Process for preparing embossed, coated paper

Claim 2

A process for preparing embossed, coated paper, comprising the steps of: A) providing a web of paper; B) providing a polymeric film; C) extrusion coating a layer of molten resin onto the web of paper; and D) simultaneously performing the steps of: i) contacting the polymeric film to the layer of resin, thereby forming a composite comprising the web of paper, polymeric film, and resin layer therebetween; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll; and iii) embossing the exposed surface of the polymeric film.

Claim 3

The process for preparing embossed, coated paper, according to claim 1, wherein the paper is selected from the group consisting of kraft paper, natural pulp paper, synthetic pulp paper, paperboard, linerboard, and cardboard.

Claim 4

The process for preparing embossed, coated paper, according to claim 2, wherein the paper is kraft paper.

Claim 5

The process for preparing embossed, coated paper, according to claim 1, wherein the thickness of the paper is from about 5 mils to about 300 mils.

Claim 6

The process for preparing embossed, coated paper, according to claim 4, wherein the thickness is from about 5 mils to about 100 mils.

Claim 7

The process for preparing embossed, coated paper, according to claim 1, wherein the polymeric film is selected from the group consisting of high, medium, and low density polyethylene.

Claim 8

The process for preparing embossed, coated paper, according to claim 1, wherein the polymeric film thickness is from about 0.3 mil to about 10 mils.

Claim 9

The process for preparing embossed, coated paper, according to claim 7, wherein the thickness is from about 0.5 mil to about 1 mil.

Claim 10

The process for preparing embossed, coated paper, according to claim 1, wherein the resin is selected from the group consisting of high, medium and low density polyethylene.

Claim 11

The process for preparing embossed, coated paper, according to claim 1, wherein the nip roll has a Durometer hardness from 50 to 75.

Claim 12

The process for preparing embossed, coated paper, according to claim 10, wherein the Durometer hardness is about 60.

Claim 13

The process for preparing embossed, coated paper, according the claim 1, wherein the laminating of step Dii is conducted utilizing a pressure, between the nip roll and engraved chill roll, from about 20 pli to about 200 pli.

Claim 14

The process for preparing embossed, coated paper, according to claim 12, wherein the pressure is from about 50 pli to about 150 pli.

Claim 15

The process for preparing embossed, coated paper, according to claim 13, wherein the pressure is from about 80 pli to about 100 pli.

Claim 16

The process for preparing embossed, coated paper, according to claim 1, wherein the temperature of the engraved chill roll is from about 55° F. to about 150° F.

Claim 17

The process for preparing embossed, coated paper, according to claim 1, wherein the extrusion coating of step C is conducted so as to form a resin layer from about 0.3 mil to about 5 mils in thickness in the composite of step Di.

Claim 18

The process for preparing embossed, coated paper, according to claim 16, wherein the resin layer is from about 0.5 mil to about 1.5 mils.

Claim 19

The process for preparing embossed, coated paper, according to claim 1, wherein steps A and B are conducted at the same running speed, from about 50 ft/min to about 500 ft/min.

Claim 20

The process for preparing embossed, coated paper, according to claim 18, wherein the running speed is from about 350 ft/min to about 450 ft/min.

Claim 21

A process for preparing embossed, coated paper, comprising the steps of: A) providing, at a running speed from about 50 ft/min to about 500 ft/min, a web of paper, selected from the group consisting of kraft paper, natural pulp paper, synthetic pulp paper, paperboard, linerboard, and cardboard, having a thickness from about 5 mils to about 300 mils; B) providing, at the running speed of step A, a polyethylene film, selected from the group consisting of low, medium, and high density polyethylene, having a thickness from about 0.3 mil to about 10 mils; C) extrusion coating at a temperature from about 500° F. to about 700° F., a layer of polyethylene resin, selected from the group consisting of low medium, and high density polyethylene, onto the web of paper; and D) simultaneously performing the steps of: i) contacting the polyethylene film to the layer of polyethylene resin, thereby forming a composite comprising the web of paper, polyethylene film, and polyethylene resin layer therebetween, the polyethylene resin layer having a thickness from about 0.3 mil to about 5 mils; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll, the nip roll having a Durometer hardness from about 50 to about 75, the engraved chill roll maintained at a temperature from about 55° F. to about 150° F., and the pressure between the nip roll and engraved chill roll from about 20 pli to about 200 pli; and iii) embossing the exposed surface of the polyethylene film.

Claim 22

A process for preparing embossed, coated paper, comprising the steps of: A) providing, at a running speed from about 50 ft/min to about 500 ft/min, a web of paper, selected from the group consisting of kraft paper, natural pulp paper, synthetic pulp paper, paperboard, linerboard, and cardboard, having a thickness from about 5 mils to about 300 mils; B) providing, at the running speed of step A, a polyethylene film, selected from the group consisting of low, medium, and high density polyethylene, having a thickness from about 0.3 mil to about 10 mils; C) extrusion coating at a temperature from about 500° F. to about 700° F., a layer of polyethylene resin, selected from the group consisting of low medium, and high density polyethylene, onto the web of paper; and D) simultaneously performing the steps of: i) contacting the polyethylene film to the layer of polyethylene resin, thereby forming a composite comprising the web of paper, polyethylene film, and polyethylene resin layer therebetween, the polyethylene resin layer having a thickness from about 0.3 mil to about 5 mils; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll, the nip roll having a Durometer hardness from about 50 to about 75, the engraved chill roll maintained at a temperature from about 55° F. to about 150° F., and the pressure between the nip roll and engraved chill roll from about 20 pli to about 200 pli; and iii) embossing the exposed surface of the polyethylene film.

Claim 23

The process for preparing embossed, coated paper, according to claim 20, wherein the paper is kraft paper.

Claim 24

The process for preparing embossed, coated paper, according to claim 20, wherein the thickness of the paper is from about 5 mils to about 100 mils.

Claim 25

The process for preparing embossed, coated paper, according to claim 20, wherein the polyethylene film thickness is from about 0.5 mil to about 1 mil.

Claim 26

The process for preparing embossed, coated paper, according to claim 20, wherein the Durometer hardness is about 60.

Claim 27

The process for preparing embossed, coated paper, according to claim 20, wherein the laminating of step Dii is conducted utilizing a pressure, between the nip roll and the engraved chill roll, from about 50 pli to about 150 pli.

Claim 28

The process for preparing embossed, coated paper, according to claim 25, wherein the pressure is from about 80 pli to about 100 pli.

Claim 29

The process for preparing embossed, coated paper, according to claim 20, wherein the extrusion coating of step C is conducted so as to form a polyethylene resin layer from about 0.5 mil to about 1.5 mils in thickness in the composite of step Di.

Claim 30

The process for preparing embossed coated paper, according to claim 20, wherein the temperature of the extrusion coated resin in step C is from about 580° F. to about 625° F.

Claim 31

The process for preparing embossed, coated paper, according to claim 20, wherein steps A and B are conducted at the same running speed, from about 350 ft/min to about 400 ft/min.

Claim 32

A process for preparing embossed, coated paper, comprising the steps of: A) providing, at a running speed from about 350 ft/min to about 450 ft/min, a web of kraft paper, having a thickness from about 5 to about 100 mils; B) providing, at the running speed of step A, a polyethylene film, selected from the group consisting of low, medium, and high density polyethylene, having a thickness from about 0.5 mil to about 1 mil; C) extrusion coating, at a temperature from about 580° F. to about 625° F., a layer of polyethylene resin, selected from the group consisting of low, medium, and high density polyethylene, onto the web paper; and D) simultaneously performing the steps of: i) contacting the polyethylene film to the layer of polyethylene resin, thereby forming a composite comprising the web of paper, polyethylene film, and polyethylene resin layer therebetween, the polyethylene resin layer having a thickness from about 0.5 mil to about 1.5 mils; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll, the nip roll having a Durometer hardness of about 60, the engraved chill roll maintained at a temperature of from about 55° F. to about 150° F. and the pressure between the nip roll and engraved chill roll from about 80 pli to about 100 pli; and iii) embossing the exposed surface of the polyethylene film.

Claim 33

A process for preparing embossed, coated paper, comprising the steps of: A) providing, at a running speed from about 350 ft/min to about 450 ft/min, a web of kraft paper, having a thickness from about 5 to about 100 mils; B) providing, at the running speed of step A, a polyethylene film, selected from the group consisting of low, medium, and high density polyethylene, having a thickness from about 0.5 mil to about 1 mil; C) extrusion coating, at a temperature from about 580° F. to about 625° F., a layer of polyethylene resin, selected from the group consisting of low, medium, and high density polyethylene, onto the web paper; and D) simultaneously performing the steps of: i) contacting the polyethylene film to the layer of polyethylene resin, thereby forming a composite comprising the web of paper, polyethylene film, and polyethylene resin layer therebetween, the polyethylene resin layer having a thickness from about 0.5 mil to about 1.5 mils; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll, the nip roll having a Durometer hardness of about 60, the engraved chill roll maintained at a temperature of from about 55° F. to about 150° F. and the pressure between the nip roll and engraved chill roll from about 80 pli to about 100 pli; and iii) embossing the exposed surface of the polyethylene film.

Claim 34

A process for preparing embossed, coated paper, comprising the steps of: A) providing a web of paper; B) providing a polymeric film; C) extrusion coating a layer of resin with a temperature from about 500° F. to about 700° F. onto the web of paper; and D) simultaneously performing the steps of: i) contacting the polymeric film to the layer of resin, thereby forming a composite comprising the web of paper, polymeric film, and resin layer therebetween; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll; and iii) embossing the exposed surface of the polymeric film.

Claim 35

A process for preparing embossed, coated paper, comprising the steps of: A) providing a web of paper; B) providing a polymeric film; C) extrusion coating a layer of resin with a temperature from about 500° F. to about 700° F. onto the web of paper; and D) simultaneously performing the steps of: i) contacting the polymeric film to the layer of resin, thereby forming a composite comprising the web of paper, polymeric film, and resin layer therebetween; ii) laminating the composite, by passing the composite between a nip roll and an engraved chill roll; and iii) embossing the exposed surface of the polymeric film.

Claim 36

The process for preparing embossed, coated paper, according to claim 31, wherein the temperature is from about 580° F. to about 625° F.