is a layer of thermally fusible plastic such as a thermoplastic polyester, the second ply of material is a layer of paper or paperboard and at least one of the first and second plies of material includes a microwave interactive material capable of converting microwave energy to thermal energy. The microwave interactive material may consist of a metallized surface on the plastic layer or the paper, and in such cases the metal layer may be arranged between the plastic layer and the paper. The first and second plies of material are ultrasonically bonded along a multiplicity of bonding lines or rows of bonding spots. In this process, the heat fusible plastic is melted and resolidified to secure the first ply to the second ply.

Abstract: Recyclable and compostable coated paper stock comprising a substrate coated on at least one surface with a primer coat and a top coat both of which are water based dispersions. The primer coat comprises a water based dispersion of a polymer selected from the group comprising acrylic polymers, acrylic copolymers, polyvinyl acetate, polyvinyl alcohol, poly-ethylene vinyl acetate, poly-ethylene vinyl chloride, styrene butadiene copolymers, polyvinylidiene chloride or starch. The top coat comprises a water based dispersion of a polymer selected from the group comprising acrylic polymers, acrylic copolymers, styrene butadiene copolymers or polyvinylidiene chloride. In another embodiment the top coat further includes a wax component comprising 15-90 wt. % of the polymer and 5-85 wt. % of the wax. The substrate is coated with a primer coat prior to the application of the top coat to seal the substrate surface.

Abstract: A pouch suitable for packaging disposable consumer products having a pressure sensitive adhesive coated on a portion of a surface thereof. The pouch is formed from a silicone polymer coated paper with the silicone coating forming an internal surface of the pouch, thereby allowing easy removal of the product from the pouch and avoiding permanent sticking of the pressure sensitive adhesive coating to the pouch material. The silicone polymer coated paper used to form the pouch has, as a part of the composition thereof, a thermoplastic component which can be a thermoplastic basecoat, or an admixed thermoplastic polymer included in the silicone polymer coating, or a thermoplastic coating on the surface of the paper opposite the silicone coating, or combinations of these alternatives. In all cases, the thermoplastic component is provided in the form of a water-based emulsion or dispersion of a thermoplastic polymer, such as an emulsion of an ethylene vinyl acetate copolymer.

Abstract: A blank for a paperboard container is provided on one of its surfaces with a layer of food-contacting polymethylpentene. The container formed from the blank, as by bending the blank along fold lines, requires one or more overlapped joints such as the usual manufacturer's joint. To overcome the non-stick properties of the polymethylpentene layer, the layer is flame treated so that it will adhere to a conventional water based, FDA approved adhesive and thereby make possible the formation of a seam or other overlapped joint or joints. Flame treatment is restricted to portions of the area of the polymethylpentene layer that are involved in the formation of the overlapped joint or joints. Alternatives to flame treatment include corona treatment, solvent treatment or treatment of the polymethylpentene surface with a solvent based primer.

Abstract: A blank for a paperboard container is provided on one of its surfaces with a layer of food-contacting polymethylpentene. The container formed from the blank, as by bending the blank along fold lines, requires one or more overlapped joints such as the usual manufacturer's joint. To overcome the non-stick properties of the polymethylpentene layer, the layer is flame treated so that it will adhere to a conventional water based, FDA approved adhesive and thereby make possible the formation of a seam or other overlapped joint or joints. Flame treatment is restricted to portions of the area of the polymethylpentene layer that are involved in the formation of the overlapped joint or joints.

Abstract: A microwave susceptor material which comprises a substrate such as paper or paperboard treated with a polar organic compound having microwave interactive characteristics. A salt, which is soluble in the polar organic compound, can be added to alter the microwave heating performance of the material. The invention provides susceptor materials useful for cooking food items in a microwave oven with enhancement of the quality of the cooked food, such as the browning and crisping of the food surface. The susceptor materials are formed by treatment of the substrates with the polar organic compounds under conditions that cause the polar organic compounds to penetrate the substrate.

Abstract: A pouch for the packaging of products having a pressure sensitive adhesive thereon, such as sanitary napkins. The pouch is formed of paper of plastic film coated on one side with a layer of silicone, the pouch construction being such that the silicone coating defines the interior surfaces of the pouch. Due to the nonstick characteristic of the silicone coating, the usual protective liner for the adhesive on the packaged product can be omitted. The side seams of the pouch are formed by the application of heat or ultrasonic energy in combination with mechanical deformation of the paper or film to produce embossments in the seam areas. The side seams may be comprised of two or three layers of material. The nature of these side seams may be such that the pouch may be opened by peeling apart the seams, or the seams may be sealed so tightly that the pouch can be opened only by tearing the material.

Abstract: A flexible, open ended microwave cooking tube formed of paper. The paper is provided with a layer of microwave susceptor material such as vacuum deposited metal. The tube is formed of a rectangular blank of the stock comprised of the paper and microwave susceptor material. A pair of opposite, parallel ends of the blank are seamed together and are provided with handle forming holes. In operation, a food item is placed within the tube. During the cooking process, the susceptor material reaches the high temperature required to brown and crispen the food. The seamed, handle portion of the tube, not being provided with susceptor material, remains relatively unheated and is hence less dangerous to the user when the tube and food are removed from the microwave oven. The tube can be formed from a continuous length of the paper/susceptor stock and wound into a roll. Short lengths of the tube can then be cut from the roll to provide individual containers for microwave cooking.

Abstract: A microwave cooking tray for microwave ovenable foodstuffs which usually display browned or crisped areas upon conventional oven cooking. The container is formed from a one piece blank of dielectric material, such as paperboard, which is bent and folded to form a trough shaped tray. A microwave interactive component included in the blank provides thermal heating effects such as browning and crisping for foodstuff placed in the tray and heated in a microwave oven. The tray is foldable to a flat configuration to facilitate shipment and storage. In one embodiment, the tray is flat on its entire upper portion when cooking.

Abstract: An ovenable food tray for cooking foodstuffs, such as frozen foodstuffs, in an oven of either the microwave or conventional type. The tray is formed from a flat, unitary laminate blank by deforming the blank in any conventional male and female die apparatus under pressure and heat. The laminate includes a food contacting PET bi-axially oriented film coating adhered to a paperboard base stock by means of a crosslinkable adhesive. The use of such a coating and such an adhesive formulation permits use of the tray in oven temperatures to about 400 degrees F. without delamination of the coating from the paperboard or cracking of the coating.

Abstract: An ovenable food tray formed from paperboard, the food-containing surface of which is coated with a food grade resin. The other surface of the paperboard is adhered to a paper coated with an essentially nonburning coating. This paperboard-adhesive-paper laminate yields improved flame resistance, particularly in electric ovens where the food tray may be accidentally placed very near an oven heating element.

Abstract: A microwave ovenable package including a layer of material that will convert a portion of the microwave energy to heat and a layer of paperboard interposed between the energy-converting layer and the food in the package which is to be cooked and browned. The energy-converting layer may be carried on a plastic film, the latter being adhered to the side of the paperboard layer which does not contact the food. An additional layer of paperboard may be used to sandwich the energy-converting layer and the plastic film between layers of paperboard. The heat from the energy-converting layer provides a surface heating effect on the food such as browning, crisping, or singeing. The presence of the paperboard layer between the energy-converting layer and the food prevents contamination of the food which might otherwise occur due to the degradation of the plastic in those cases where the microwave cooking causes the energy-converting layer to reach a temperature higher than intended.

Abstract: An ink-printed ovenable food container is prepared by(a) printing a layer of paperboard with an ink containing a sulfonated polyester pigment binder,(b) coating the resultant ink-printed paperboard with an unpigmented composition containing a sulfonated polyester,(c) coating the resultant ink-printed and sulfonated polyester coated paperboard with a polyester resin sealing coating, and(d) forming the resultant polyester resin sealed paperboard into a container.

Abstract: An electrically conductive non-woven web for a heating element is formed from a non-woven sheet comprising conductive fibers which is saturated with a dispersion comprising conductive particles. Embodiments adapted for use at low voltages and at household voltages are provided. In a preferred, flame-resistant embodiment, the heating element is a sandwich containing, from bottom to top, a first insulating non-woven sheet comprising polyaramid fibers, an electrically conductive web comprising carbon fibers, polyaramid fibers, and carbon black. A pair of conductive strip attached in electrical contact to the web, and a second insulating non-woven sheet comprising polyaramid fibers.

Abstract: A process for preparing a flowable, nonaqueous, solvent-free highly-pigmented, low viscosity, thermoplastic, hot-melt coating compound, which comprises the steps of: (a) mixing in an initial stage from about 70% to about 95%, by weight, of pigment with from about 5% to about 30%, by weight, of low viscosity thermoplastic binder material for a period of time sufficient to obtain a homogeneous concentrate; and (b) mixing in one or more subsequent stages the homogeneous concentrate of step (a) with sufficient additional amounts of low viscosity thermoplastic binder material to yield a final homogeneous, flowable compound comprising from about 30% to about 70%, by weight, of pigment and from about 30% to about 70%, by weight, of low viscosity thermoplastic binder material.

Abstract: Disclosed is an apparatus and process for the molding of hollow articles such as full length Foley catheters. The apparatus preferably comprises a mold with two lumen forming wires longitudinally disposed therein. A set of two receiving wires are spaced distally from the distal ends of the lumen forming wires and are longitudinally aligned therewith. A first follower is slidably disposed about the lumen forming wires in close abutment with the wires and inside wall of the mold. The first follower is preferably disposed toward the proximal end of the mold and preferably at least two other followers are provided spaced distally of the first follower. One of the other followers preferably bridges the space between the lumen forming wires and receiving wires. Sets of gates are preferably provided along the length of the mold in fluid communication with a source of molding material.