HK1091178A - Various banding apparatus and methods for using such - Google Patents

Description

Strapping devices and methods of using the same

Cross Reference to Related Applications

The present application claims priority from U.S. provisional patent application No.60/438,911 entitled "Various strapping devices and Methods for Using same" (filed on 8/1/2003), the disclosure of which is incorporated herein by reference in its entirety.

Technical Field

The present invention provides apparatus and methods related to the manufacture and recycling of paper products. More particularly, the present invention provides paper-based strapping articles and methods of use thereof. The paper industry processes pulp into paper products. The process may include transferring the pulp to a paper manufacturer. The pulp is placed in a process tank and reduced in preparation for the manufacture of paper products. In some cases, this includes removing the packaging material that binds the pulp prior to placing the pulp in the vat. This is time consuming and wasteful.

Background

Some progress has been made in developing and using a binding material that can be placed into the tank with the pulp. One example is that twisted paper-based tapes have been used to bind the pulp. Binding includes placing the tape around the pulp and adhering the two ends of the tape to each other.

In addition, currently available paper straps exhibit significant liquid resistance that limits the rate at which the paper strap breaks down in the pulping process. The manufactured paper product may comprise a paper-based container or carton. Such cartons are used to contain the articles for shipment and may be recycled after shipment. The material typically used to secure such cartons must have significant strength. For this reason, plastics and metal bands are often used. The use of such a strap is problematic because the strap must be discarded and the carton itself recycled. The process of separating the non-recyclable materials from the recyclable materials is time consuming.

Therefore, there is a need in the art to address the various problems described above. As will be appreciated from the following disclosure, the apparatus and method according to the present invention address these and many other problems associated with manufacturing, using, and/or recycling paper products.

Disclosure of Invention

The present invention provides apparatus and methods related to the manufacture and recycling of paper products. More particularly, the present invention provides paper strapping articles and methods of use thereof.

Some embodiments of the present invention provide paper straps that include a paper body formed from a composite structure and an adhesive material formed on at least a portion of the paper body. This method does not require the application of adhesive while the paper strap is in use. This can reduce the time required to bundle cartons or pulp bales. Furthermore, this may eliminate expensive and inefficient clean-up that occurs with the use of external adhesives. In some examples, the composite structure is a folded structure, while in other examples the composite structure is a linear (strunged) and folded structure, a corrugated structure, or a corrugated and folded structure. As used herein, a folded structure includes a laminated structure in which layers of the structure may be formed from continuous paper material or non-continuous paper material (e.g., separate strips of paper that are stacked one on top of the other). In various examples, the paper body consists essentially of raw fibers. As such, paper straps can be used in the paper industry to make the finished product useful for human internal use, such as feminine sanitary napkins.

In some examples of embodiments, the paper body is pulpable and/or exhibits minimal liquid resistance. In this way, the paper body can be reduced relatively quickly during the papermaking process. In some cases, the adhesive material is also similarly pulpable (pulpalable) and/or decomposes relatively quickly when placed in a liquid bath. For example, in one particular case, the adhesive material may include starch and another adhesive. The adhesive material may be activated by one or more activators. Such activators may include, but are not limited to, heat activation, pressure activation, liquid activation, or any combination thereof. As an example, pressure activation may cause both ends of a paper strap or the paper strap to be attached to another surface, such as a surface of a carton. Similarly, liquid activation may include applying a small amount of liquid (e.g., water) so that the tape adheres thereto. The heat activation may include applying a heat source (e.g., an iron) such that the adhesive is activated to adhere the paper strap thereto.

In other embodiments of the present invention, methods of using paper straps are provided. This method includes providing a paper based carton and a paper strap. The paper strap is formed from a composite structure with an adhesive material formed on at least a portion of the paper body. The paper-based carton is taped using the paper tape. This bundling includes contacting a first end of the paper base strip with a second end of the paper base strip and applying an activator of adhesive.

Other embodiments of the present invention provide methods for recycling paper based cartons. The method includes receiving at least one paper-based cartridge and at least one paper strap. The paper strap includes a paper body formed from a composite structure, and an adhesive material formed on at least a portion of the paper body. The method further comprises placing the paper based carton and the paper strap into a common recovery vat (batch). Another example is that the paper-based waste after consumption can be bundled into a bundle using a paper base tape. Such paper-based tapes may be paper tapes according to embodiments of the present invention. When the bundle is then introduced into the recycling process, the paper base tape can remain, unlike metal and plastic bags currently in use.

Other embodiments provide methods of manufacturing paper products including providing a plurality of pulp bales and binding the plurality of pulp bales using a paper strap. The paper strap includes a paper body formed from a composite structure with an adhesive material formed on at least a portion of the paper body. Other embodiments provide other methods of making paper products. The method includes receiving a bundle of pulp bales that are bundled by a paper strap. The paper strap includes a paper body, wherein the paper body is formed from a composite structure, and an adhesive material formed on at least a portion of the paper body. The bundle of pulp bales including the paper strap is placed into a pulper where the paper strap and the pulp bales form part of the manufactured paper product.

This summary merely provides a general outline of an embodiment in accordance with the invention. Many other objects, features and advantages of the present invention will become more fully apparent from the following detailed description, the appended claims and the accompanying drawings.

Drawings

A further understanding of the nature and advantages of the inventions herein may be realized by reference to the figures which are described in remaining portions of the specification. In the drawings, like numbering refers to like elements. In some instances, a sub-label consisting of a lower case letter is associated with a reference numeral to denote one of multiple similar components. When reference is made to a reference numeral without specification to an existing sub-label, it is intended to refer to all such multiple similar components.

FIG. 1 illustrates a paper strap useful with embodiments of the present invention;

FIG. 2 illustrates an alternative paper strap useful with embodiments of the present invention;

FIG. 3 illustrates another paper strap in accordance with embodiments of the present invention;

FIG. 4 illustrates the paper strap of FIGS. 1-3 after an adhesive material has been applied in accordance with an embodiment of the present invention;

FIG. 5 illustrates a method of using the paper strap of FIGS. 1-4 in accordance with an embodiment of the present invention;

FIG. 6 illustrates a method of using the paper strap of FIGS. 1-4 in accordance with an embodiment of the present invention;

FIG. 7 illustrates another method of using the paper strap of FIGS. 1-4 in accordance with other embodiments of the present invention;

FIG. 8 illustrates various composite structures according to embodiments of the invention;

FIG. 9 illustrates an imprint pattern formed on a surface of a ribbon according to an embodiment of the present invention;

FIG. 10 illustrates needling the tape body in accordance with an embodiment of the present invention; and

fig. 11 shows a combination of the needling of fig. 10 and the embossing of fig. 9.

Detailed Description

The present invention provides an improved paper strap that can be used in, but is not limited to, strapping equipment in the packaging industry. In some examples, paper straps can be used to bundle pulp bales (pulp rolls) used in the paper industry and to bundle cartons used in shipping. In some cases, the paper strap is composed of a biodegradable material. In certain cases, the belt is made of a material that decomposes relatively quickly when placed in a pulping process, while in other cases the belt is made of a material that is recyclable and reduces the energy and/or time required in the recycling process.

The belt according to the invention differs significantly from the belts of the prior art (e.g. plastic and metal belts). Such prior art belts take 80 to 450 years to decompose in the environment. In contrast, the paper straps of the present invention can disintegrate in a matter of weeks only. For example, one particular belt according to the present invention disintegrates after about eight weeks.

In addition, many prior art straps are tied using metal ties at the point of contact of the strap. This method requires the removal of metal prior to recycling or introduction into the pulper (i.e., the tank or process used to convert the pulp into paper products). In contrast, various embodiments of the present invention include an adhesive material formed on and attached to the paper strap. Thus, no additional adhesive is required to adhere to the tape. When the two ends of the paper strap are placed in contact and the activator is applied, the paper strap forms a complete loop. In some cases, the activator is a high temperature source, a water vapor source, a pressure source, and/or combinations thereof. In some cases, the binder is compatible with pulping and/or recycling processes. Thus, cartons or pulp bales bound by a paper strap can be recycled or introduced into the pulper along with the entire paper strap.

Referring to FIG. 1d, a prior art stringed paper strap 150 useful with various embodiments of the present invention is disclosed. Stringed paper strap 150 is formed from a plurality of paper strips 100 twisted into paper threads 120 and then adhered to one another. Fig. 1a shows a paper thread 120, which paper thread 120 is twisted as shown in fig. 1 b. This twisting process continues until the slip 100 forms a paper thread 120 as shown in fig. 1 b. In one particular example, the paper threads 120 are formed with a diameter 125 of about 1 to 2 millimeters thick. The plurality of paper threads 120 are bonded using an adhesive to form stringed paper strap 150 as shown in FIG. 1 d. This is stringed paper strap 150 known in the art.

According to some embodiments of the invention, the paper strip 100 may be formed from pulp. Thus, for example, when stringed paper strap 150 is used to bundle pulp bales, it is advantageous to use paper strap 100 made of the same pulp as the pulp to be bundled. This eases the pulping process in which stringed paper strap 150 and the pulp bales bound therewith are both introduced into a common pulping vat. In some embodiments of the present invention, stringed paper strap 150 is also folded and an adhesive is applied to hold the folded portions together. FIG. 1e illustrates one example of a stringed and folded paper strap 170 in accordance with various embodiments of the invention. This linear and folded structure is a composite structure as used herein. Further, as used herein, the term "folded" refers to one portion of the belt being folded over another portion of the belt, or two different belt portions being layered upon each other. Both folding methods provide substantially the same laminating effect.

Stringed paper strap 150 and paper strap 170 can each be made from biodegradable and/or repulpable materials. Thus, for example, paper strip 100, the adhesive used to bond paper threads 120 to form stringed paper strap 150, and the adhesive used to bond the various layers of stringed and folded paper strap 170 can be biodegradable and/or repulpable. In some cases, the adhesive used is water soluble. Further, according to embodiments of the present invention, needling or additional openings can be used to increase the exposed surface area of stringed paper strap 150. When the tape is placed in a liquid, the increase in exposed surface area causes the liquid to break down the tape more quickly.

Referring to FIG. 2, an alternative prior art folded paper strap 220 useful with embodiments of the present invention is shown. Paper strap 220 is formed from one or more paper strips 200 that are stacked or folded upon one another. In some cases, each layer has a substantially equal width, while in other cases, the layers have different widths. For example, the outermost layer may be wider than any of the inner layers such that the outer layer folds around and encompasses the inner layers. The paper strip 200 may be made of pulp. Thus, for example, when bundling pulp bales with folded paper strap 220, it may be advantageous to use paper strips 200 made of the same pulp as the pulp to be bundled. This eases the pulping process in which both paper strap 220 and the pulp bales bound with it are introduced into a common pulping vat.

As shown in fig. 2b, paper strip 200 is folded in two to create portions 225, 230, and 235. The stack of portions 225, 230 and 235 forms a composite structure of the paper body of folded strip 220. Portions 225 and 230 are joined by fold region 240 and portions 230 and 235 are joined by fold region 245. In some examples, an adhesive may be placed between the folded portions 225, 230, and 235 to join adjacent portions. For example, in one particular example, the binding material is comprised of starch. In other cases, multiple adhesive materials are used and one of them is starch. Based on the disclosure provided herein, one of ordinary skill in the art will recognize a variety of adhesive materials that may be used in conjunction with the present invention. Further, in some embodiments, folded paper straps are formed from different portions 225, 230, 235 that are not joined by fold areas 240, 245. Based on the disclosure provided herein, one of ordinary skill in the art will appreciate that any number of portions 225, 230, 235 may be used where additional or reduced strength of paper strap 220 is desired. This process can be used to form folded paper straps having a thickness of one hundredth of a millimeter to three millimeters or more. In fact, it is envisioned that the tape may have any desired thickness.

In certain embodiments of the present invention, folded paper strap 220 can be made from a biodegradable and/or repulpable material. Thus, for example, paper strip 200, the adhesive used to join portions 225, 230, 235 may be biodegradable and/or repulpable. Again, the adhesive used in some cases is water soluble.

In a particular embodiment of the present invention, folded paper strap 220 is formed in part by folding the sides of paper strip 200 and adding additional layers. Thus, for example, two or more folded paper straps 220 as shown may be stacked on top of one another with an adhesive applied therebetween to form a composite structure of paper bodies.

For some applications, folded paper strap 220 may be advantageous over stringed paper strap 150, as previously described. As one example, folded paper strap 220 provides greater repulpability. As another approach, stringed paper strap 150 will be less prone to disintegration. This is at least in part because a large area of stringed paper strap 150 cannot be immediately exposed to liquids in the papermaking process. Generally, paper threads 120 of stringed paper strap 150 must be separated from one another and then unwound to fully disintegrate and enter the manufacturing process. In addition, the difficulty of breaking up stringed paper strap 150 is related to the pulper temperature, dwell time, pulper type and rotor type. The portion of the linear pulp 150 that is not sufficiently repulped or disintegrated may clog screens or enter the paper forming process and cause the finished paper to be out of specification due to small fiber bundles in the finished product. Stringed paper strap 150 can limit repulpability when the pulper is operated at a lower temperature, provides a shorter residence time, provides reduced mechanical energy, or has a worn rotor. However, while folded paper strap 220 provides some advantages over stringed paper strap 150, stringed paper strap 150 is still a viable strap for use in some pulping processes.

Referring to FIG. 3, an alternative folded paper strap 320 is shown in accordance with various embodiments of the present invention. Paper strap 320 is formed from one or more paper strips 300 that are stacked or folded upon one another. Again, in some cases, each layer has a substantially equal width, while in other cases, the layers have different widths. For example, the outermost layer may be wider than any of the inner layers such that the outer layer folds around and encompasses the inner layers. As shown in fig. 3b, paper strip 300 is folded in two to create portions 325, 330, and 335. The paper strip 300 may be made of paper or pulp. Again, for example, when bundling pulp bales with folded paper strap 220, it is advantageous to use paper strips 300 made of the same pulp as the pulp to be bundled. This eases the pulping process in which both paper strap 320 and the pulp bales bound with it are introduced into a common pulping vat. In various embodiments, folded paper strap 320 is made from one hundred percent raw fiber. This method allows paper products that include the reduced portion of folded paper strap 320 to be approved by food and drug administration in different countries for use in human products, such as feminine hygiene products.

Further, one or more of the portions 325, 330, 335 are corrugated, as illustrated by corrugation 331. The stack of portions 325, 330, 335 including the corrugated portions forms a composite structure of the paper body of folded strip 320. Such corrugations add additional mass and strength to folded paper strap 320. Portions 325 and 330 are joined by fold region 340 and portions 330 and 335 are joined by fold region 345. In some examples, an adhesive may be placed between the folded portions 325, 330, 335 to join the relevant portions. Moreover, in some embodiments, folded paper strap 320 is formed from different portions 325, 330, 335 that are not joined by fold areas 340, 345. Based on the disclosure provided herein, one of ordinary skill in the art will recognize that any number of portions 325, 330, 335 may be employed where additional or reduced strength of paper strap 320 is desired. This process can be used to form folded paper straps having a thickness of one hundredth of a millimeter to three millimeters or more. Again, it is envisioned that the tape may have any desired thickness.

Folded paper strap 320 can be made from a biodegradable and/or repulpable material. Thus, for example, paper strip 300, the adhesive used to join portions 325, 330, 335, may be biodegradable and/or repulpable. Again, the adhesive used in some examples is water soluble.

In a particular embodiment, folded paper strap 320 is formed in part by folding portions 325, 335 and corrugating central portion 330, with the addition of additional layers. Thus, for example, two or more folded paper straps 320 as shown may be stacked on top of each other with adhesive therebetween to form a composite structure of paper bodies.

Similar to the discussion provided with respect to folded paper strap 220, folded paper strap 320 can be more advantageous than stringed paper strap 150, previously described. For similar reasons, folded paper strap 320 can be more easily broken down during the papermaking process and thus is more advantageous for such a process. An additional advantage is that the corrugations in some cases expose increased surface area to the liquids used in the pulping and recovery process.

Although not depicted, the outer surfaces of stringed paper strap 150, 170, 220, 320 can also be corrugated or ribbed. Such corrugations add stiffness to assist in loading and/or transporting the paper strap into the tracks of the roll cutter and/or the strap binder, as further described in U.S. Pat. No.6,363,689. The valleys of the outer surface corrugations will contain more adhesive than a flat outer surface. This will produce a welding effect and increase the strength of the joint.

Again, although not shown, various other enhancements may be made to the paper strap in accordance with embodiments of the present invention. For example, a dimpled or knurled design may be employed. This can be used with any of the previously described paper straps 150, 170, 220, 320. In this design, the embossed pattern is applied to the exposed surface of the paper strap, similar to the cover of a golf ball. The frequency pattern and size of the dimples will provide the ability to control the amount of adhesive applied to the outer surface of the paper strap. The ability to vary the dimple size and frequency will provide flexibility in the type of adhesive. The application of the adhesive can be metered to optimize the bond strength. Excess or insufficient adhesive may be detrimental to the strength of the tape attachment or may in some cases cause the sealing mechanism to become inoperative or ineffective.

As another example, a needle tip design may be used. Again, this can be used with any of the previously described paper straps 150, 170, 220, 320. This design places small needle point type holes in the tape without significantly compromising the tensile strength of the paper tape. The advantage of this design is that it allows another way for the liquid to penetrate into the interior of the belt and thus accelerate the process of decomposition when the liquid (e.g., water) is introduced. The frequency, pattern and size of the holes may be determined according to the type of paper, the desired tensile strength, the desired rate of disintegration, the number of paper layers and the type of adhesive.

Referring now to FIG. 4, in some embodiments of the present invention, paper strap 410 is covered by an adhesive material 420. The adhesive is dried after application. The drying process may include, but is not limited to, air flow, modulation, infrared, gas, oven, and/or ultraviolet. The type of drying can be determined by the line speed and the winding conditions. Combinations of more than one drying type may be employed in some cases. The dried paper web may then be slit and/or folded to a desired width and wound onto a reel ready for packaging. The size of the reel will vary depending on the application.

Paper strap 410 can be, for example, stringed and folded paper strap 170, folded paper strap 220, folded paper strap 320, and the like. Adhesive material 420 is added to make paper strap 410 easier to use in various processes. Adhesive material 420 can be applied to top surface 440 of paper strap 410, bottom surface 450 of paper strap 410, side surfaces 460 of paper strap 410, or a combination thereof. Such adhesives are known to those of ordinary skill in the art. In some cases, when recyclability or repulpability is considered, a binder may be selected that can decompose in a particular process. Again, one of ordinary skill in the art will know the various adhesive properties that make a particular adhesive responsive to a particular process. Adhesive 420 may be applied by soaking paper strap 410 in a bath of such adhesive or applying adhesive 420 to paper strap 410 using an applicator.

In some cases, adhesive 420 is a water soluble material and can be activated or reactivated by the application of heat, moisture, pressure, or a combination thereof at the strapping location. This method of activation of the pre-applied adhesive is clean as compared to hot melt or similar liquid or spray adhesives and requires minimal cleaning and/or maintenance. This post-application adhesive process can cause the heads of the strapping station to clog and drip or spray onto other mechanisms, requiring the mechanisms to be shut down for maintenance and/or cleaning.

Furthermore, the time required to adhere portions of the paper strap pre-coated with adhesive may be reduced compared to post-application of adhesive. Many automated strapping processes require the strap to be applied every ten seconds on average. Some tape constructions may require less than four seconds of intermediate time for the two tape applications. In many cases, this may not have enough time to add adhesive, squeeze the overlapping strap and wait for it to cure before the strapped object moves.

One use of a paper strap in accordance with the present invention for papermaking is depicted in FIG. 5 a. FIG. 5a shows a set of pulp bales 500 comprising a plurality of pulp bales 540 that are individually banded with paper strap 521. Paper strap 521 can be a paper strap as previously described. Then, the pulp bales 540 are joined in a group by a belt 511. In one particular case, belt 511 is a plastic or metal belt that must be removed prior to introducing stack 500 into the pulping process. Alternatively, where the belts 511 are paper-based belts, they may either be removed prior to introducing the stack 500 into the pulping process, or left in place and processed into a paper product. By using paper strap 521 that can be reduced during the pulping process, group 500 can be introduced into the pulping vat with no or only minimal preparation.

Referring to fig. 5b, the process of bundling the pulp bales 540 is described. The pulp bale 540 is covered by an outer pulp skin 560. Paper strap 521 is then wrapped around pulp bale 540. An upper surface 523 of one end of paper strap 521 is brought into contact with a lower surface 522 of paper strap 521 as indicated by arrows 523,524. An activator 570 is then applied at the point of contact between the two ends of paper strap 521. The activator may be, for example, a thermal activator 570c, a pressure activator 570a, and/or a moisture activator 570 b. When activator 570 is applied, the adhesive material pre-applied to paper strap 521 is activated or re-activated and the two ends of paper strap 521 are joined to each other. Based on the disclosure provided herein, one of ordinary skill in the art will appreciate that the process illustrated in FIG. 5b may also be applied to many other scenarios. For example, one of ordinary skill in the art will recognize that the process may be applied to sealed cartons, which may include, but are not limited to, cardboard boxes.

Referring now to FIG. 6, a flow diagram 600 illustrates a method of forming a group 500 in accordance with various embodiments of the invention. Following flow diagram 600, pulp is formed into a bundle, for example, included in pulp bale 540 (block 610). In some cases, the pulp bale is formed from hundreds or even thousands of pulp sheets. The pulp bundle is wrapped with a sheet of pulp, such as the outer pulp skin 560 described above (block 620). The pulp bundle or pulp bale is then bundled, as discussed with respect to fig. 5b (block 630). A determination is then made as to whether the number of bundles within the set 500 is complete (block 640). When the number is not complete, the process of blocks 610 through 630 is repeated until the number is complete. Alternatively, when the number is complete (block 640), the pulp bundles 540 are assembled to form the group 500 (block 650). The assembled pulp bundle is then bundled together, similar to that discussed above with respect to fig. 5 b.

Referring to FIG. 7, a flow chart 700 illustrates a method of recycling paper based cartons banded with paper straps in accordance with the present invention. Following flow diagram 700, a paper-based carton banded with a paper strap is received (block 710). The tape is removed and the carton is opened and emptied (block 720). At this point, the tape and carton are discarded together into the same recycling bin (block 730).

Based on the disclosure provided herein, one of ordinary skill in the art will appreciate various advantages associated with using paper straps in accordance with the present invention. For example, paper straps are much safer than metal, high tensile wire or plastic straps that often slip when cut. Uncontrolled movement of the severed tape often causes human soft tissue damage in the vicinity of the severed tape. Indeed, in some manual removal operations, special safety equipment is required. Which is not required where paper straps are used. Furthermore, paper fiber based tapes also provide retained tension as a safety consideration. It is less stretchable like plastic due to its minimal elasticity. Thus, for example, the amount of displacement occurring during shipment of the stacked items can be reduced. This reduces the likelihood of the item becoming loose and falling out of extension.

As another example, paper straps in accordance with the present invention can be non-contaminating. The paper strip formed by paper and water-soluble binder does not contaminate the process of recycling paper or the production of white paper. In effect, the paper strap adds volume to the unused or recycled paper produced. Eliminating the need to remove the strapping material prior to processing saves time and money, regardless of whether the removal of the strapping material is automated or manual.

Another example is that paper fiber tapes are easily formed to meet tensile strength and/or repulpability requirements. The weight of the paper and the number of layers will make the belt meet the strength requirements as the case may be. The hydrolytic nature of the water-soluble adhesive will allow the tape to meet repulpability requirements as the case may be. Folded tapes comprising laminated tapes accelerate the speed of tape disintegration (repulpability) without the edges of the layers being joined to one another in the folded tape. When a liquid (e.g., water) used in the manufacture of paper products is introduced into the belt, it follows the path of least resistance. In which case the liquid will readily penetrate into the soluble adhesive and carry it out of the paper body. This causes the remaining paper to be completely engulfed by the liquid, thereby enhancing disintegration. The laminated tape will have a thin layer of water soluble adhesive in the middle of the paper, which is exposed at all edges and readily disintegrates when immersed in a liquid. The more edges that are exposed, the faster the liquid can penetrate into the interior of the paper strap.

Further examples include the use of adhesives to facilitate the formation of adhesive on the outer surface of the paper strap. Applying and drying the adhesive-bearing outer surface during tape manufacture will cause the adhesive to be reactivated by introducing moisture and/or heat to join the overlapped areas for sealing. This is a cleaner and more efficient method than applying adhesive when strapping.

Several different belt types can be assembled using the same basic manufacturing process. The end use of the belt may determine the final assembly requirements. Some belts may require greater tensile strength and less repulpability, while other belts may require greater repulpability and less tensile strength. Ribbed paper straps may also be used to add stiffness to meet the objectives as desired. A flat paper and/or a dimple pattern may also be used. In any case, the two basic elements will be paper fibers of various weights and water-soluble binders of various degrees of hydrolysis.

Further, based on the disclosure provided herein, one of ordinary skill in the art will appreciate the wide variety of uses to which paper straps in accordance with the present invention may be applied. For example, paper straps according to the present invention may be used in any industry that currently utilizes metal, plastic, or paper straps for packaging. Additional applicability is provided to any industry where the end user does not need to remove the tape (e.g., pulp or recycled paper packaging). Other possible industries include, but are not limited to, corrugated boxes for grocery or other retail stores, cotton wrapping, tobacco wrapping, tree root tying, and the like.

Referring to FIG. 8, various alternative composite structures according to various embodiments of the present invention are shown. As shown in fig. 8a and 8b, the composite structure may have two or three flat folds or layers. Further, based on this disclosure, one of ordinary skill in the art will appreciate that there may be four or more folds or layers in such a composite structure. Figure 8c shows a composite structure with a continuous undulating or corrugated layer. Similarly, fig. 8d and 8e show composite structures with two or three successive undulating or corrugated layers. Again, based on this disclosure, one of ordinary skill in the art will appreciate that there may be four or more folds or layers in such a composite structure. As alluded to previously, the outer surface with the corrugated composite structure, the additional adhesive material, may adhere the tape to another body, such as the other end of the tape. It will be appreciated that the desired strength of the joint is used to determine the required combination of adhesive and corrugation.

Fig. 8f-8h illustrate composite structures with one or more continuously undulating or corrugated layers combined with one or more flat layers. More specifically, fig. 8f shows a composite structure with one continuous corrugated layer and one flat layer. Based on this disclosure, one of ordinary skill in the art will appreciate that the various layers may be interchanged. Fig. 8g shows a composite structure with one flat layer between two corrugated layers, while fig. 8h shows a composite structure with two flat layers between two corrugated layers. Again, one of ordinary skill in the art will appreciate that there may be three or more lay-flat folds or layers in such a composite structure.

Figures 8i-8k illustrate composite structures stacked using continuous folds (as compared to, for example, the non-continuous folds illustrated in figure 8 b). More specifically, fig. 8i shows a composite structure with folded flat layers. Fig. 8j and 8k show a composite structure with a folded continuous corrugated layer. As before, one of ordinary skill in the art will appreciate that there may be three or more folds and four or more layers in such a composite structure.

Referring to FIG. 9, various methods of dimpling, knurling, and/or embossing are shown according to various embodiments of the present invention. FIG. 9a illustrates a composite structure, such as the composite structure shown in FIG. 8, having surface indentations in a paper strap. Similarly, FIG. 9b illustrates a composite structure having a non-continuous pattern of impressions in a paper strap. These dimples and embossed patterns facilitate the adhesion of the paper strap because they accommodate the additional amount of adhesive, which creates a stronger bond in the paper strap.

Referring to fig. 10, a needling method in accordance with various embodiments of the present invention is illustrated. As shown in FIG. 10, holes or tips are formed through or partially through a composite structure (e.g., the composite structure shown in FIG. 8 and stringed paper strap 150 in other figures). In particular embodiments of the invention, the tips may be between 0.1 mm and 1 mm in diameter, depending on the desired speed of disintegration and the desired tensile strength of the tape. The holes in the paper strap increase the surface area of the paper strap that can be exposed to liquids, thereby providing a faster disintegration capability of the paper strap. The needle-tip composite structure may be produced in two alternative forms. In the first form, adhesive is added to the paper strap and allowed to dry. Holes are then formed. This allows the liquid to contact the surface of the paper strap before the adhesive decomposes. In the second form, holes are first punched in the paper strap and then the adhesive is added. The adhesive may then be filled into the holes, thereby increasing the tensile strength of the paper strap. In some cases, a binder is used that disintegrates faster than the paper from which the tape is formed. During processing, the adhesive decomposes so that the processing liquid contacts the surface of the paper at the needle point.

Referring to fig. 11, a hybrid structure including dimples (knurling or embossing) and needle tips is shown. This approach is applicable to composite structures such as that shown in fig. 8. As shown in fig. 11a, the dimple as shown in fig. 9a may be combined with the needlepoint composite structure as shown in fig. 10 to form a hybrid of the two composite structures. The hybrid structure combines the additional adhesive strength of the dimpled composite structure with the improved resolution of the needlepoint composite structure. Also, as shown in FIG. 11b, the non-continuous imprint pattern as shown in FIG. 9b may be combined with a needle-tip composite structure as shown in FIG. 10 to form a hybrid. The mixing also combines the additional adhesive strength of the non-continuous embossed pattern composite structure with the improved resolution of the needlepoint composite structure.

The invention has been described in detail for purposes of clarity and understanding. It will be appreciated, however, that certain changes and modifications may be practiced within the scope of the appended claims. It should therefore be appreciated that many other systems, functions, methods, and combinations thereof are possible in accordance with the present invention. Therefore, while the present invention has been described with reference to particular embodiments and drawings, the embodiments and drawings are illustrative of the invention only and not limiting. Rather, the scope of the invention is to be determined solely by the appended claims.

Claims (36)

1. A paper strap, the paper strap comprising:

a paper body, wherein the paper body is formed from a composite structure; and

an adhesive material formed on at least a portion of the paper body.

2. The paper strap of claim 1, wherein the composite structure is a folded structure.

3. The paper strap of claim 1, wherein the composite structure is a stringed and folded structure.

4. The paper strap of claim 1, wherein the composite structure is selected from the group consisting of a corrugated structure, a corrugated and a folded structure.

5. The paper strap of claim 1, wherein the paper body consists essentially of raw fibers.

6. The paper strap of claim 1, wherein the paper body is pulpable.

7. The paper strap of claim 1, wherein the paper body exhibits a liquid resistance that is less than a liquid resistance of the stringed paper strap.

8. The paper strap of claim 1, wherein the adhesive material is activated by an activator selected from the group consisting of heat activation, pressure activation, and liquid activation.

9. The paper strap of claim 1, wherein the adhesive material is pulpable.

10. The paper strap of claim 1, wherein a surface of the paper body is pitted.

11. The paper strap of claim 1, wherein the paper body is at least partially perforated.

12. The paper strap of claim 11, wherein a needlepoint pattern is used in the perforations.

13. The paper strap of claim 1, wherein a surface of the paper body is embossed.

14. The paper strap of claim 1, wherein the surface of the paper body is corrugated.

15. A method of using a paper strap, the method comprising:

providing a paper base cassette;

providing a paper strap, wherein the paper strap comprises:

a paper body, wherein the paper body is formed from a composite structure; and

an adhesive material formed on at least a portion of the paper body;

and

bundling the paper based carton with the paper strap, wherein bundling the paper based carton includes contacting a first end of the paper based strap with a second end of the paper based strap and applying an activator of an adhesive.

16. The method of claim 15, wherein applying an adhesive activator comprises applying heat to the paper tape.

17. The method of claim 15, wherein applying an adhesive activator comprises applying a liquid to the paper strap.

18. The method of claim 15, wherein applying an adhesive activator comprises applying pressure to the paper strap.

19. The method of claim 15, wherein the paper body exhibits minimal liquid resistance.

20. A method of recycling paper based cartons, comprising:

receiving at least one paper-based carton and at least one paper strap, wherein

The paper strap includes:

a paper body, wherein the paper body is formed from a composite structure; and

an adhesive material formed on at least a portion of the paper body;

and

placing the paper-based carton and the paper tape into a common recovery tank.

21. The method of claim 20, wherein the paper body exhibits minimal liquid resistance.

22. The method of claim 20, wherein the adhesive material is compatible with paper recycling processes.

23. The method of claim 20, wherein the composite structure is selected from the group consisting of a folded structure, a linear and folded structure, and a corrugated and folded structure.

24. A method of making a paper product, the method comprising:

providing a plurality of pulp bales;

binding the plurality of pulp bales using a paper strap, wherein the paper strap comprises:

a paper body, wherein the paper body is formed from a composite structure; and

an adhesive material formed on at least a portion of the paper body.

25. The method of claim 24, wherein the composite structure is selected from the group consisting of a folded structure, a linear and folded structure, and a corrugated and folded structure.

26. The method of claim 24 wherein said paper body consists essentially of virgin fiber.

27. The method of claim 24, wherein the paper body is pulpable.

28. A method of making a paper product, the method comprising:

receiving a bundle of pulp bales, wherein the bundle of pulp bales is banded by a paper strap, wherein the paper strap comprises:

a paper body, wherein the paper body is formed from a composite structure; and

an adhesive material formed on at least a portion of the paper body;

and

placing a bundle of pulp bales including the paper strap into a pulper, wherein the paper strap and the pulp bales form a portion of a manufactured paper product.

29. The method of claim 28, wherein the composite structure is selected from the group consisting of a folded structure, a linear and folded structure, and a corrugated and folded structure.

30. The method of claim 28 wherein said paper body consists essentially of virgin fiber.

31. The method of claim 28, wherein the paper body is pulpable.

32. A paper strap, the paper strap comprising:

a linear paper body, wherein the linear paper body includes a needled region that increases exposed surface area.

33. The paper strap of claim 32, wherein the paper strap further comprises:

an adhesive material formed on at least a part of the exposed surface of the linear paper body.

34. The paper strap of claim 32, wherein the paper strap further comprises:

an adhesive material formed on at least a portion of the exposed surface of the linered paper body, wherein the adhesive material is formed after the formation of the needled regions such that at least some of the needled regions are at least partially covered by the adhesive material.

35. The paper strap of claim 34, wherein the adhesive material exhibits a lower liquid resistance than the stringed paper body.

36. The paper strap of claim 32, wherein the paper strap further comprises:

an adhesive material formed on at least a portion of the exposed surface of the linear paper body, wherein the adhesive material is formed prior to the formation of the needle punched area.