Abstract: Unexpectedly unique and environmentally friendly composite material structures, storage articles fabricated therefrom, and related methods. The composite structure includes at least one or more fiber-containing layers, such as fiberboard or other layers having fibers from natural and/or synthetic sources, and one or more mineral-containing layers. The mineral-containing layer(s) comprises a thermoplastic bonding agent fixing the mineral particles in place. The fiber-containing layer(s) and mineral-containing layer(s) can be shaped, sized, and manufactured such that the composite structure formed therefrom is capable of being machined to form the storage article. The composite structure can be repulped and recycled without the use of dispersions, emulsions, or aqueous solutions. Further, the composite reduces layer mass requirements for heat seal, barrier, and fiber adhesion compared to polymer layers.

Abstract: A composition used to form thermoplastic films and coatings comprising a thermoplastic polyolefin and a ground natural mineral material wherein a film or coating formed of said composition heat seals at or above 200 degrees F. with a dwell time exceeding approximately 0.5 seconds, has a TAPPI T-525 Whiteness % over 78, a TAPPI T-425 Opacity % over 78, a post corona treated ASTM D-2578 dyne level over 38, a minimum moisture barrier transmission rate of 4.0 g/mil/100 sq. in./24 hrs. at 100 degrees F. at 90% relative humidity, and a minimum oxygen barrier of 350 cc/mil/100 sq. in/24 hrs. at 23 degrees C.