Classifications

• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H11/00—Pulp or paper, comprising cellulose or lignocellulose fibres of natural origin only
  • D21H11/02—Chemical or chemomechanical or chemothermomechanical pulp
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H23/00—Processes or apparatus for adding material to the pulp or to the paper
  • D21H23/02—Processes or apparatus for adding material to the pulp or to the paper characterised by the manner in which substances are added
  • D21H23/04—Addition to the pulp; After-treatment of added substances in the pulp
  • D21H23/06—Controlling the addition
  • D21H23/08—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH
  • D21H23/10—Controlling the addition by measuring pulp properties, e.g. zeta potential, pH at least two kinds of compounds being added
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/10—Packing paper
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/30—Multi-ply
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
  • D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
  • D21H27/30—Multi-ply
  • D21H27/38—Multi-ply at least one of the sheets having a fibrous composition differing from that of other sheets
• • D—TEXTILES; PAPER
  • D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
  • D21J—FIBREBOARD; MANUFACTURE OF ARTICLES FROM CELLULOSIC FIBROUS SUSPENSIONS OR FROM PAPIER-MACHE
  • D21J3/00—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds
  • D21J3/10—Manufacture of articles by pressing wet fibre pulp, or papier-mâché, between moulds of hollow bodies

Definitions

• Molded pulp article comprising two or more regions in a single layer, wherein the two or more regions differ based on fiber type.
• cellulosic articles are generally formed from either a dry process where sheets of pulp (i.e. paper) and/or loose pulp are combined and compressed into the shape of the desired article, or a wet process where cellulosic fibers (i.e. pulp) is suspended (usually in water) as a slurry which is then formed onto a porous mold and subsequently dried to provide the article of the desired shape.
• the slurry may further include additives to modify the properties of the cellulosic material.
• molded pulp articles are generally formed from a single pulp slurry.
• a pulp article may be formed that has different properties in different regions of the article, but these properties are attained by manipulation of forming steps in addition to the original molding step. For example, additional layers of pulp may be applied in certain areas following the original formation step to increase the thickness of certain regions. The addition of multiple pulp layers increases the cost of production due to increased complexity and time for manufacturing.
• differing levels of thickness of the pulp on the forming mold can be achieved by varying the degree of pressure/vacuum that is applied when forming the slurry onto the porous mold (US20190240926). These techniques are limited to only modifying the properties of the pulp article based on the wall thickness of the molded article.
• a further method to alter the characteristics of a molded pulp article involves the use of coatings including the use of multiple coatings.
• Coatings are different from slurry additives in that coatings are generally applied after the cellulosic article is formed. Coatings can be applied using any manner of conventional techniques, from dipping to spraying; but the use of coatings faces the same disadvantages as using multiple layers, in that it results in additional post molding processing steps, increased time and cost.
• the desire to form articles from cellulosic materials further includes the desire to form articles that vary in their properties across regions of the article. For example, a bottle formed from plastic can be formed to have rigidity relative to top-loading while further including a flexible panel that a user can squeeze in order to dispense product from the bottle.
• a multi-region pulp article comprises a first region comprising a first pulp-fiber type; a second region comprising a second pulp-fiber type; wherein the first region and the second region are disposed in a single pulp layer; wherein the first fiber-type differs from the first second fiber-type.
• FIG. 1 illustrates a bottle with a neck region according to the present invention.
• FIG. 2 illustrates a bottle with a base region according to the present invention.
• FIG. 3 illustrates a bottle with both a neck region and a base region according to the present invention.
• FIG. 4 illustrates a bottle with a squeeze panel region according to the present invention.
• FIG. 5 illustrates a bottle formed from joining two portions.
• FIG. 6 illustrates a closure with a living hinge according to the present invention.
• FIG. 7 A illustrates a side view of a closure with a living hinge for a wipes-tub according to the present invention.
• FIG. 7B illustrates a perspective view of a closure with a living hinge for a wipes-tub according to the present invention.
• FIG. 8A illustrates a side view of a tray according to the present invention.
• FIG. 8B illustrates a perspective view of a tray according to the present invention.
• FIG. 9A illustrates a stop view of a tray with a living hinge according to the present invention.
• FIG. 9B illustrates a side view of a tray with a living hinge according to the present invention.
• FIG. 12 shows a pulp molded article forming apparatus.
• FIG. 13 shows a pulp molded article forming apparatus.
• FIG. 14 shows a pulp molded article forming apparatus.
• FIG. 15 shows a pulp molded article forming apparatus.
• FIG. 16 shows a pulp molded article
• FIG. 17 is a graph showing pulp molded article tensile strength.
• FIG. 18 is a graph showing pulp molded article tensile strength.
• FIG. 19 is a graph showing pulp molded article tensile strength.
• FIG. 20 is a graph showing pulp molded article tensile strength.
• FIG. 21 is a graph showing pulp molded article tensile strength.
• FIG. 22 is a graph showing pulp molded article tensile strength.
• FIG. 23 is a graph showing pulp molded article tensile strength.
• FIG. 24 is a graph showing pulp molded article tensile strength.
• FIG. 25 is a graph showing pulp molded article tensile strength.
• FIG. 26 is a graph showing pulp molded article tensile strength.
• FIG. 27 is a graph showing pulp molded article tensile strength.
• the present invention includes a pulp molded article (article) with two or more regions containing different fiber types.
• the different fiber types may include different cellulosic materials formed together to create pulp-based composites (molded composites).
• the different fiber types comprising the different regions on the article provide different properties to the regions. These different properties can be attained without the need to vary the thickness of the material used in forming the different regions. Exemplary properties conferred to the different regions include compressive strength, tensile strength, folding endurance, surface roughness, porosity, surface tension, water vapor transmission rate, density, rigidity, brightness.
• substantially parallel with respect to two coplanar lines of direction, describes lines of direction that are precisely parallel (never intersect), and coplanar lines of direction that intersect and thereby deviate from precisely parallel, by no more than 10 degrees.
• Substantially perpendicular with respect to two coplanar lines of direction, describes lines of direction that are precisely perpendicular (intersect at an angle of 90 degrees), and coplanar lines of direction that deviate from precisely perpendicular by no more than 10 degrees (i.e., intersect at an angle from 80 degrees to 100 degrees).
• substantially cylindrical refers to and includes the outer shape of a cylinder, but also includes shapes such as slightly oblate or slightly flattened cylinders, slightly curved cylinders, and other tubular shapes which have diameters and/or cross-sectional areas that vary slightly along their lengths, wherein minor deviation from a precise cylindrical shape does not compromise product manufacturability, function or utility.
• the “longitudinal axis” is a centerline extending along the length of an article.
• “Lateral” refers to a direction perpendicular to its longitudinal axis. “Width” refers to a dimension measured along a direction perpendicular to the longitudinal axis.
• Cross section refers to a perimeter or area outlined by a feature of an article measured along a direction perpendicular to the longitudinal axis.
• Longitudinal refers to a direction parallel to its longitudinal axis. “Length” refers to a dimension measured along a direction parallel to the longitudinal axis.
• Axial movement of an element means movement along the longitudinal axis of an element.
• An “axial” direction is substantially parallel to the longitudinal direction.
• Coaxial refers to the movement of an ejection plunger within a barrel portion of an applicator assembly, whereby the plunger moves within the barrel portion and substantially along and/or parallel to longitudinal axis of the barrel portion.
• the cellulosic material used in forming a given region of the article may include a random (i.e. not layered) mixture of fiber types.
• cellulose include cellulosic fibers obtained or derived from plants, such as wood fiber, wood pulp, and other natural plant fibers, regenerated cellulose fiber such rayon, viscose or Cuprammonium rayon, and high pulping yield fibers, unless specified differently.
• cellulosic fibers obtained or derived from plants, such as wood fiber, wood pulp, and other natural plant fibers, regenerated cellulose fiber such rayon, viscose or Cuprammonium rayon, and high pulping yield fibers, unless specified differently.
• chemically treated natural plant fibers such as mercerized pulps, chemically stiffened or crosslinked fibers, or sulfonated fibers.
• mercerized natural plant fibers regenerated natural cellulosic fibers, fibers of cellulose produced by microbes, the rayon process, cellulose dissolution and coagulation spinning processes, and other cellulosic material or cellulosic derivatives.
• Other cellulose fibers included are paper broke or recycled fibers and high yield fibers.
• High yield pulp fibers are those fibers produced by pulping processes providing a yield of about 65% or greater, more specifically about 75% or greater, and still more specifically about. 75% to about 95%. Yield is the resulting amount of processed fibers expressed as a percentage of the initial wood mass.
• Such pulping processes include bleached chemithermomechanical pulp (BCTMP), chemithermomechanical pulp (CTMP), pressure/pressure thermomechanical pulp (PTMP), thermomechanical pulp (TMP), themiomechanical chemical pulp (TMCP), high yield sulfite pulps, and high yield Kraft pulps, all of which leave the resulting fibers with high levels of lignin but are still considered to be natural fibers.
• BCTMP bleached chemithermomechanical pulp
• CMP chemithermomechanical pulp
• PTMP pressure/pressure thermomechanical pulp
• TMP thermomechanical pulp
• TMCP thermomechanical pulp
• TMCP thermomechanical chemical pulp
• high yield sulfite pulps high yield sulfite pulps
• Kraft pulps high yield sulfite pulps
• natural plant fibers refers to cellulosic fibers obtained from plants, including wood fibers and wood pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; and hardwood fibers, such as eucalyptus, maple, birch, beech, oak, sweetgum, and aspen; and nonwood cellulosic fibers, such as those of bamboo, cotton, abaca, kenaf, sabai grass, flax, esparto grass, strawjute hemp, bagasse, milkweed floss, and pineapple leaf.
• wood fibers and wood pulp fibers such as those obtained from deciduous and coniferous trees, including softwood fibers, such as northern and southern softwood kraft fibers; and hardwood fibers, such as eucalyptus, maple, birch, beech, oak, sweetgum, and aspen
• nonwood cellulosic fibers such as those of bamboo, cotton, abaca
• Cellulose pulp fibers can be prepared in high-yield or low-yield forms and can be pulped in any known method, including kraft, sulfite, high-yield pulping methods and other known pulping methods.
• Natural plant fibers contemplated by the present disclosure may include recycled fibers, virgin fibers or mixes thereof.
• Fiber type refers to the fibrous material or materials that comprise the cellulosic materials that form the article. Different fiber types may be distinguished from one another on the basis of their source (i.e. wood fibers such as hardwood or softwood, non-wood fibers such as cotton, manufactured fibers such as rayon or Lyocell, or reclaimed/ recycled fibers), on the basis of the means by which the source was processed to yield the fibers (i.e. chemical processing, mechanical processing, chemi -mechanical processing), or on the basis of a physical property of the fibers themselves (i.e. fiber length, fiber width, fiber coarseness, degree of fibrillation (i.e. micro- fibrillated cellulose), fiber Canadian freeness, amount of fines). Fiber types may be distinguished from one another as differing in one of more of these aspects.
• Non-limiting examples of hardwood fibers include fibers derived from hardwood sources such as eucalyptus, maple, birch, beech, oak, sweetgum, and aspen.
• Non-limiting examples of softwood fibers include fibers derived from softwood sources such as pine, spruce, and fir.
• Non-limiting examples of non-wood fibers include fibers derived from non-wood sources such as bamboo, cotton, abaca, kenaf, sabai grass, flax, esparto grass, straw, jute hemp, bagasse, milkweed floss, com stover, miscanthus, pineapple leaf, and linen.
• Non-limiting examples of manufactured fibers include fibers derived from regenerated cellulose, such as viscose rayon, Lyocell, regenerated bamboo.
• Non-limiting examples of reclaimed/ recycled fibers include fibers derived from postindustrial recycled (PIR) waster or post-consumer recycled waste (PCR) and may include Mixed paper, old newspaper/ newsprint (ONP), old corrugated containers (OCC), pulp substitutes (unprinted, uncoated, unadulterated paper and board), high-grade deinked,
• Non-limiting examples of chemically processed fibers include Kraft, sulfite, and soda.
• Nonlimiting examples of mechanically processed fibers include stone-ground wood, refinermechanical pulp (RMP), and thermomechanical pulp (TMP).
• Non-limiting examples of chemi- mechanically processed fibers include Chemiground wood, Cold soda, NSSC (Neutral sulfite semichemical), High yield sulfite, High yield kraft.
• Non-limiting examples of fiber physical properties include fiber length, fiber width, fiber coarseness, drainability, cellulose solution viscosity (cellulose degree of polymerization).
• Additive refers to a non-cellulosic material included with the cellulosic material (i.e. different fiber types) in the slurry. Additive are distinguished from coating in that coatings are applied to one or more surfaces of the article after it is formed, while additives are included in the slurry and therefore generally incorporated within and evenly dispersed throughout the cellulosic material forming a region of the article.
• Additives may impart any of a number of properties to the cellulosic material and therefore to the region of the article. These properties may derive primarily from the incorporation of the additive itself or may further be modified by any post-formation treatment of the article such as drying or compressing.
• Additives may be used for “sizing” or to impart resistance to fluid penetration to the cellulosic material.
• sizing agents include non-reactive systems such as rosin systems commonly used in acidic papermaking, natural resin can be processed from southern pines tall oil (a byproduct from alkaline pulping), and reactive systems such as those based on alkyl ketene dimers or alkenyl succinic anhydrides.
• sizing agents may include acid chlorides, acid anhydrides, enol esters, alkyl isocyanates, rosin anhydrides, starch (including amylose and/or amylopectin), animal glue, methyl cellulose, carboxymethyl cellulose (CMC), polyvinyl alcohol, waxes and wax emulsions, alginates, or polymers such as Styrene Maleic Anhydride (SMA), polyurethanes, and styrene acrylate.
• SMA Styrene Maleic Anhydride
• Additives may be used to provide strength to the cellulosic material including wet strength and/or dry strength.
• wet strength additives include thermosetting resins such as amino resins including urea-formaldehyde resins, thermosetting aminoplastic resins such as melamine formaldehyde resins, amine-epichlorohydrin resins such as amine-epichlorohydrin polymeric resins, polyamide-epichlorohydrin resins, polyamide-amine-epichlorohydrin (PAE) resins and the like, glyoxalated polyacrylamide (GPAM) resins including crosslinked and noncrosslinked GPAM polymers, modified starch such as dialdehyde starch, and/or polycarboxylic acids.
• thermosetting resins such as amino resins including urea-formaldehyde resins, thermosetting aminoplastic resins such as melamine formaldehyde resins, amine-epichlorohydrin resins such as amine-
• Non-limiting examples of dry strength additives include polysaccharides and modified polysaccharides such as starch (including amylose and/or amylopectin), modified starch, modified cellulose(s) such as carboxymethyl cellulose (CMC) and/or chitosan, as well as crosslinked/branched polysaccharides such as hemicellulose(s) and/or polysaccharide gums including locust gum and/or tamarind gum and/or guar gum among others, cationic and/or anionic modified polysaccharides including combinations of cationic and anionic modified polysaccharides as poly electrolyte multilayers (PEM’s), polyacrylamides (PAMs), and latex additives.
• PEM poly electrolyte multilayers
• PAMs polyacrylamides
• Additives may also include colorants (i.e. dyes and pigments). It has been found that fiber-based articles may be relatively unaffected in quality, by addition of limited quantities of pigments, colorants and filler materials, provided that, the pigment material selected is not chemically reactive with water or any of the other components of the molding composite under the molding conditions referenced herein. Accordingly, the composite described herein enables the manufacturer to mold parts in a large variety of colors. In order to avoid substantial effect on the moldability of the composite, it is believed that pigment, if desired, should be included to a maximum of 5 percent, more preferably 4 percent, and still more preferably 3 percent, by weight of the diy component blend.
• colorants i.e. dyes and pigments
• Additives may also include fillers which impart various properties to the article or article region including brightness, opacity, whiteness, gloss, smoothness, and printability. Fillers can also be used to modify the density of the article or region. Non-limiting examples of fillers include titanium dioxide, clays such as kaolin, calcium carbonate, aluminum trihydrate, silicas, silicates and aluminosilicates, and calcium sulfoaluminates.
• Additives may include binders that impart structural integrity to the article. Any suitable binder may be used, but binders that exhibit human bio-compatibility, relatively rapid biodegradability, source sustainability and dispersibility are preferred. Polysaccharides including starches (e.g. com starch and/or potato starch) may be suitable binders.
• Additives may include dispersing agents that may facilitated the dispersion of a co-additive in the slurry'. Dispersing agents may be particularly useful for dispersing co-additives which are not fully water-soluble such as hydrophobic or hydrophobically-modified additives, or particulate additives. Non-limiting examples of dispersing agents include salts of carboxymethylcellulose such as sodium carboxymethylcellulose (CMC salt). Additives may include lubricating agents that may improve releasability of the molded article from the mold (i.e., reducing chances that the molded object will stick to the mold).
• Non-limiting examples of lubricating agent may include long-chain fatty acids and salts thereof such as nonalkali metal salts thereof such as calcium stearate, magnesium stearate, zinc stearate, calcium laurate, magnesium laurate, zinc laurate, aluminum laurate, strontium laurate, aluminum stearate, strontium stearate, and mixtures thereof.
• the lubricating agent may preferably be included in a quantity from 0.2 to 2.0 weight percent of the total dry component blend.
• Additives may be at least partially water-soluble and may be at least partially dissolved in the slurry or may be particulate.
• the additive(s) may be suspended in the slurry as particles or as emulsions or dispersions.
• “Slurry” as used herein refers to the suspension of the cellulosic material(s), fiber type(s) and additive(s) that is applied to the porous mold when forming the article.
• the slurry is generally, but not necessarily, suspended in water.
• the slurry may be dilute and contain a high (i.e. >90% w/w) amount of water or may be concentrated and contain a low (i.e. ⁇ 90% w/w) amount of water.
• Water is added to the dry wood pulp fibers and any additives to transform the dry components into a moldable paste or slurry.
• the quantity of water added may be varied to achieve an optimized balance of viscosity and minimization of the quantity of water that must be removed during the drying process following formation.
• the volume ratio of dry component blend to water may be from 55:45 to 75:25, and may be adjusted according to the desired dry component composition selected for optimized viscosity and water content for molding and molded object porosity.
• dry/precursor components of the molding composite may be dispersed in a relatively high-water content slurry, as disclosed in, by way of non-limiting example, PCT App. No. WO 2020/016416, which is incorporated herein by reference in its entirety.
• “Region” as used herein refers to area of an article that contains a fiber type. Different regions of an article are comprised of different fiber types.
• the different regions of the article can be conferred with different properties on the basis of the fiber type(s) comprising the cellulosic material forming each region.
• properties may include density, rigidity/ flexibility, porosity, water vapor transmission rate (WVTR), absorbency, surface tension, surface smoothness, tensile strength, compressive strength, folding endurance.
• a region’s size, shape, and thickness will depend upon a number of factors, such as the type of articles and its intended use, components of the region, desired properties of the region, desired properties of other regions, method of manufacture.
• the composition of a region can include fiber type(s) and additive(s).
• An article may be formed to comprise regions of different density or basis weight. Densities of the various regions may have any practical value that suits the purpose of the article and the regions of the article. For example, a region of the article may have densities from about 0.2 to 2.0 g/cm 3 . Varying the density (or basis weight) of the different regions of the article may further contribute to differences in other mechanical properties such as tensile strength, compressive strength, drop strength, and strength at the opening. Density of basis weight can be measured by any known means in the art such as by determining the weight of a region and separately determining its thickness (e.g. by using calipers) and calculating density as weight divided by thickness.
• An article may be formed to comprise regions of different tensile strength.
• Tensile strength of the various regions may have any practical value that suits the purpose of the article and the regions of the article.
• a region of an article may have a tensile strength of 5 MPa or more, particularly 10 MPa or more.
• Articles with tensile strengths in these ranges are less prone to rupture due to shocks, etc.
• Tensile strength can be measured by any known means in the art such as by compendial methods Tappi T494.
• An article may be formed to comprise regions of different compressive strength.
• Compressive strength of the various regions may have any practical value that suits the purpose of the article and the regions of the article.
• a region of an article may have a compressive strength of 100 Nm 2 /g or more, particularly 110 Nmri'g or more. Compressive strengths within these ranges allow articles to survive compression insults, such as those caused during travel or storage.
• An article may be formed to comprise regions of different water vapor transmission rate (WVTR). WVTR of the various regions may have any practical value that suits the purpose of the article and the regions of the article.
• WVTR water vapor transmission rate
• a region may have a WVTR of 100 g/(m 2 -24 hrs) or less, preferably 50 g/(m 2 -24 hrs) or less.
• a low WVTR may be useful in minimizing the extent to which moisture in the air can penetrate the region, which may be important if the article is a container for moisture-sensitive contents.
• WVTR can be measured by any known means in the art such as by compendial methods Tappi T448 om-21 and T464 om-18.
• An article may be formed to comprise regions of different surface tension.
• Surface tension of the various regions may have any practical value that suits the purpose of the article and the regions of the article.
• a region may have a surface tension of 10 dyn/cm or less and water repellency of R10, which would imply the region has water repellency.
• Surface tension can be measured by any known means in the art such as by compendial methods Tappi T458.
• Transition Region refers to an area of an article that is adjacent to a Region but contains less of a type of fiber present in the adjacent Region.
• the transition region may include fibers of both types of those in the regions to which it is adjacent.
• the transition region may be adjacent to more than two regions and as such may contain fibers of each of the types of those in the regions to which it is adjacent. In embodiments a transition region will typically blend or feather into the bordering regions, rather than forming an abrupt change.
• the multiple fiber types in the transition region may be randomly mixed or layered.
• Transition regions can have a configuration corresponding to the border regions.
• the depth or size of a transition region will depend upon the one or more factors, such as the article and its intended use, composition of the regions, method of manufacture, and so on.
• the terms “include,” “includes,” and “including” are meant to be non-limiting. Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition, and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.
• Every' maximum numerical limitation given throughout this specification includes every' lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include even,' narrower numerical range that, falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.
• FIGURES 1-9 Various embodiments of the present invention are described below in FIGURES 1-9, in particular embodiments comprising a bottle with various functional regions comprising different cellulosic materials; however, the description is for illustration purposes only and it is understood the invention may take additional forms of an article comprising two or more regions, as described herein.
• the bottle 20 may include a neck region 21, and a body region 23.
• the neck region 21 may include all part or some of the top of the bottle.
• the neck region may comprise a cellulosic material comprising softwood fibers and/or long fibers and/or highly fibrillated fibers.
• the softwood, highly fibrillated and/or long fibers provide the neck region with hardness and top-load strength.
• the bottle may further comprise a body region 23 and a transition region 25.
• the body region and transition region may include all part or some of the bottom and sidewalls of the bottle.
• the body region may comprise a cellulosic material comprising hardwood and/or short fibers.
• the bottle with a base region 30 may include a base region 31, and a body region 33.
• the base region 31 may include all part or some of the bottom of the bottle.
• the base region may comprise a cellulosic material comprising softwood fibers and/or long fibers and/or lightly fibrillated fibers. These softwood fibers, long fibers, and/or lightly fibril fated fibers provide the base region with flexibility and resilience relative to drop-strength.
• the bottle may further comprise a body region 33 and a transition region 35.
• the body region may comprise a cellulosic material comprising hardwood and/or short fibers. These hardwood or short fibers provide the body region with a smooth surface finish to allow for easier decoration (i.e. the ability to accurately print on the surface).
• the neck region 41 may include all part or some of the top of the bottle.
• the base regi on 41 may include all part or some of the bottom of the bottle.
• the body region 43 may include all part or some of the sidewalls of the bottle.
• the neck region 41 may comprise a cellulosic material comprising softwood fibers and/or long fibers and/or highly fibrillated fibers. The softwood, highly fibrillated and/or long fibers provide the neck region 41 with hardness and top-load strength.
• the base region 42 may comprise a cellulosic material comprising softwood fibers and/or long fibers and/or lightly fibrillated fibers.
• the softwood fibers, long fibers, and/or lightly fibrillated fibers provide the base region with flexibility and resilience relative to drop-strength.
• the body region 43 may comprise a cellulosic material comprising hardwood and/or short fibers. These hardwood or short fibers provide the body region with a smooth surface finish to allow for easier decoration (i.e. the ability to accurately print on the surface).
• the bottle may further comprise transition regions 45 and 46 intermediate the base and body regions and neck and body regions, respectively.
• the squeeze panel region 51 may include all part or some of the sidewall of the bottle.
• the squeeze panel region 51 preferably is contained entirely within the sidewall of the bottle.
• the squeeze panel region 51 may comprise a cellulosic material comprising a combination of long non-wood fibers and hardwood fibers. These long non-wood fibers and hardwood fibers confer flexibility and tensile strength to the squeeze panel region 51 and provide the squeeze panel region 51 with flexibility and resilience.
• the perimeter region 53 may include all part or some of the top and the bottom of the bottle and may further include part of the sidewall. The perimeter region 53 may generally surround the squeeze panel 51.
• the perimeter region 53 may comprise a cellulosic material comprising a majority of softwood fibers and/or long fibers.
• the softwood, highly fibrillated and/or long fibers provide the perimeter region 53 with rigidity so that only the squeeze panel region 51 def onus when activated by a user.
• the bottle may further comprise a transition region 55 intermediate the squeeze panel region and the perimeter region.
• a bottle of the present invention may be formed as a unitary part or may be formed from two or more parts that, are joined after being formed.
• the two or more parts may be joined by any means known in the art such as adhesive binding, overlapping seams via folding, heat sealing, ultrasonic bonding and the like.
• the bottle may be formed from the joining of two portions, such as a front portion 61 and a back portion 63 as depicted in FIG. 5.
• the neck region 21, body region 23 and transition region 25 of bottle 20; or the base region 31, body region 33 and transition region 35 of bottle 30; or the neck region 41, base region 42, body region 43 and transition regions 45 and 46 of bottle 40; or the squeeze panel region 51, perimeter region 53 and transition region 55 of bottle 50 may be formed as regions in one or more of the two or more parts.
• FIG’s 6 and 7A and 7B Various embodiments of the present invention are described below in FIG’s 6 and 7A and 7B, in particular embodiments comprising a closure with a living hinge with various functional regions comprising different cellulosic materials; however, the description is for illustration purposes only and it is understood the invention may take additional forms of an article comprising two or more regions, as described herein.
• the closure 80 with a living hinge includes a lid region 81, an attachment region 83, and a transition region 85.
• the transition region 85 may serve as the living hinge.
• the lid region 81 may comprise a cellulosic material comprising a majority of hardwood fibers. These hardwood fibers confer rigidity to the lid region 81 that enables it to snap shut.
• the attachment region 83 may comprise a cellulosic material comprising a majority of non-wood fibers (including recycled nonwood fibers). These non-wood fibers confer flexibility to the attachment region 83.
• the transition region 85 may comprise a random mixture of the hardwood and non-wood fibers comprising regions 81 and 83.
• This random mixture of the hardwood and non-wood fibers may confer tensil e strength to the transition region that is greater than that of either the lid region 81 or the attachment region 83.
• the living hinge may comprise a third region in addition to the lid region and the attachment region with transition regions intermediate the living hinge region and each of the attachment region and the lid region.
• the closure 90 includes a lid region 91, an attachment region 93 capable of attaching to a tub 97 and a living hinge region 95.
• the lid region 91 may comprise a cellulosic material comprising a majority of hardwood fibers. These hardwood fibers confer rigidity to the lid region 91 that enables it to snap shut.
• the attachment region 93 may comprise a cellulosic material comprising a majority of non-wood fibers (including recycled non-wood fibers). These non-wood fibers confer flexibility to the attachment region 93 allowing it to fit easily onto the tub 97.
• the living hinge region 95 may comprise the transition region between regions 91 and 93 and may comprise a random mixture of the hardwood and non-wood fibers comprising regions 91 and 93. This random mixture of the hardwood and non-wood fibers may confer tensile strength to the transition region that is greater than that of either the lid region 91 or the attachment region 93.
• the living hinge may comprise a third region in addition to the lid region and the attachment region with transition regions intermediate the living hinge region and each of the attachment region and the lid region.
• the tray 120 as depicted includes a rim region 121, a body region 123, and a transition region 125.
• the rim region 121 may include all part or some of the top of the tray and may comprise a perimetric flange 127 comprising a top surface 128.
• the rim region may comprise a cellulosic material comprising a blend of refined softwood long fibers and short hardwood fibers. This blend of refined softwood long fibers and short hardwood fibers provide the rim region with rigidity and surface smoothness which are necessary' for the rim to accept a seal such as an adhesively joined film seal (including polymeric and non-polymeric films).
• the tray may further comprise a body region 123 and a transition region 125.
• the body region may comprise a cellulosic material comprising recycled fibers including post-industrial or post-consumer recycled fibers. The recycled fibers may be desirable for the body region for their low' cost and ready availability.
• FIG’s 9A and 9B a tray 130 according to the present invention is depicted.
• the tray 130 may include a lid region 131, a body region 133, and a transition region 135.
• the transition region 135 may serve as a living hinge.
• the lid region 131 may comprise a cellulosic material comprising a majority of hardwood fibers. These hardwood fibers confer rigidity to the lid region 131 that enables it to snap shut.
• the tray may further comprise a bodyregion 133 and a transition region 135.
• the body region may comprise a cellulosic material comprising long and/or a on- wood.
• the transition region 135 may comprise a random mixture of the cellulosic materials comprising the hardwood and long and/or non-wood fibers of regions 131 and 133.
• the living hinge may comprise a third region in addition to the lid region and the attachment region with transition regions intermediate the living hinge region and each of the attachment region and the lid region.
• Articles of the present invention may be formed from a process that includes depositing the regionally disposed cellulosic materials on a porous forming male or female mold from an aqueous slurry.
• the mold may be in the form of a mirror image of the article to be manufactured and may take any form (i.e. porous plate, wire mesh, additively or subtractive created) capable of accepting the slurry and allowing deposition of the cellulosic material therefrom.
• the cellulosic material is deposited on the porous mold via pressure, including either (or both) of positive pressure applied to the slurry-facing side of the mold while the mold is exposed to the slurry or vacuum applied to the non-slurry facing side of the mold while the mold is exposed to the slurry.
• the slurry By establishing a pressure differential between the slurry-facing side of the mold and the non-slurry- facing side of the mold, the slurry is drawn to the surface of the pores on the porous mold, trapping fiber particles in the shape of the mold.
• the slurry may be applied to the porous mold by any means such as by immersion of the mold in the slurry, pouring of the slurry over the mold, spraycoating of the slurry onto the mold and the like.
• the different fiber types comprising the different regions of the article may be deposited on the mold from different slurries.
• the different slurries may be applied simultaneously or sequentially. Without being bound by theory it is believed that depositing the slurries simultaneously may result in the different fiber types comprising the different regions be randomly mixed within the transition region while sequential application of the slurries may result in layering of the different fiber types in the transition region.
• Deposition of the fibers on the porous mold may continue until a desired thickness of the fibers on the mold is achieved, including the fibers comprising the various regions comprising the desired article.
• the resulting accumulation of fibers in the rough form of the finished article i.e. the article “blank” is dried and/or cured.
• the process may be operated as a closed loop system, in that the unused slurry is re-circulated back into the system and re-used for forming a subsequent article.
• Drying of the blank may be achieved by any means.
• the blank may simply be airdried with no further processing.
• the blank may be actively dried (i.e. with heat) and may further be subject to compression.
• Conventional “hot press” drying may include drying/curing the blank at a temperature range of about 150°C to about 250°C, with a pressure range about 140 to about 170 kg/cm2.
• the blank may be transferred to a transfer tool before or during the drying process.
• the transfer tool may also be porous to facilitate further drying of the blank.
• the blank may be subjected to further temperature and pressure while in contact with the transfer tool.
• the pressure applied to may be about 200 to about 900 mbarA (millibar absolute) or about 300 to about 800 mbarA.
• the temperature applied to the blank may be about 150-500 Q C, about 150-400 °-C, 200-500 °-C, 200- 400 °-C or 200-300 °-C, and in most cases 240-280 Q C.
• at least one mold face contacting the blank may be heated.
• the articles of the present invention may be made by injection molding as disclosed in US2022/0296434, which is incorporated herein by reference in its entirety.
• the articles of the present invention may have applied to them a topical coating of additives, such as preservatives, repellants, retardants, colorants, hardeners, anti-microbial substances, waxes, and/or resins for example.
• additives such as preservatives, repellants, retardants, colorants, hardeners, anti-microbial substances, waxes, and/or resins for example.
• the shaped pulp articles of the present invention may, by way of non-limiting example only, be sprayed with a water repellant and/or stain repellant product in order to repel the infiltration of moisture and/or staining of the shaped pulp articles.
• the different regions composed of the different fiber types may have different densities and/or different tensile strengths.
• the densities may vary from as low as about 350kg/m3 to as high as about 1200 kg/m3 from one region to another.
• the tensile strengths may vary from as low as about 3kN/m to as high as about 21kN/m from one region to another.
• Standard plaques refer to non-regionalized plaques that may include a single fiber type or a homogeneous blend of fiber types.
• Experimental plaques refer to regionalized plaques in which different fiber types comprise different regions of the plaques.
• the fibers were sourced from various pulp mills in the form of flat sheets or bundled fibers that have already gone through some form of pulping process. These supplied fiber forms first need to be re-separated and dispersed or suspended in water. This process of re-wetting and re-fiberizing is generally considered re-pulping. Any known repulping method and/or device could be used such as a blender (Waring Commercial Blender with modified blade) or a standard British disintegrator or lab pulper.
• a Waring Commercial Blender with modified blade was utilized for the standard and experimental plaques reported in Table 1, a Waring Commercial Blender with modified blade was utilized.
• plaques were made using the various fiber types, blends or regions.
• the target dose for each experimental plaque tested was 10g of total dry fiber for a circular plaque with diameter of ⁇ 159mm.
• the 10g dose comprised the appropriate portion of each fiber type to be included in the final plaque. For example, a 50% portion would contain 5g of that portion’s type of fiber. From the supplied fibers, portions of convenient size were taken to achieve the target weight for the dose or dose portion.
• the target weight of fiber was measured using a balance accurate to 0.01g. Each fiber portion was re-pulped as a separate charge or dose. Re-pulping was carried out at the consistency recommended by the re-pulping device manufacturer. Consistency is the ratio of fiber to water. Consistency (in percent) equals the fiber weight (in grams) divided by the sample volume used (in milliliters) times 100. Generally, the repulping devices were low consistency devices where the recommendation is less than 3% pulp in water. For the Samples listed in TABLE 1, 1000ml of water was used for each sample in the repulping device. The amount of water was measured using a graduated cylinder or laboratory beaker. This water amount would result in a consistency of 0.5% for 5g or 50% portion dose and 1% for 10g 100% full dose. The same preparation and procedure would be used for any target dosage level or plaque dry weight.
• the re-pulping device was charged by combining the measured water and pulp.
• the resulting slurry was vigorously agitated in the blender for 1-4 minutes or until the fibers were separated and distributed in the water. This time could vary by fiber type, but for the Samples listed, the time was generally 2 minutes.
• the plaques were then formed using a manual forming device.
• This laboratory device is available from various lab and instrument suppliers and meets the standards for Tappi 205 as represented in FIG’s 12-15.
• the Samples reported in TABLE 1 were formed using a modified version of a Sheet Former 73-60 manufactured by Testing Machines Inc.
• the device is generally comprised of a vertical stainless-steel column that is hinged and latched so it can be opened for a meshed screen or porous mold to be inserted into the bottom (FIG’s 12, 13 and 15). Beneath the inserted screen or mold is a drain with valve lever that can be manually operated.
• the internal diameter of the column and related screen or mold is 159mm and forms a circular plaque of similar diameter.
• Standard plaques refer to non-regionalized plaques that may include a single fiber type or a homogeneous blend of fiber types.
• Experimental plaques refer to regionalized plaques in which different fiber types comprise different regions of the plaques.
• the drain valve can then be opened, and the water drains out of the column through the screen or mold and deposits the fibers on the screen or mold resulting in the formation of a wet sheet of fibers across the surface.
• the column was opened for access and the wet sheet of fibers.
• the wet sheet can then be processed by any means.
• the mold used in forming the Samples of TABLE 1 was a circular porous plate mold correlating to the 159mm diameter of the sheet former.
• a vacuum may be applied to the drain to more forcefully and rapidly draw the water through the altered screen or mold.
• the Samples in TABLE 1 were formed using a 1 lOcfm vacuum applied to the drain.
• Sample 6 was processed by a largely conventional papermaking process in that the wet sheets were pressed using a roller and transferred to a dryer. Samples 1-5 and 7-9 were processed under temperature and pressure. After being removed from the mold, the plaques were transferred to a heated pressing device where the wet sheet was pressed with a controlled amount of pressure using a flat pressing surface. For the Samples in TABLE 1, pressure was set to 1500psi. In addition, a fixed gap was set using gage blocks to prevent over pressure or damage to the screen or mold. This fixed gap was adjusted from 0 to 1mm or larger.
• the primary gap for the Samples listed was 0.5mm defined as the controlled gap between the surface of the screen or mold and the pressing surface.
• the pressure surface was set to a controlled temperature. Temperature was set to between 300-400 degrees Fahrenheit. Temperature could vary by fiber type due to the dewatering capability of the fibers (known in the art as freeness). The elevated temperature accelerates the removal of water as steam and the freeness of fibers can limit the rate at which the moisture can exit without damaging the sheet.
• the resulting hand sheet forming method was: To form sheets in the sheet former, after ensuring the drain valve was closed, the screen or mold was inserted and the column was closed and latched, and the column was partially filled with water so that the column was at least halfway full. The dosage or charge from the re-pulping device was added to the column and stirred into the previously added water to disperse and dilute the charge uniformly in the column. The vacuum source was then turned on and the drain valve can then be opened, and the water was drawn out of the column through the screen or mold and deposits the fibers on the screen or mold resulting in the formation of a wet sheet of fibers across the surface.
• the column was opened for access.
• the screen or mold with the wet sheet of fibers was then removed from the column and transferred to the heated pressing device.
• the wet sheet of fibers was then pressed with controlled pressure and temperature until sufficiently dry. The dried sheet was then removed from the mold for testing.
• the resulting hand sheet forming method was: To form sheets in the sheet former, after ensuring the drain valve was closed, the screen or mold was inserted and the column was closed and latched, and the column was partially filled with water so that the column was at least halfway full. The various separate dosages or charges of each fiber type from the re-pulping device(s) were added to the column and stirred together into the previously added water to disperse and dilute the combined portions into a full charge uniformly in the column.
• the vacuum source was then turned on and the drain valve can then be opened, and the water was drawn out of the column through the screen or mold and deposits the fibers on the screen or mold resulting in the formation of a wet sheet of fibers across the surface.
• the column was opened for access.
• the screen or mold with the wet sheet of fibers was then removed from the column and transferred to the heated pressing device.
• the wet sheet of fibers was then pressed with controlled pressure and temperature until sufficiently dry. The dried sheet was then removed from the mold for testing.
• a partial charge or dose of each different fiber type was used in a modified process/apparatus.
• This modification was the insertion of a divider (FIG. 14) into the hand sheet former column as shown in FIG. 12.
• This divider created two side by side partial column dosing chambers preventing the blending of fibers between the chambers.
• This divider was such that it could be moved and adjusted in the vertical direction so that there could either be a tight fit to the mold surface or there could be an adjustable gap between the bottom edge of the divider and the surface of the mold.
• This interface between the vertical divider and the surface of the mold influences the amount of blending and intermingling of fibers occurs between the two zones or regions of different fibers and creates a transition zone or joint area.
• the divider was gasketed along the interior side-wall of the column. The addition of the divider and desire to keep the different fiber charges or doses separated changed the preparation method.
• the resulting forming method for the experimental plaques was: To form sheets in the sheet former, after ensuring the drain valve was closed, the screen or mold was inserted, and the column was closed and latched. The divider was then inserted into the column bisecting the cylindrical volume in half and creating two semi-circular chambers as shown in FIG. 13. The column was then partially filled with water so that the column and resulting chambers were at least halfway full. The separate dosages or charges of each fiber type were re-pulped separately from the repulping device(s) and added to the column, each portion charge or dose was added into each separate chamber created by the divider.
• the vacuum source was then turned on and the drain valve was then opened, and water drawn out of the column through the screen or mold and the fibers deposited on the screen or mold resulting in the formation of a wet sheet of fibers across the surface with regions created by the divided chambers.
• a transition or interface region between the regions of fiber was created as shown in FIG. 15.
• the extent and degree of mixing of fibers in the transition region can be affected by the size of the gap between the bottom edge of the divider and the surface of the mold.
• the gap size for the experimental plaques was also recorded in TABLE 1. This transition region can also be further affected during subsequent pressing of the sheet.
• Post-formation treatment of the wet sheets in forming the plaques in TABLE 1 included either rolling and drying (as in standard paper making) or compressive drying in a heated pressing device.
• the heated pressing device presses and dries the wet sheet of fibers with controlled pressure and temperature until sufficiently dry.
• the plaques presented in TABLE 1 post-treated with compressive drying were dried at 150°C under 1500psi pressure for 30 seconds while remaining on the porous mold. After drying, the plaques were removed from the mold for testing.
• Plaque thickness was measured using a magna-micrometer device. Thickness measurements were taken of the standard plaques and of each of the regions of the experimental plaques. Thickness measurements were taken at 5 randomly selected points within each fiber region and averaged. Plaque weight was measured using a balance sensitive to ,01g. Five plaques were weighed together, and the resulting average weight (i.e. total weight divided by five) was recorded in TABLE 2.
• Basis Weight was determined using the average mass as defined above (in grams) divided by the unit area of the plaques. As noted, the plaques were formed using a 159mm diameter porous mold, so the plaques have a standard area of 200cm 2 or 0.02m 2 . Basis weight was reported as g/m 2 so basis weight was calculated as:
• the samples were tested for tensile properties and surface roughness.
• the tensile properties (tensile strength, stretch and energy absorption) of the plaques were calculated from measured force and elongation values obtained using a constant rate of elongation test until the sample breaks.
• the test was run in accordance with compendial method Tappi T494 - “Tensile Properties of Paper and Paperboard (Using constant rate of elongation apparatus)” with procedural specifics and modifications noted herein. Measurements were made on a constant rate of extension tensile tester using a load cell for which the forces measured were within 1% to 99% of the limit of the cell.
• the instrument used was the Instron Model 5965 using Bluehill Universal Software, both available from Instron (Norwood, MA), or equivalent.
• Samples were cut from the plaques for tensile testing. Samples were cut using a cutting die comprising a steel cutting rule to cut controlled sample sizes from the finished plaques. This sample cutting die cleanly and consistently cuts rectangular samples of 20mm x 60mm using a swing arm die cutting press (or “clicker” press). The cut samples should be free from residual contaminants or other materials. Measurements were made with the long side of the sample parallel to the direction of the extension force.
• the tensile tester was computer operated and programmed for a constant rate of extension uniaxial elongation to break as follows. Set the gauge length (test span) to 60 mm using a calibrated gauge block and zero the crosshead. Insert the test sample into the grips such that the long side was centered and parallel to the central pull axis of the tensile tester. Raise the crosshead at a rate of 0.8 mm/s (48mm/min) until the test sample breaks, collecting force (N) and extension (mm) data at 100 Hz throughout the test.
• the reported parameters including tensile strength, stretch and energy absorption were calculated by the software. Generally, these parameters were calculated as follows. Construct a graph of force (N) versus extension (mm). Read the maximum force (N) from the graph and record as Peak Force to the nearest 0.1 N. Read the extension at the maximum force (N) from the graph and record as Elongation at Break to the nearest 0.01 mm. From the graph, determine the point (z) where the tangent to the curve, with a slope equal to the maximum slope of the curve, intersects the elongation axis. Now calculate the area under the force vs elongation curve from point z up to the point of maximum force and report to the nearest 0.1 mJ.
• Tensile strength was calculated by dividing the Mean Peak Force (N) by the width of the test sample (20.0 mm). Calculate the tensile strength for the replicates and report as Tensile Strength to the nearest 0.1 kN/m.
• Stretch at break was calculated by dividing the Mean Elongation at Break (mm) by the initial test length (test span) of 60 mm, and then multiplying by 100. Calculate the stretch at break for the replicates and report as Stretch at Break to the nearest percent. Surface roughness was measured as line roughness using a contact type profilometer.
• the device used to generate the data in TABLE 1 was a Mitutoyo Surffest SJ-310. This device uses an automated stylus device to traverse the surface of a sample over a given line path. The vertical deviation of the stylus was measured to within lum. The measurements taken within the linear path length of the stylus are then calculated and output.
• the outputted parameters include:
• Ra When dealing with the roughness profile, Ra is referred to as the arithmetic mean roughness height of the line of measurement. Arithmetical mean height indicates the average of the absolute value along the sampling length.
• the maximum height of the profile indicates the absolute vertical distance between the maximum profile peak height and the maximum profile valley depth along the sampling length line. Rz is referred to as the maximum roughness.
• Rq - Root mean square deviation indicates the root mean square along the sampling length.
• Rq is referred to as the root-mean-square roughness.
• Sample preparation was the same as that for measuring tensile properties.
• the sample was affixed to a flat surface prior to testing.
• the sample can be affixed to the flat surface by any suitable means such as gluing, clamping weighting and the like.
• gluing gluing, clamping weighting and the like.
• weighting For the data presented in Table 1 the sample was affixed to the flat surface by weighting.
• the test results showed unexpected results, particularly in the characterization of the transition regions.
• the results showed that regions comprising a common fiber composition generally shared the same properties as that fiber composition formed as a single-region/ standard plaque.
• the transition regions between fiber regions may have properties that may be similar to one or the other of the adjacent singleregion properties or may have properties that closer to an average of the adjacent single-region properties or may have properties that were substantially different from those of the adjacent single-regions. In an example as illustrated in FIG.
• Sample 4 comprises longer recycled cotton or non-wood fiber deposited in the common fiber region 1 and Eucalyptus or short fiber hardwood deposited in the common fiber region 2 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle.
• Sample 4 results captured in TABLE 2 and FIG. 17 it can be seen that both the maximum tensile force before break and the tensile displacement or elongation at break were both noticeably improved within the transition region 3 over the same test results performed on the common fiber regions 1 and 2.
• the sample preparation for this Sample 4 included a set starting gap of l-2mm between the inserted divider in the sheet former and the surface of the hand sheet screen or mold.
• Samples 6A and 6B comprised longer recycled cotton or non-wood fiber deposited in the common fiber region 1 and long softwood fibers deposited in the common fiber region 2 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition region 3.
• the sample was pressed in the conventional hand sheet method outlined in Tappi 205 by pressing the water out of the sheet using a roller and drying in flat dryer.
• the Sample 6B was processed using controlled heat and pressure to press and dry the sheet to better simulate a pulp molding process.
• Samples 7 A and 7B comprised longer recycled cotton or non-wood fiber deposited in the common fiber region 1 and long softwood fibers deposited in the common fiber region 2 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition region 3.
• the softwood samples were processed using the CTMP method.
• Samples 7A and 7B were the same and were tested for replication of results.
• the maximum tensile force seen at break for the transition region 3 was between the maximum force at break in common fiber regions 1 and 2.
• the tensile displacement or elongation seen at break for the transition region 3 was also between the maximum force at break in common fiber regions 1 and 2.
• Sample 8 comprised longer recycled cotton or non-wood fiber deposited in the common fiber region 2 and long softwood fibers deposited in the common fiber region 1 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition zone 3.
• the softwood samples were a Northern Softwood variation.
• the maximum tensile force seen at break for the transition region 3 was between the maximum force at break in common fiber regions 1 and 2, as were the tensile displacement or elongation seen at break for the transition region 3.
• Sample 9 comprised short hardwood fibers deposited in the common fiber region 2 and long softwood fibers deposited in the common fiber region 1 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition region 3.
• the softwood samples were a Northern Softwood variation.
• both the maximum tensile force before break and the tensile displacement or elongation at break were both noticeably improved within transition region 3 over the same test results performed on the common fiber regions 1 and 2.
• regions as illustrated in FIG. also formed in regions as illustrated in FIG.
• Sample 10 comprised short hardwood fibers blended equally with long softwood fibers deposited in the common fiber region 2 and long softwood fibers deposited in the common fiber region 1 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition region 3.
• the softwood samples were a Northern Softwood variation and the softwood fibers in region 1 have been heavily fibrillated.
• Sample 10 data captured in TABLE 2 and shown in FIG. 26 the maximum tensile force seen at break for the transition region 3 was between the maximum force at break in common fiber regions 1 and 2, as were the tensile displacement or elongation seen at break for the transition region 3.
• Sample 11 comprised unbleached recycled fibers deposited in the common fiber region 2 and short hardwood fibers blended equally with long softwood fibers deposited in the common fiber region 1 and a transition region 3 created during forming and pressing where the two common fiber regions were adjacent to one another, and the different fibers co-mingle to create the transition region 3.
• the softwood samples were a Northern Softwood variation and the softwood fibers in region 1 have been heavily fibrillated.
• Sample 11 data captured in TABLE 2 and shown in FIG. 27, the maximum tensile force seen at break for the transition region 3 was between the maximum force at break in common fiber regions 1 and 2, as were the tensile displacement or elongation seen at break for the transition region 3.

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