A product, uses of the same, and a method

Description

1 / 62 “A PRODUCT, ITS USES, AND A METHOD” FIELD

[0001] The present invention relates to coated fibrous structures and, more particularly, to coated molded fibrous structures comprising cellulosic and / or lignocellulosic fibers. FUNDAMENTALS

[0002] Fibrous structures and products comprising cellulosic and / or lignocellulosic fibers are manufactured, for example, by wet setting, air setting or molding methods. Such fibrous structures are widely used in packaging technology as an alternative to all-plastic packaging.

[0003] The application of various coating films, such as barrier coatings, to packaging and containers made of fibrous cellulosic materials, such as cardboard, is well known. The purpose of such coating films is often to provide surface properties adapted or improved to the fibrous structure.

[0004] The application of a barrier coating typically needs to be carried out in a separate process after the actual manufacture of the fibrous substrate. For example, food containers and packaging are currently made of paper or cardboard comprising plastic or wax-based barrier coatings on the food-contact side of the container, such as laminated or extruded barrier coatings made of polyethylene terephthalate or polyethylene. Petition 870260042878, dated 07 / 05 / 2026, page 6 / 147 2 / 62

[0005] Known coating films suffer from many disadvantages related to the adhesion of the coating film to the rest of the product, such as a fibrous product, and to the deterioration of the mechanical properties of the coating film during the drying and conversion stages in manufacturing or during humidity variation in transport and storage. For example, the coating may shrink differently compared to the substrate on which the coating rests. Shrinkage problems are especially relevant in the case of using water-diluted bio-based coating compositions.

[0006] Water-based coatings generally present many challenges and requirements for the fibrous substrate, such as structural problems during rewetting and the need for drying. Another challenge is the insufficient level of gas barrier, for example, against water vapor and oxygen.

[0007] It is a challenge to prepare a smooth coating on a substrate or three-dimensional object using known methods and, in particular, to obtain a uniform distribution of the coating material on the side walls and bottom of the object.

[0008] Furthermore, known deep drawing molding processes face challenges, since the laminated or coated substrate must be press-moldable and also flexible enough so that the coating does not crack in the process.

[0009] With known coating methods, preparing a three-dimensional substrate with Petition 870260042878, dated 07 / 05 / 2026, page 7 / 147 3 / 62 High barrier properties combined with good thermal sealing capacity.

[0010] It is an object of the present invention to solve at least some of the problems present in known technology. SUMMARY OF THE INVENTION

[0011] According to a first aspect of the present invention, a product is provided comprising: a fibrous structure comprising a cellulosic and / or lignocellulosic fibrous material and obtained by a molding process; and a coating, such as at least one coating layer, on at least one surface of the fibrous structure, wherein the coating was obtained by a dry coating process, preferably by a powder coating process.

[0012] Several modalities of the first aspect may comprise at least one feature from the following bulleted list: • The coating forms either a top layer or a bottom layer of the product. • The product comprises at least two coating layers located on different surfaces of the fibrous structure, such as on opposite sides of a flat fibrous structure. • The product also includes a non-fibrous intermediate layer between said coating and the fibrous structure. • The coating was applied to a curved or non-horizontal surface of the fibrous structure. Petition 870260042878, dated 07 / 05 / 2026, page 8 / 147 4 / 62 • The coating is a non-fibrous coating and comprises or consists of a thermoplastic polymeric material or a thermosetting polymeric material, such as polyolefin, polyester, polyethylene terephthalate (PET), polyhydroxyalkanoate or polylactic acid. • The coating comprises a non-fibrous layer comprising or consisting of a biodegradable thermoplastic polymeric material. • The coating comprises at least 80% by weight, such as at least 90% by weight, of a thermoplastic polymeric material or a thermosetting polymeric material. • The coating comprises at least 20% by weight, or at least 60% by weight, of bio-based materials. • The coating comprises less than 80% by weight, as well as less than 40% by weight of fossil-based materials. • A coating is a functional coating adapted to alter the functional properties of a surface, such as barrier properties, visual properties, functional properties, and / or haptic properties. • The coating, or a portion thereof, is adapted to enhance the barrier properties of the fibrous structure's surface, and the barrier properties include one or more of the following: oil and grease resistance, liquid resistance, water resistance, water vapor resistance, aroma resistance, gas resistance, oxygen resistance, and taste barrier. Petition 870260042878, dated 07 / 05 / 2026, page 9 / 147 5 / 62 • The coating is adapted to alter the hardness, microscopic roughness, macroscopic roughness, friction properties, tactile properties, or color of the fibrous structure surface. • The product has a dry basis weight in the range of 5 to 900 g / m2, for example, in the range of 100 to 800 g / m2, as well as in the range of 200 to 600 g / m2. • The coating has a dry basis weight in the range of 2 to 80 g / m2, for example, 10 to 35 g / m2. • The coating thickness is at least 1 µm, such as in the range of 2 to 50 µm, for example, 5 to 30 µm. • The fibrous structure is substantially free of plastic materials and resin. • The fibrous structure is a multi-layered fibrous structure comprising at least a first fibrous layer and a second fibrous layer, each comprising cellulosic and / or lignocellulosic fibrous material. • The product further comprises, between the first and second fibrous layers, one or more inner fibrous layers, each comprising a cellulosic and / or lignocellulosic fibrous material, preferably comprising mechanical pulp, such as CTMP or BCTMP, and / or waste. • Cellulosic and / or lignocellulosic fibrous material comprises one or more of the following: bleached or unbleached chemical pulp, semi-chemical pulp, mechanical pulp, thermomechanical pulp, chemothermal pulp, bleached chemothermal pulp, recycled cellulosic and / or lignocellulosic fibers, Petition 870260042878, dated 07 / 05 / 2026, page 10 / 147 6 / 62 fibrillated cellulose, such as microfibrillated cellulose or nanofibrillated cellulose, nanocellulose, waste, cellulosic by-products, regenerated cellulosic fibers, and any other cellulosic material comprising cellulosic fibers or parts of cellulosic fibers, originating from any perennial or annual plants. • The fibrous structure comprises at least 50% by weight of a cellulosic and / or lignocellulosic fibrous material, calculated from the total dry matter. • One or more of the fibrous layers or the entire fibrous structure were obtained by foaming, water forming, immersion forming, vacuum forming, pressure forming, thermoforming, or dry forming, or any combination thereof. • A fibrous structure is a three-dimensional molded fibrous structure, obtained using a mold comprising at least one three-dimensional, non-planar mold surface, wherein said fibrous structure exhibits a three-dimensional shape conforming to the shape of said three-dimensional, non-planar mold surface. • The product, or a part thereof, has an overall shape adapted to hold a liquid or fluid material, such as the overall shape of a cup or bowl. • The fibrous structure is a multilayered fibrous structure comprising at least two fibrous layers. • All fibrous layers of the fibrous structure were obtained by a foaming method in a mold. Petition 870260042878, dated 07 / 05 / 2026, page 11 / 147 7 / 62 • The aforementioned dry coating comprises powder coating.

[0013] According to a second aspect of the present invention, the product is provided for use according to the first aspect as packaging or a container for food, such as dairy products, fish or meat, or as packaging for medicines or cosmetics, or as a part thereof.

[0014] According to a third aspect of the present invention, the use of the product according to the first aspect is provided for storing, handling, preparing or cooking food.

[0015] According to a fourth aspect of the present invention, a method is provided comprising: providing at least one fibrous composition comprising cellulosic and / or lignocellulosic fibers and water; in a mold, forming a fibrous structure from said at least one fibrous composition; applying a coating to at least a portion of a fibrous surface of the molded fibrous structure by a dry coating process, such as a powder coating process.

[0016] Several modalities of the fourth aspect may comprise at least one feature from the following bulleted list: • The aforementioned formation stage comprises the formation of a three-dimensional fibrous structure from said at least one fibrous composition using a three-dimensional mold. • The aforementioned powder coating process comprises electrostatically applying a dry powder to the aforementioned Petition 870260042878, dated 07 / 05 / 2026, p. 12 / 147 8 / 62 surface of the fibrous structure, and cure or fuse the applied powder, preferably by heating and / or hot pressing with or without contact, to form a film. • The fibrous structure to be coated has a dry matter content of at least 90%, such as 90 to 96%. • The fibrous structure to be coated has a dry matter content of at least 50%, such as at least 60%, such as at least 70%, for example, 50 to 99%. • The dry powder comprises pigments, binders and additionally one or more additives, which additives may be selected from the following group: resins and fillers, such as barite, silica, carbonates, silicates, aluminum hydroxide, and mixtures thereof. • The aforementioned application involves spraying. • The aforementioned curing or fusion comprises heating with or without contact, hot pressing, IR curing or microwave curing, or any combination thereof, preferably heating with or without contact at a temperature of at least 80 °C, for example, at least 120 °C, such as at least 150 °C. • The aforementioned curing or fusion process involves heating, with or without contact, to a temperature of 80 to 300 °C, for example, 120 to 250 °C. • The aforementioned forming process includes water forming, foam forming, immersion forming, vacuum forming, pressure forming, thermoforming, dry forming, or any combination thereof, preferably foam forming. Petition 870260042878, dated 07 / 05 / 2026, p. 13 / 147 9 / 62 • The method further comprises, after the aforementioned forming stage and before applying the coating: dehydrating the structure; hot pressing the dehydrated structure to obtain the molded three-dimensional fibrous structure, wherein said hot pressing produces a surface that is directly suitable for dry coating, such as powder coating, for example, powder painting. • The fibrous structure to be coated has a dry matter content of at least 60%. • After applying the coating, the coated fibrous structure is hot-pressed, and then hot-pressed a second time. • The density of the fibrous structure to be coated is at least 700 kg / m3. • The fibrous structure is a multilayered fibrous structure comprising at least two fibrous layers. • Each fibrous layer of the fibrous structure is obtained by foaming from a respective fibrous composition in a mold. • The aforementioned dry coating comprises powder coating. Advantages of the Invention

[0017] The present invention can facilitate the preparation of smooth and uniform coating films on fibrous substrates, particularly three-dimensional fibrous substrates. Petition 870260042878, dated 07 / 05 / 2026, p. 14 / 147 10 / 62

[0018] The present invention can facilitate obtaining a sufficiently smooth substrate for the purpose of preparing a successful and smooth coating on the substrate, for example, by means of a dry coating process, such as a spraying process.

[0019] The present invention can provide fibrous products with improved surface properties, such as barrier, optical, visual and / or haptic properties.

[0020] Problems related to insufficient adhesion of the coating film, typically adhesion on a fibrous substrate, can be avoided.

[0021] Furthermore, problems related to heat sealing capacity, such as insufficient adhesion to a fibrous substrate, can be avoided.

[0022] Dry coating, such as powder coating, can provide many benefits compared to wet painting processes. The powder coating composition that has been sprayed onto the object to be painted can be collected and reused, thus reducing waste and costs compared to wet painting processes. After the powder-coated objects have cooled, they can be stacked or packed against each other without any risk of sticking together. A powder coating process is faster than a wet painting process. A powder-coated surface is typically not susceptible to cracking from impact or bending.

[0023] The present invention can facilitate the use of bio-based raw materials in coatings or paints for molded fiber products. Petition 870260042878, dated 07 / 05 / 2026, page 15 / 147 11 / 62

[0024] The present invention may enable the formation of a dry coating film, such as paint, by a variety of methods, such as by contact heating, oven heating, microwave heating or IR (infrared) heating or any combination thereof.

[0025] The present method can avoid problems related to rewetting of the fibrous substrate and, more generally, the need to use water (i.e., water consumption) can be reduced compared with known water-based coating methods.

[0026] In the present method, a separate conversion step may not be necessary, as the coating can be prepared in a step that is integrated into an existing manufacturing line.

[0027] The present method, particularly powder coating, can make it possible to bring functional materials to the surface, such as thermal insulation material.

[0028] The present method may allow the preparation of molded fiber products with a standardized surface.

[0029] The present product may provide one or more of the following: high heat resistance, non-flammability, excellent shape following ability or dimensional stability, strength, functional material transport property, acid resistance, enhanced flexibility, enhanced gas barrier properties, improved water vapor barrier properties or grease and / or water resistance. Petition 870260042878, dated 07 / 05 / 2026, page 16 / 147 12 / 62

[0030] This product may be suitable for indicative packaging or temperature-controlled packaging.

[0031] These structures and products can be used in packaging, serving, storing and preparing any products containing oil and / or containing water, such as food, medicines or cosmetics. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 schematically illustrates a coated fibrous structure according to at least some embodiments of the present invention. MODALITIES

[0033] Unless otherwise indicated or clear from the context, any percentages referred to herein are expressed as a percentage by weight based on the total dry weight of the respective composition.

[0034] The dry matter content of a composition is typically expressed as a percentage by weight based on the total weight of the composition.

[0035] In the present context, “dry coating” typically refers to any suitable coating method in which a coating material is applied or deposited in a dry state, for example, as dry particles or dry powder or dry paint, onto a surface.

[0036] In the present context, “powder coating” normally refers to a coating method in which a substantially dry powder or dry paint is applied or deposited onto a surface, usually by means of an electrostatic coating method. Petition 870260042878, dated 07 / 05 / 2026, p. 17 / 147 13 / 62

[0037] In the present context, a coating” refers to a coating that may consist of one or more coating layers, which may have been formed in the same coating process or in different coating processes.

[0038] In the present context, “resistant,” such as water-resistant, means that the material or layer resists penetration by the substance in question. In a preferred embodiment, the material or layer exhibits “repellentness,” such as water repellency, meaning that the substance in question cannot easily penetrate the material or layer. In a more preferred embodiment, the material or layer exhibits “impermeability,” such as impermeability, meaning that the substance in question cannot penetrate the material or layer during typical use of a product comprising said material or layer. In other words, the resistance to penetration of the substance in question increases in the order “resistant” < “repellent” < “proof.”

[0039] Also in the present context, any reference to “resistant” means at least resistant”, that is, the material or layer may also exhibit repellency and even impermeability.

[0040] The present invention provides novel molded and coated fibrous products. At least part of the product can be manufactured by a foam-based process. Foam formation advantageously allows the preparation of multi-layered molded structures and the adaptation of the properties of the individual layers.

[0041] According to the present invention, the product comprises: a fibrous structure comprising a material Petition 870260042878, dated 07 / 05 / 2026, page 18 / 147 14 / 62 fibrous cellulosic and / or lignocellulosic material obtained by a molding process; and a coating, such as at least one coating layer, on at least one surface of the fibrous structure, wherein the coating was obtained by a dry coating process, preferably by a powder coating process.

[0042] The coating may consist of a single coating layer or alternatively the coating may comprise multiple coating layers, such as 2 to 10 coating layers on top of each other.

[0043] The coating may form an exposed upper surface or layer or a more exposed lower surface or layer of the product.

[0044] The coating can form a non-fibrous top or bottom layer, typically exposed, of the product.

[0045] The product may comprise at least two coatings that are located on different surfaces of the fibrous structure, such as on opposite sides of a flat fibrous structure or on different sides of a three-dimensional structure. Each of the coatings may consist of one or more coating layers.

[0046] The product may comprise at least two coating layers that are located on different surfaces of the fibrous structure, such as on opposite sides of a flat fibrous structure or on different sides of a three-dimensional structure.

[0047] The product may also comprise a non-fibrous or fibrous intermediate layer, for example, a layer Petition 870260042878, dated 07 / 05 / 2026, page 19 / 147 15 / 62 of primer or a flame pre-treatment layer, between said coating and the fibrous structure.

[0048] In one embodiment, the product may comprise a surface refinement layer between said coating and the fibrous structure.

[0049] The primer layer can be prepared by nanotechnology or microstructuring technology. For example, the primer layer can comprise microfibrillated cellulose (MFC) or nanofibrillated cellulose (NFC).

[0050] The product may comprise an additional coating in addition to the coating according to the present invention. Although the present coating is prepared by a dry coating process, any additional coating may be prepared by any means, for example, by a wet coating process. The additional coating may be located below or alternatively above the present coating that was prepared by a dry coating process.

[0051] In one embodiment, a coating layer was applied to a curved or non-horizontal surface of the fibrous structure.

[0052] The coating or part thereof may comprise a thermoplastic polymeric material or a thermosetting polymeric material.

[0053] Typically, the coating is a non-fibrous layer and comprises or consists of a thermoplastic polymeric material or a thermoset polymeric material, such as polyolefin, polyester, copolyester elastomer, polyethylene terephthalate (PET), nylon, polyhydroxyalkanoate or polyethylene terephthalate. Petition 870260042878, dated 07 / 05 / 2026, p. 20 / 147 16 / 62 polylactic acid (PLA). The polyolefin may comprise polyethylene and / or polypropylene.

[0054] In some embodiments, the coating is a non-fibrous layer and comprises or consists of a biodegradable thermoplastic polymeric material.

[0055] In some embodiments, the coating is a non-fibrous layer and comprises or consists of a bio-based or non-fossil-based thermoplastic polymeric material.

[0056] In one embodiment, the coating layer comprises at least 50% by weight, such as at least 80% by weight, such as at least 90% by weight of a thermoplastic polymeric material or a thermosetting polymeric material.

[0057] The coating may comprise a functional layer adapted to alter functional properties of the surface, such as barrier properties, optical properties, visual properties and / or haptic properties.

[0058] The coating can be adapted to increase the barrier properties of the fibrous structure surface. Barrier properties may include one or more of the following: oil and grease resistance, liquid resistance, water resistance, water vapor resistance, aroma resistance, gas resistance, oxygen resistance, taste barrier.

[0059] For example, the coating can be adapted to alter the hardness, microscopic roughness, macroscopic roughness, or frictional properties of the fibrous structure surface.

[0060] In some applications, coating can be used to bring visual and / or tactile effects to Petition 870260042878, dated 07 / 05 / 2026, page 21 / 147 17 / 62 surface, such as color, metallization effects, color swirls, waves, droplet-like elevations, crater-like cavities, stripes of varying transparency, or 3D effects, for example, for anti-counterfeiting and security purposes.

[0061] In some embodiments, the coating provides surface properties such as artificial leather skin surface, non-slip surface or embossed effects.

[0062] In other embodiments, the coating may provide a tactile finish layer, or a layer whose color can be altered by electrical or other physical impulses, or a layer that provides a visual impression of reflectivity or depth.

[0063] The product may have a dry basis weight in the range of 5 to 900 g / m2, for example, in the range of 100 to 800 g / m2, as well as in the range of 200 to 600 g / m2.

[0064] The coating can have a dry basis weight in the range of 2 to 80 g / m2, as well as in the range of 2 to 35 g / m2, for example, in the range of 10 to 30 g / m2.

[0065] In one embodiment, the coating thickness is at least 1 pm, such as in the range of 2 to 20 pm, for example, 5 to 10 pm.

[0066] The structure of the fibrous structure according to some modalities is discussed below.

[0067] Preferably, the fibrous structure comprises at least 30% by weight, for example, at least 50% by weight, such as 50 to 95% by weight of a cellulosic and / or lignocellulosic fibrous material, calculated from the total dry matter. Petition 870260042878, dated 07 / 05 / 2026, page 22 / 147 18 / 62

[0068] Preferably, the fibrous structure is substantially free of plastic and resin materials.

[0069] The fibrous structure can be a single-layered fibrous structure.

[0070] Alternatively, the fibrous structure may be a multilayered fibrous structure. The multilayered fibrous structure may comprise at least two fibrous layers, for example, a first fibrous layer and a second fibrous layer, each comprising a cellulosic and / or lignocellulosic fibrous material.

[0071] The product may also comprise, between the first and second fibrous layers, one or more inner fibrous layers, each comprising a cellulosic and / or lignocellulosic fibrous material.

[0072] The fibrous compositions of the layers may differ from each other or alternatively be the same.

[0073] The fibrous structure to be coated, or the layer of the fibrous structure to be coated, may comprise additives, such as pigments and / or fillers, which are adapted to facilitate the dry coating process. For example, said additives may increase the moisture content, softness and / or surface energy of the structure or layer to be coated. The fibrous layer containing additives may have a base weight in the range of 30 to 600 g / m2, such as 30 to 400 g / m2.

[0074] Having a multi-layered fibrous structure can make it easier to adapt the compressibility of the structure, which can be advantageous in view of the dry coating process. Petition 870260042878, dated 07 / 05 / 2026, p. 23 / 147 19 / 62

[0075] Cellulosic and / or lignocellulosic fibrous material may comprise one or more of the following: chemical wood pulp, semi-chemical wood pulp, mechanical wood pulp, thermomechanical wood pulp, chemothermomechanical wood pulp, bleached chemothermomechanical pulp, bleached semichemical pulp, ground wood pulp, pressure-ground wood pulp, stone-ground wood pulp, recycled cellulosic and / or lignocellulosic fibers, fibrillated cellulose, such as microfibrillated cellulose or nanofibrillated cellulose, nanocellulose, waste, cellulosic by-products, regenerated cellulosic fibers and any other cellulosic and / or lignocellulosic material comprising cellulosic fibers or parts of cellulosic fibers.

[0076] The pulp may be bleached or unbleached or a mixture of both.

[0077] The pulp can be refined or unrefined or a mixture of both.

[0078] Chemical pulp can be derived from any chemical pulping process, such as sulfate process, sulfite process or organosolv process.

[0079] Chemical pulp may include bleached chemical pulp.

[0080] Mechanical pulp can be from any mechanical pulping process, such as mechanical pulp, thermomechanical pulp (TMP), chemothermomechanical pulp (CTMP), bleached chemothermomechanical pulp (BCTMP), semi-chemical pulp, ground pulp (GW), pressure milled pulp (PGW), stone milled wood pulp (SGW) and combinations thereof.

[0081] Scrap may include scrap waste. Petition 870260042878, dated 07 / 05 / 2026, page 24 / 147 20 / 62

[0082] Cellulosic and / or lignocellulosic fibrous material may comprise non-wood pulp.

[0083] In one embodiment, the pulp may be made from any broadleaf tree, such as a tree of the Betulaceae family, for example, birch or aspen, of the Salicaceae family, eucalyptus, mixed tropical wood or pine, or any combination thereof. The pulp may also be made from any conifer, such as fir or pine, or any combination thereof. The pulp may also be made from a combination of broadleaf and coniferous trees.

[0084] In one embodiment, the pulp can be made from any annual plant, such as straw, rush, canary grass, bamboo, sugar cane, bagasse, or any grass plant.

[0085] In one embodiment, the cellulosic and / or lignocellulosic fibrous material of the fibrous structure or a part thereof comprises bleached hardwood chemical pulp and bleached chemothermal processing pulp, such as 10 to 50% by weight of bleached hardwood chemical pulp and 50 to 90% by weight of bleached chemothermal processing pulp, of total dry matter.

[0086] Typically, one or more surface layers of the product may comprise chemical pulp, such as bleached chemical pulp, for example, bleached hardwood chemical pulp, for example, bleached birch chemical pulp.

[0087] In one embodiment, one or more of the inner fibrous layers may comprise or consist of mechanical pulp, such as chemimechanical pulp (CTMP) or bleached chemimechanical pulp (BCTMP), and / or waste, for Petition 870260042878, dated 07 / 05 / 2026, page 25 / 147 21 / 62 example, 60 to 95% by weight of BCTMP and 5 to 40% by weight of waste, of the total dry matter.

[0088] In one embodiment, one or more of the inner fibrous layers may comprise or consist of mechanical pulp, such as chemimechanical pulp (CTMP) or bleached chemimechanical pulp (BCTMP). Preferably, said inner fibrous layers are substantially free of waste.

[0089] In some embodiments, the fibrous cellulosic and / or lignocellulosic material comprises virgin wood pulp, such as virgin bleached chemical pulp that is substantially free of lignin, which may make the product particularly suitable for cooking, heating and safe contact with food.

[0090] One advantage of virgin pulp is that it is free of residual ink and other unwanted chemicals. Recycled waste often contains chemical and microbiological contaminants, which can affect its safe use. Mixtures of chemical compounds and microbial products can leach from recycled materials and cause a variety of negative impacts on health or the environment. Not only the harmfulness of individual chemical compounds, but also their interactions with other chemical compounds and microbial products can increase the toxicity of recycled materials and their emissions. Therefore, the present invention preferentially avoids the use of recycled materials.

[0091] One advantage of chemical pulp, such as bleached chemical pulp, is that it is substantially free Petition 870260042878, dated 07 / 05 / 2026, page 26 / 147 22 / 62 of lignin. Pulps containing lignin may be susceptible to aging and yellowing of the material.

[0092] In some embodiments, the fibrous cellulosic and / or lignocellulosic material comprises lignin, for example, in the form of lignocellulosic fibrous material, such as bleached or unbleached mechanical pulp. The present invention may benefit from the presence of lignin in the fibrous structure. As there is a coating layer above the fibrous structure, any fibrous material or layer containing lignin is separated from the environment, for example, from the food contents in a package.

[0093] In one embodiment, the fibrous cellulosic and / or lignocellulosic material of the fibrous structure or a part thereof comprises or consists of bleached softwood chemical pulp.

[0094] In one embodiment, the cellulosic and / or lignocellulosic fibrous material of the fibrous structure or a part thereof comprises or consists of bleached hardwood chemical pulp.

[0095] In one embodiment, the fibrous cellulosic and / or lignocellulosic material of the fibrous structure or a part thereof comprises or consists of a mixture of bleached softwood chemical pulp and bleached hardwood chemical pulp.

[0096] With regard to the manufacture of a molded fibrous structure or a part thereof, any suitable molding method may be applied, such as injection molding, vacuum molding, compression molding, transfer molding, extrusion molding, blow molding, dip molding, rotational molding, Petition 870260042878, dated 07 / 05 / 2026, page 27 / 147 23 / 62 foam molding, lamination, deep drawing, thermoforming, pressure molding, hydroforming, suction molding, closed mold forming, open mold forming, dry forming or foam forming, or any combination thereof.

[0097] In the present context, the terms “molding” and “formation” can be used interchangeably.

[0098] The molding method may be supplemented by additional processes, such as various forming processes, for example, in-mold drying, cold and hot pressing, calibration pressing, bending or shearing, or machining processes, for example, turning, drilling, shaping, sharpening, hot sealing, printing or finishing, or cutting, or any combination thereof.

[0099] In a preferred embodiment, one or more of the fibrous layers of the fibrous structure, or the entire fibrous structure, were obtained by foaming or water forming or wet forming in a mold, preferably by foaming in a mold.

[0100] Preferably, all fibrous layers of the product were obtained by foaming in a mold.

[0101] The fibrous structure may be a three-dimensional molded fibrous structure, obtained using a mold comprising at least one three-dimensional and non-planar mold surface. In this case, the fibrous structure exhibits a three-dimensional shape conforming to the shape of said three-dimensional and non-planar mold surface.

[0102] The product or a part thereof may have a general shape adapted to hold a liquid or fluid material, such as the general shape of a cup or a bowl. Petition 870260042878, dated 07 / 05 / 2026, page 28 / 147 24 / 62

[0103] In one embodiment, the OGR of the product's oil and grease resistance is measured by ASTM F119, with olive oil at 60 °C, and is at the 'moderate' level or better, such as more than 10 min, typically 10 min to 6 h, in one example more than 3 h.

[0104] In one embodiment, the OGR of the product's oil and grease resistance is measured by ASTM F119, with olive oil at 60 °C, and is at the 'medium' level or better, such as more than 6 h, typically 6 to 72 h, in one example more than three days.

[0105] In one embodiment, the moisture resistance of the product is measured by ISO 2528 and ASTM E96, under standard conditions of 23 °C and 50 % RH, and is at the 'moderate' level or better, such as less than 250 g / m2 / d, typically 100 to 250 g / m2 / d, in one example, less than 150 g / m2 / d.

[0106] In one embodiment, the moisture resistance of the product is measured by ISO 2528 and ASTM E96, under standard conditions of 23 °C and 50 % RH, and the water vapor transmission rate is at the 'good' level or better, such as less than 100 g / m2 / d, typically 10 to 50 g / m2 / d, in one example, less than 30 g / m2 / d.

[0107] The present invention may enable the achievement of good gas barrier properties, for example, suitable for packaging chilled foods. In one embodiment, the oxygen transmission rate of the product is measured by ASTM D-3985, under standard conditions of 23 °C and 50% RH, and is at the 'good' level or better, such as less than 100 cm3 / m2 / d, typically in the range of 50 to 100 cm3 / m2 / d, or less than 50 cm3 / m2 / d. Petition 870260042878, dated 07 / 05 / 2026, p. 29 / 147 25 / 62

[0108] Chilled foods typically require a high oxygen barrier, such as 40 to 60 cm3 / m2 / d. Chilled foods usually require a water vapor barrier of 1 to 1.5 g / m2 / d.

[0109] In one embodiment, water absorption on the coated side or on the surface of the product is measured by ISO 535, Cobb value after 5 min, and is at the 'moderate' level or better, such as less than 100 g / m2, typically 50 to 100 g / m2, in one example, less than 75 g / m2.

[0110] In one embodiment, the water absorption on the coated side or on the surface of the product is measured by ISO 535, Cobb value after 5 min, and is at the 'medium' level or better, such as less than 50 g / m2, typically 5 to 50 g / m2, in one example, less than 15 g / m2.

[0111] Preferably, the density of the fibrous structure to be coated is in the range of 300 to 1000 kg / m3, such as 350 to 800 kg / m3, for example, 450 to 700 kg / m3, such as greater than 500 kg / m3, calculated as the weight of dry solids per volume.

[0112] In one embodiment, the density of the fibrous structure to be coated is in the range of 700 to 1000 kg / m3, such as 750 to 950 kg / m3, for example, 775 to 900 kg / m3, such as greater than 800 kg / m3, calculated as weight of dry solids per volume.

[0113] In some embodiments, the density of the fibrous structure may be relatively low, such as less than 500 kg / m3, as the presence of a powder-coated layer may provide a dense, closed structure or surface layer above the fibrous structure. Petition 870260042878, dated 07 / 05 / 2026, p. 30 / 147 26 / 62

[0114] In some embodiments, the density of the fibrous structure may be less than 800 kg / m3, as well as less than 700 kg / m3, as well as less than 600 kg / m3.

[0115] Preferably, the smoothness of the surface of the fibrous structure to be coated is in the range of 50 to 3000 ml / min, such as 100 to 1000 ml / min, for example, 150 to 600 ml / min, measured by the ISO 8791-2 Bendtsen method. An advantage of having a smooth surface is that powder coating, for example by a spraying method, is facilitated.

[0116] In one embodiment, the surface smoothness of the fibrous structure to be coated is in the range of 10 to 1000 ml / min, such as 20 to 500 ml / min, for example, 50 to 250 ml / min, measured by the ISO 8791-2 Bendtsen method. Preferably, the surface smoothness of the fibrous structure to be coated is less than 400 ml / min. An advantage of having a smooth surface is that powder coating, for example by a spraying method, is facilitated.

[0117] The fibrous structure to be coated or a part thereof, such as a fibrous layer of the fibrous structure, may comprise one or more additives or additive chemicals. In one embodiment, at least one surface layer to be coated or a part of the surface to be coated of the fibrous structure comprises one or more additive chemicals.

[0118] The fibrous structure to be coated or a part thereof, such as a fibrous layer of the fibrous structure, may comprise one or more of the following additives: pigments, such as talc, clay, calcium carbonate, and metallic salt pigments, for example, aluminum trihydrate, gypsum, silicates, silica compounds, and dioxide Petition 870260042878, dated 07 / 05 / 2026, p. 31 / 147 27 / 62 titanium; barrier agents; latex binders; water-soluble binders such as PVA (polyvinyl alcohol), starch and CMC (carboxymethylcellulose); adhesives such as AKD (alkyl ketene dimer or alkenyl ketene dimer), ASA (alkenyl succinic anhydride) and resins; reinforcing agents such as CMC, MFC (microfibrillated cellulose) and NFC (nanofibrillated cellulose).

[0119] In one embodiment, the additives comprise reinforcing agents, such as CMC (carboxymethylcellulose), MFC (microfibrillated cellulose), NFC (nanofibrillated cellulose) or any combination thereof.

[0120] In one embodiment, the additives comprise additives, such as pigments, that are capable of increasing the smoothness of the surface to be coated.

[0121] In one embodiment, the surface to be coated is made more hydrophobic by incorporating suitable additives, such as hydrophobizing agents, into the fibrous structure or a surface thereof, such as surface sizing agents, for example, alkyl ketene dimer (AKD) and / or starch.

[0122] In one embodiment, the surface to be coated is made more hydrophilic by incorporating suitable additives, such as hydrophilizing agents, into the fibrous structure or a surface thereof.

[0123] The amount of additives may be in the range of 0.01 to 30% by weight, such as 0.01 to 10% by weight, such as 0.1 to 8% by weight, for example, 1 to 5% by weight, calculated from the total dry matter. Petition 870260042878, dated 07 / 05 / 2026, p. 32 / 147 28 / 62

[0124] In one embodiment, the amount of additives may be in the range of 0.01 to 40% by weight, calculated from the total dry matter.

[0125] Additives or chemicals may be added to the fibrous mixture or slurry before the forming stage, preferably the foaming stage, in a consistency of, for example, 0.5 to 15%, such as 0.8 to 10%, such as 2 to 10%, or alternatively, before forming, preferably before foaming, for example, to the foam to be mixed with the fibrous slurry.

[0126] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of talc.

[0127] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of clay.

[0128] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of calcium carbonate.

[0129] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises barrier agents selected from the following group: dispersion polymers, polyolefins, polyesters, other thermoplastic polymers, biodegradable polymers such as polylactic acid, starch and its derivatives, plastomers, elastomers, ethylene vinyl alcohol and any derivatives thereof, copolymers and mixtures thereof.

[0130] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 10% by weight, such as 0.1 to 5% by weight of barrier agents, Petition 870260042878, dated 07 / 05 / 2026, page 33 / 147 29 / 62 such as dispersion polymer barrier agents. Such barrier agents typically provide barrier properties throughout the fibrous structure or fibrous layer.

[0131] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of polymeric latex binders, such as styrene butadiene latex, styrene acrylate latex, polyvinyl acetate latex.

[0132] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of polyvinyl alcohol (PVA).

[0133] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 20% by weight, such as 0.1 to 5% by weight of starch.

[0134] Starch can be native, cooked, or swollen cationic starch.

[0135] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 5% by weight of carboxymethyl cellulose (CMC).

[0136] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 20% by weight of mineral fillers.

[0137] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 20% by weight of pigments, of total dry matter. Preferably, a surface layer or part of the surface to be coated comprises 0.1 to 20% by weight of pigments.

[0138] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises 0.1 to 20 Petition 870260042878, dated 07 / 05 / 2026, page 34 / 147 30 / 62% by weight of reinforcing additives, such as microcrystalline cellulose (MCC), nanocellulose or other reinforcing cellulose.

[0139] In one embodiment, the fibrous structure or at least one of its fibrous layers comprises reinforcing additives, such as microfibrillated cellulose (MFC), nanofibrillated cellulose (NFC) or other reinforcing cellulose or any combination thereof.

[0140] In one embodiment, the amount of reinforcing additives is 0.1 to 20% by weight.

[0141] Preferably, the fibrous structure or at least one of its fibrous layers comprises less than 10% by weight, such as less than 5% by weight, such as less than 2% by weight of waxes, plastics and fluorinated chemicals. In one embodiment, the fibrous structure or at least one of its fibrous layers comprises less than 2% by weight of waxes. In one embodiment, the fibrous structure or at least one of its fibrous layers comprises less than 2% by weight, such as less than 1% by weight of plastics. In one embodiment, the fibrous structure or at least one of its fibrous layers comprises less than 2% by weight, such as less than 1% by weight of fluorinated chemicals.

[0142] In some embodiments, the product is substantially free of waxes, plastics and fluorinated chemicals, particularly plastics.

[0143] For products intended for applications in food packaging, additives and foaming chemicals may be selected from all additives that are approved for use in food packaging or contact materials. By 'contact materials with Petition 870260042878, dated 07 / 05 / 2026, page 35 / 147 31 / 62 'food' refers to all materials and articles intended to come into contact with food, such as packaging and containers.

[0144] The amount of barrier additive in the fibrous structure or in a part thereof may be in the range of 1 to 10% by weight, such as 5 to 8% by weight, calculated from the total dry weight of the fibrous layer.

[0145] In some embodiments, the coating or a portion thereof may impart barrier properties of the first type, and the fibrous structure beneath it may impart barrier properties of the second type that differ from the first type of barrier properties. For example, the coating or a portion thereof may impart barrier properties to water, and the fibrous structure may impart barrier properties to oil and / or grease.

[0146] In some embodiments, the coating or a part thereof may improve barrier properties, such as barrier properties against oil and / or grease which are provided by the fibrous structure beneath it.

[0147] If the product comprises an additional coating below or above the coating that was prepared by a dry coating process, said additional coating may also impart barrier properties. For example, the coating prepared by a dry coating process may impart oxygen barrier properties, while an additional coating prepared by a wet coating process may impart different barrier properties, such as water barrier properties. Petition 870260042878, dated 07 / 05 / 2026, page 36 / 147 32 / 62

[0148] The present coated structure can be used on materials and articles in contact with food.

[0149] In one embodiment, the present product complies with Regulation (EC) No 1935 / 2004.

[0150] In addition to or instead of uses in contact with food, many other areas of application can be foreseen for the present structures and products.

[0151] In one embodiment, at least one of the fibrous layers comprises an adhesive, such as modified rosins, waxes, oils, or polymers. An advantage of using an adhesive is that the unwanted absorption of liquid and / or water and / or moisture into the foam-formed structure can be reduced. Thus, the moisture or water resistance of the product is improved.

[0152] An example of a wax is alkyl ketene dimer (AKD). An example of an oil is alkenyl succinic anhydride (ASA). An example of a polymer glue is styrene acrylate emulsion (SAE).

[0153] A preferred glue is AKD or a similar wax.

[0154] The adhesives applicable in some embodiments of the present invention may be a cationic surface adhesive or an anionic surface adhesive, such as a rosin-based adhesive. In addition to or as an alternative to these, some reactive adhesives, such as alkyl ketene dimer (AKD), may be used as a surface adhesive.

[0155] Suitable cationic adhesives include cationic starches and starch derivatives, as well as corresponding natural carbohydrate-based polymers. Of synthetic polymers, for example, styrene / acrylate copolymers. Petition 870260042878, dated 07 / 05 / 2026, page 37 / 147 33 / 62 (SA), polyvinyl alcohols, polyurethanes and alkylated urethanes can be used.

[0156] Suitable anionic glues may include anionic starches and starch derivatives and corresponding natural carbohydrate-based polymers, such as carboxymethylcellulose and its salts, alkylcelluloses, such as methylcellulose and ethylcellulose. Synthetic polymers may include: styrene / maleic acid copolymer (SMA), diisobutylene / maleic anhydride, styrene acrylate copolymers, acrylonitrile / acrylate copolymers and polyurethanes and similar latex products containing the same chemical functionalities.

[0157] In one embodiment, the glue comprises alkyl ketene dimer (AKD).

[0158] In one embodiment, additives such as pigments, binders, and glues are compatible with products that can be baked in the oven.

[0159] In some embodiments, the product or fibrous structure may comprise only a fibrous layer.

[0160] In some embodiments, the product may comprise from 1 to 20 fibrous layers, such as at least two fibrous layers, such as at least three fibrous layers.

[0161] In some embodiments, the product comprises an intermediate layer, such as a pre-coating layer, between the coating and the fibrous structure.

[0162] The intermediate layer may comprise or consist of MFC, PVA, CMC, starch, talc or combinations thereof. Petition 870260042878, dated 07 / 05 / 2026, p. 38 / 147 34 / 62

[0163] One advantage of using an intermediate layer between the coating and the fibrous structure is that the adhesion and functionality of the coating can be improved.

[0164] The present method makes it possible to obtain a smooth surface on the fibrous structure to be coated, which facilitates the application or fixing of the coating, particularly a powder-coated layer on the fibrous structure.

[0165] The coating and optional intermediate layers are all typically applied after the forming stage, preferably after the hot pressing stage.

[0166] One or more intermediate layers can be prepared before a hot pressing step, for example, already in a forming or molding step.

[0167] In one embodiment, the coating is applied before any hot pressing or between two stages of hot pressing. Thus, during hot pressing, the coating layer forms a film, typically a smooth and continuous film, as a result of the applied heat. Thus, the heat melts the powder coating and converts it into a film. In this way, it may be possible to prepare embossed or other textured structures for the exposed surface of the coating, which normally forms the outermost surface of the product.

[0168] The hot pressing stage, which may comprise at least two hot pressing stages, can provide a smooth external surface to the final product. Petition 870260042878, dated 07 / 05 / 2026, page 39 / 147 35 / 62 Ideally, all exterior or exposed surfaces of the final product should be made smooth.

[0169] For example, a first hot pressing step can remove water that originates from the forming step, and a subsequent second hot pressing step can produce a film structure from the applied powder coating.

[0170] Figure 1 schematically illustrates a coated fibrous structure according to at least some embodiments of the present invention. The structure comprises a first fibrous layer 1, a second fibrous layer 2, and an inner fibrous layer 3 between the first fibrous layer 1 and the second fibrous layer 2. Additionally, the structure comprises, on top of the first fibrous layer, an intermediate layer 4, and a coating 5. In other embodiments, the intermediate layer 4 may be absent. In some embodiments, the structure may comprise a second coating (not shown) on the opposite side of the fibrous layers, under the second fibrous layer 2. An intermediate layer may be applied between such a second coating and the second fibrous layer 2 in a similar manner as between the (first) coating 5 and the first fibrous layer 1.

[0171] In another embodiment, the product comprises only a fibrous layer, such as the first fibrous layer 1, a coating 5, and optionally an intermediate layer 4.

[0172] In yet another modality, the product does not include any intermediate layer. Petition 870260042878, dated 07 / 05 / 2026, page 40 / 147 36 / 62

[0173] In some embodiments, the product does not comprise internal fibrous layers. In other embodiments, the product comprises one, two, or three internal fibrous layers between the first fibrous layer 1 and the second fibrous layer 2.

[0174] The multilayered fibrous structure is preferably obtained in such a way that all the fibers to be included in the final structure, typically the fibrous structure to be coated, go through a foaming process.

[0175] The advantage of foaming is that a lighter and more voluminous product can be prepared. In addition, a more homogeneous formation can be achieved. The use of foam allows for the easy preparation of multi-layered fibrous structures in a batch process, i.e., all fibrous layers can be formed in the same mold to form a multi-layered stack in the mold, which is then hot-pressed.

[0176] One advantage of dehydrating the entire multi-layered fibrous structure in the same mold is that the bonding between layers can also be improved during dehydration compared to dehydrating the layers individually.

[0177] In some embodiments, in addition to layers formed by foam, the final product may also comprise layers formed by water as part of the fibrous structure. Such water-based layer or layers may be formed in a separate process and combined with the foam layer or with the multi-layered foam structure formed by hot pressing. One advantage of the formation Petition 870260042878, dated 07 / 05 / 2026, page 41 / 147 37 / 62 of water is that the preparation of flat or planar structures is easy. In water forming methods, the individual fibrous layers are typically formed and removed from the mold independently of each other. Separate molds can be used. After being removed from the mold(s), the fibrous layers can be stacked and joined to each other and / or to other layers by hot pressing.

[0178] In one embodiment, the fibrous structure comprises several fibrous layers that have been prepared by water-forming processes and combined with each other and optionally additionally with at least one fibrous layer formed by foam, to form the fibrous structure to be coated.

[0179] In some forms, the fibrous structure can be formed solely by water-forming methods.

[0180] In one embodiment, the fibrous structure comprises one or more internal fibrous layers that have been prepared by a foaming process.

[0181] In one embodiment, the entire fibrous structure was prepared by a foam-forming process.

[0182] Preferably, the fibrous structure is a multi-layered three-dimensional molded fibrous structure, obtained using a mold comprising at least one non-planar three-dimensional mold surface, wherein said fibrous structure exhibits a three-dimensional shape conforming to the shape of said non-planar three-dimensional mold surface.

[0183] For example, the product may be shaped like a cup, a plate, a bowl, a pan, a ladle or a tray. Petition 870260042878, dated 07 / 05 / 2026, page 42 / 147 38 / 62

[0184] Typically, the product is packaging or a container for food or liquids or a product for serving food or liquids, such as a drinking glass or a food tray or plate.

[0185] The product can be used to package, store, cook and / or heat food, liquids or beverages. Examples include frozen food packaging intended to be heated, yogurt containers and trays for fresh meat or fish.

[0186] For example, the product can be used for packaging various industrial products, such as food products, for packaging trays for cold cuts of meat, fish, cheese and other sliced ​​foods, for storage and transport of items such as food, beverages, medicines, cosmetics and materials sensitive to moisture and oxygen.

[0187] In some embodiments, the product can be used as a heat-resistant cushioning material or a heat-resistant shielding material.

[0188] More generally, the product can be used to package and store any products containing oil and / or containing water.

[0189] In one example, the product is packaging for cosmetics.

[0190] In one example, the product is packaging for medicines.

[0191] The product can be used as packaging for food or liquids or as a product for serving food or liquids or as a bakery product or as part of it. Petition 870260042878, dated 07 / 05 / 2026, page 43 / 147 39 / 62

[0192] Next, we describe the fabrication of a dry coated fibrous structure according to some embodiments.

[0193] The method comprises providing at least one fibrous composition comprising cellulosic and / or lignocellulosic fibers and water. In a mold, a fibrous structure is formed from said at least one fibrous composition. After that, a coating layer is applied to at least part of a surface of the molded fibrous structure. Said coating layer is applied by a dry coating process, such as a powder coating process.

[0194] Preferably, the said formation step comprises the formation of a three-dimensional fibrous structure from said at least one fibrous composition using a three-dimensional mold.

[0195] The said powder coating process may comprise the electrostatic application of a dry composition, for example, a dry powder, such as a powder paint, onto said surface of the fibrous structure, and curing or melting or film formation of the applied powder, preferably by heating.

[0196] The application of the dry composition, such as a thermoplastic powder coating composition, can be carried out using an electrostatic spraying device or by any other suitable means or method, for example, by fluidized bed coating or using a mini-coating machine. Petition 870260042878, dated 07 / 05 / 2026, page 44 / 147 40 / 62

[0197] The dry composition, such as a powder paint, may comprise particles that typically have an average particle size in the range of 2 to 50 µm.

[0198] In some embodiments, the powder coating has a softening temperature Tg in the range of 70 to 90 °C, a melting temperature in the range of 120 to 180 °C, and is typically cured at a temperature of 180 to 220 °C.

[0199] In some embodiments, the dry composition, such as a powder coating, is cured at a temperature of 180 to 240 °C.

[0200] Advantageously, the coating comprises a thermoplastic powder coating, which may require only sufficient heat and time to fuse the powder into a smooth, continuous film.

[0201] Properties such as adhesion, coating lubricity, coating flexibility and elongation, and many more can be optimized for a given application. For thermoplastic coatings, the powder can exhibit these properties inherently without the need for additional curing or crosslinking once applied to an object or surface.

[0202] In one embodiment, the fibrous structure to be coated has a dry matter content of at least 60%, such as at least 70%, for example, 60 to 80%.

[0203] In one embodiment, the fibrous structure to be coated has a dry matter content of at least 60%, such as 60 to 95%.

[0204] In one embodiment, at least part of a surface to be coated is substantially dry. For example, the top layer of the fibrous structure a Petition 870260042878, dated 07 / 05 / 2026, p. 45 / 147 41 / 62 to be coated may be substantially dry, such as heat-dried.

[0205] The dry powder to be applied to the said surface may comprise pigments and additionally one or more additives, which may be selected from the following groups: resins, binders, and fillers, such as barite, silica, carbonates, silicates, aluminum hydroxide, latex, nylon, polyethylene, polyester, polypropylene and polyvinyl chloride, and mixtures thereof.

[0206] In one embodiment, the coating layer is generated on said surface by spraying. The present invention may allow the application of a powder coating by direct spraying onto a vertical or curved surface.

[0207] In some embodiments, the fibrous structure to be coated is placed in the vicinity of, or on, an article made of a metallic material, such as a sheet of metal foil, during the application of the coating layer. In this way, the fibrous structure obtains sufficient electrical charge.

[0208] Other means of generating the coating layer may be used, such as preparing a coating film separately by a powder coating method and then fixing or pressing the ready coating film onto a desired surface of the molded fibrous structure.

[0209] Curing or melting or preparing the film may comprise heating with or without contact, hot pressing, IR curing or microwave curing or any combination thereof, preferably heating to a Petition 870260042878, dated 07 / 05 / 2026, page 46 / 147 42 / 62 temperature of at least 120 °C, for example, at least 150 °C.

[0210] In one example, the film preparation step comprises a first step of melting the applied dry composition, such as dry powder paint or dry particles, by IR melting and a second subsequent step of curing or final preparation of the film by one or more hot pressing steps.

[0211] Preferably, the film preparation step includes or consists of contact heating, such as hot pressing.

[0212] In one embodiment, the aforementioned film preparation step, such as contact heating, may have a total duration of less than 2 min, such as less than 1 min, optionally divided into several steps.

[0213] Pressure can be applied in the curing or melting or film preparation stages, for example, in one or more hot pressing stages.

[0214] During the film preparation stage, such as a hot pressing stage, heat can be applied to the coating layer from one or both sides of the coating. For example, heat can be applied from below, through the fibrous structure, or alternatively from above the coating. Different heating profiles can be applied to each side of the coating.

[0215] In hot pressing, the temperature is typically higher than ambient temperature, for example, at least 50 °C, such as at least 100 °C, for example, in the range of 150 to 240 °C, typically on at least one side of the structure to be hot pressed. Petition 870260042878, dated 07 / 05 / 2026, p. 47 / 147 43 / 62

[0216] For example, the temperature applied above the coating can be at least 200 °C.

[0217] For example, the temperature that is applied below the coating, through the fibrous structure, can be less than 100 °C.

[0218] In hot pressing, increased pressure can be applied.

[0219] Alternatively or additionally, in hot pressing, a subatmospheric pressure may be applied, for example, a pressure of 60 kPa or less.

[0220] Hot pressing may comprise two or more successive hot pressing stages. Said hot pressing may have a total duration of less than 2 minutes, such as less than 30 seconds, such as less than 20 seconds.

[0221] During hot pressing, heat can be applied to one or both sides of the material being pressed. In one embodiment, heat is applied to only one side.

[0222] For example, hot pressing may involve two hot pressing stages in both of which heat is applied from the same side. Alternatively, hot pressing may involve two hot pressing stages in which heat is applied from different sides.

[0223] Hot pressing may include impulse drying.

[0224] The coating stage may precede all hot pressing stages. In this case, the dry matter content of the fibrous structure to be coated may be at least 30%. Petition 870260042878, dated 07 / 05 / 2026, page 48 / 147 44 / 62

[0225] The coating stage preferably takes place between two hot pressing stages. In this case, the dry matter content of the fibrous structure to be coated can be at least 60%.

[0226] The coating stage can occur after all the hot pressing stages. In this case, the dry matter content of the fibrous structure to be coated can be at least 80%, as well as at least 90%.

[0227] In some forms, the final coating thickness is less than 100 µm, as well as less than 70 µm.

[0228] Next, we describe modalities related to the formation of foam from the fibrous structure in more detail.

[0229] In one embodiment, the fibrous structure to be coated or a part thereof is obtained by using foaming.

[0230] In some embodiments, the fibrous structure or at least one of its fibrous layers can be obtained by a method comprising the following steps: providing a fibrous slurry comprising fibers; refining the fibers of the fibrous slurry and / or adding barrier agents to the fibrous slurry; transforming the fibrous slurry into a foamy composition; forming, such as molding the foamy composition in a mold; dewatering; and hot pressing.

[0231] In this method, a foam composition comprising fibers, water, air and one or more foaming chemicals is first provided. The foam may further comprise fillers, additives, pigments, binders, reinforcing agents, barrier dispersions and bonding agents. Petition 870260042878, dated 07 / 05 / 2026, page 49 / 147 45 / 62

[0232] The foaming chemical, such as a surfactant used, may be nonionic, anionic, cationic, or amphoteric. An adequate amount of surfactant is approximately 150 to 1000 ppm by weight. Examples of anionic surfactants are alpha-olefin sulfonates, and of nonionic surfactants, PEG-6 lauramide. Particular examples include sodium dodecyl sulfate (SDS), Tween20, and mixtures thereof. Tween20 contains at least 40% by weight of lauric acid, the remainder consisting mainly of myristic, palmitic, and stearic acids.

[0233] Preferably, foaming chemicals comprise or consist of at least one anionic surfactant, such as SDS. Powder coating can be particularly advantageous in the case of using an anionic surfactant, which can provide low surface energy to the surface to be coated.

[0234] Typically, the bubble size (bubble diameter) in the foam is approximately 10 to 300 µm, for example, 20 to 200 µm, generally approximately 20 to 80 µm.

[0235] In one embodiment, the bubble size (bubble diameter) in the foam is at least 100 µm, such as 100 to 200 µm.

[0236] In one embodiment, a suitable foam-forming composition is obtained by mixing fiber mud, which has a consistency of approximately 0.5 to 7% by weight (the amount of fiber relative to the weight of the mud), with a foam that is formed from water and a surfactant and whose air content is approximately 10 to 90% by volume, for example, 20 to 80%, such as 50 to 70% in Petition 870260042878, dated 07 / 05 / 2026, page 50 / 147 46 / 62 volume, in which case a foamed fiber slurry is generated having a fiber content of approximately 0.1 to 3% by weight.

[0237] In one embodiment, a multilayer molded fibrous structure is obtained by a method comprising: forming a multilayer molded foam structure from at least one foamy fibrous composition comprising cellulosic fibers, water, air and a foaming agent and, optionally, also barrier agents; dehydrating the structure, preferably by applying vacuum; and hot pressing the dehydrated structure to obtain the multilayer molded fibrous structure. At least one of the fibrous layers of the multilayer fibrous structure exhibits substantially barrier properties throughout its structure.

[0238] In the present context, forming refers to the process of giving shape to the foam composition, such as a three-dimensional shape, in a mold.

[0239] In the preferred method, a foamy fibrous composition is fed into a mold. The mold typically comprises a cavity or an internal space defined by the internal surfaces of the mold. The fed foamy composition is molded into the cavity.

[0240] The foam composition can be fed into the mold to provide a quantity of the foam composition, such as a layer of the foam composition, onto at least one internal surface of the mold. The layer is typically non-planar and can be understood as a thickness, such as a substantially constant thickness, of the foam composition. Petition 870260042878, dated 07 / 05 / 2026, page 51 / 147 47 / 62 placed on the inner surface of the mold and conforming to the shape of said surface.

[0241] Typically, the molding step involves pressing said fibrous composition into the internal space of the mold, causing parts of the mold to come closer together.

[0242] The step of forming a multi-layered fibrous foam structure may comprise feeding a first fibrous composition in foam form into the mold and molding said first fibrous composition in the mold, to prepare a first fibrous foam layer. After that, without removing the first fibrous layer from the mold, the process continues by feeding a second fibrous foam composition into the mold and molding said second fibrous composition in the mold, to prepare a second fibrous foam layer. As a result, a two-layered molded fibrous foam structure is obtained in the mold.

[0243] Unless otherwise indicated, “mold parts” refers to the mold parts that serve to define the internal space and thus contribute to shaping the fibrous foam composition.

[0244] The second fibrous foam layer can be fed in and thus be located on top of or alternatively under the first fibrous foam layer in the mold. Furthermore, the aforementioned feeding steps can be carried out in any order: either the first layer or the second layer can be formed first in the mold.

[0245] It can also be predicted that the fibrous structure will be obtained using separate molds to prepare the Petition 870260042878, dated 07 / 05 / 2026, page 52 / 147 48 / 62 referred to as the first and second fibrous foam layers, and the first and second fibrous layers obtained are joined together in the aforementioned hot pressing step.

[0246] In one embodiment, said mold feeding comprises feeding the foamed fibrous composition in a foam form into an internal space or internal volume of the mold, wherein said internal space is limited by the internal surfaces of the mold.

[0247] The application of vacuum in the dehydration step is preferably enabled.

[0248] The final multi-layered fibrous foam structure is removed from the mold by opening the mold.

[0249] Adjusting the distance between the mold parts during feeding and molding of foam compositions is preferably allowed.

[0250] Before starting to feed another, such as a second fibrous composition, into the mold, it is usually necessary to enlarge the internal space of the mold by moving the mold parts further apart from each other. The volume of the internal space can be decreased or increased to mold the foam already fed and, respectively, to make room for the foam to be fed next.

[0251] In all adjustments of the internal mold space volume, some parts of the mold may remain stationary while other parts are moved.

[0252] In one example, one or more parts of the mold remain stationary and one or more other parts of the mold move during said approach or during said enlargement. Petition 870260042878, dated 07 / 05 / 2026, page 53 / 147 49 / 62

[0253] For example, the mold may comprise two sub-molds, such as two halves, which are arranged facing each other and are movable relative to each other. The sub-molds may be brought closer together to mold the fibrous structure. The sub-molds may be moved further apart to enlarge the internal space or even further to open the mold and remove the molded fibrous structure from the mold.

[0254] In one example, the fibrous structure can be obtained using a mold comprising two parts: a negative mold and a positive mold, which can be arranged facing each other to enclose an internal space, also called a molding space or molding cavity, between the two parts. The composition to be molded or formed is fed into the molding space and the negative mold and / or the positive mold are brought closer to each other to give the composition the shape corresponding to the shape of the molding space. By “approximation” refers a process in which the internal space is reduced by moving one or both of the positive and negative molds.

[0255] Dehydration of the structure can be achieved by applying vacuum to the internal space of the mold containing the fed foam composition(s).

[0256] The dehydration stage precedes the hot pressing stage, which leads to the final fibrous product to be coated, i.e., a fibrous structure in which all layers have been joined together. In hot pressing, the temperature is typically higher than ambient temperature, for example, at least 50 °C, such as at least 100 °C. Petition 870260042878, dated 07 / 05 / 2026, p. 54 / 147 50 / 62

[0257] The molded fibrous structure can be dried, for example, by vacuum, heating, air drying, radio frequency drying or microwave drying, or by any combination thereof. EXAMPLE

[0258] We now describe an embodiment in which a fibrous structure to be coated with a dry-coated layer according to some embodiments of the present invention is obtained by foaming using a mold consisting of two parts, which are referred to as a pair of molds.

[0259] Any of the features and combinations of features described below may be combined with the modalities and alternatives described earlier in this application.

[0260] The method is for forming a molded fibrous structure. In the method, a foam layer is formed. The layer is part of the final product. The foam, also referred to as “foam composition”, includes cellulosic and / or lignocellulosic fibers, water, air and one or more foaming chemicals. The foam may also comprise, for example, fillers and other chemicals normally used in papermaking, such as reinforcing agents, additives, pigments, dyes and binders.

[0261] The layer is formed by a pair of molds. The molds may consist of several partial molds.

[0262] In principle, one mold is a negative mold while the other is a corresponding positive mold. In this way, during formation the layer obtains a three-dimensional shape. Water and air must be removed from the foam. Petition 870260042878, dated 07 / 05 / 2026, page 55 / 147 51 / 62 This is done primarily by decreasing the distance between the molds and applying pressure. The pressure forces air and water out of the foam that has been fed between the molds. The porous surfaces (surfaces of molded products) of the molds organize the exit for water, foaming chemicals, and air, while the fibers remain and form the layer.

[0263] The foam can be fed through one of the molds. The molds are spaced apart and there is a closed cavity for the foam. In this way, the foam feeding is fast and the time can be selected more freely.

[0264] The foam can also be fed through both molds.

[0265] In this example, the pair consists of an upper mold and a lower mold, and the upper mold is movable while the lower mold is stationary. The foam is fed through the lower mold.

[0266] Foam can be fed when the pair is far apart from each other or when the pair is moving relative to each other. This shortens the forming cycle. For example, foam can be fed even if the top mold is moving upwards. On the other hand, the pair can first be moved away from each other and only then is foam feeding initiated.

[0267] Feeding the foam through the mold provides an additional advantage. It is now possible to form not just a single layer, but multiple layers, through a layer-by-layer process. The formed layer can be removed from the inside of the pair after forming. Petition 870260042878, dated 07 / 05 / 2026, p. 56 / 147 52 / 62 Alternatively, after the layer has been formed, the pair can be moved away from each other and more foam can be fed for an additional layer, and then the pair is brought closer together again. Here too, foam can be fed even when the pair is being moved away from each other.

[0268] In practice, 1 to 10 additional layers, advantageously 2 to 4 additional layers can be formed. After shaping and pressing, air and unbound water are removed and the semi-finished fibrous structure is obtained.

[0269] The next step is hot pressing to remove water bound to the fibers. The layers finally bond together in the hot pressing phase. Several hot pressing steps can be applied sequentially.

[0270] Surprisingly, after the first layer, an additional layer can be formed on either side of the first layer. In other words, the foam can be fed on either side of the previous layer. For example, an inner layer can be formed first to serve as the body layer, and then an additional layer can be formed on either side of the inner layer to serve as surface layers. Thus, there will be three layers in total.

[0271] A multi-layered fibrous structure can also be prepared in another way. The fibrous structure can be combined with partial multi-layered fibrous structures obtained from two pairs of separate molds. The partial fibrous structures formed from these two pairs can be combined and hot-pressed to obtain a single fibrous structure. For example, in one pair, an inner layer can be formed with a layer Petition 870260042878, dated 07 / 05 / 2026, page 57 / 147 53 / 62 lower. Simultaneously in the other pair, an inner layer with an upper layer can be formed. By combining these layers, a fibrous structure with four layers is formed.

[0272] Forming multiple layers quickly to constitute a single fibrous structure is a great benefit. The foam can be changed before forming the additional layer or layers after the first layer. Foams with different properties can be used in the formation of a fibrous structure. In this way, the layers can differ from each other. The fibrous structure may include, for example, one or two inner layers formed by one type of foam. Then there may be at least one outer layer of another type of foam. Thus, the foams can alter the cross-sectional profile of the fibrous structure.

[0273] Surprisingly, the fibrous structure can be formed without extra heating. Given that the foam has a low water content and contains a lot of air, the water can be efficiently removed and the fibrous structure retains its shape after formation. Simultaneously, the foam remains in shape and energy consumption is low.

[0274] The foam temperature is maintained in the range of 15 to 45 °C, advantageously in the range of 25 to 35 °C. If necessary, the foam and / or molds can be cooled to maintain a stable and sufficiently low temperature.

[0275] At such low temperatures, the fibers will still contain some moisture. During hot pressing, the moisture is expelled in the form of water and steam, which also provides a smooth surface and contributes to the internal bonding to form a solid layered fibrous structure. Petition 870260042878, dated 07 / 05 / 2026, p. 58 / 147 54 / 62

[0276] Immediately when the pair begins to move away from each other, foam is fed into the internal space of the mold. When the pair is brought closer together again, the feeding stops and the water is drained from the pair. Simultaneously, air is removed.

[0277] The removal of water and air by pressing can be aided by vacuum.

[0278] Although a single-layer fibrous structure can be formed, the method is advantageous when forming multiple layers.

[0279] Foam is made of water, air, fibers, and a foaming chemical. Foam contains small fractions or particles of the fibers in question. In addition, a foaming chemical is used to assist in foam generation and to keep it in shape.

[0280] Fibers can vary extensively in origin and composition. For example, wood fibers or vegetable fibers (e.g., straw, bagasse, and bamboo fibers) can be used, but artificial cellulosic fibers are also possible.

[0281] In a suitable foam, water and fibers and possible additives are evenly distributed in the walls of the foam bubbles. Foam is a heterogeneous, non-flocculating fibrous raw material in which the air in the bubbles carries the fibers and any other raw materials to the forming process. When using foam, fiber retention is also very high. In practice, more than 99% of the fibers remain in the fibrous structure formed from the thick foam as a carrier medium. Petition 870260042878, dated 07 / 05 / 2026, page 59 / 147 55 / 62

[0282] Additives may have different retention properties depending on their purpose.

[0283] By forming the multi-layered fibrous structure, the properties of the structure can be adapted in many ways. For example, the basic structure and surface properties of the fibrous structure can be formed with different foam compositions. In practice, each layer can have its own process parameters and raw materials. For example, the rigid body of the fibrous structure can be formed from cheaper fibers and then the surface layers from higher quality fibers. Compared to known processes that use an aqueous paste of fibers, in foam the fiber density is higher. Simultaneously, the amount of water circulating within the bubble walls is also considerably lower, and water removal during formation is easy. Foam with small volumes of water allows for fast process cycles.

[0284] Exchanging fractions or types of foam for different layers of the fibrous structure may be possible.

[0285] The foam can be fed quickly enough into the mold space, especially when vacuum is used.

[0286] In a suitable foam, the bubbles are not separated and the fibers are evenly distributed. During forming, the foam is distributed or fed into the internal space of the mold between the two molds. The volume of the internal space of the mold can be adjusted according to the required layer thickness.

[0287] For example, the formation of the next layer can occur on either side of the previous layer. Furthermore, Petition 870260042878, dated 07 / 05 / 2026, page 60 / 147 56 / 62 Foam feeding can begin as early as the separation of the pair. This is advantageous because during separation, the mold space is immediately filled with foam without any air being able to enter the space before the foam.

[0288] The foam is fed through the mold, into the inner mold space. 'The inner mold space' refers to the space between the pair of molds.

[0289] Vacuum can also be used. Vacuum helps in removing water and air. Vacuum can be applied even during foam feeding, but at the latest when pair approach is initiated. During forming, the mold space decreases, but not as much as in the actual pressing stage after forming. Furthermore, it is possible to hold the formed layer under vacuum on the desired mold surface (inner surface) to form the additional layer on the selected side of the previous layer.

[0290] Formation can be carried out without any heating, to control the ideal foam structure for uniform formation of the fibrous structure. In practice, formation is carried out at a substantially constant process temperature, advantageously between 15 and 45 °C. In addition to the pair of molds, this temperature can also be maintained throughout the foaming system to ensure an ideal bubble size or foam quality for high-quality products. In this way, the shelf life of the foam can be extended. Furthermore, it is easier to remove air than vapor, and the layer remains intact and the process stable. In practice, the foam includes more than 50% air, advantageously 55 to 75% air. Petition 870260042878, dated 07 / 05 / 2026, p. 61 / 147 57 / 62

[0291] The ideal foam bubble size in the formation can be about 10 to 500 μm in diameter, preferably 50 to 150 μm or 100 to 200 μm in diameter.

[0292] Surprisingly, the present foaming process simultaneously achieves high consistency and good formation compared with known aqueous paste-forming processes. The aforementioned water-based processes require a longer heating and dehydration time, since the consistency is much lower and the formation is poorer due to flocculation.

[0293] The layered fibrous structure is formed as layers one on top of the other. In a dehydration step, water is removed from the formed structure through the mold. The layered structure is joined together at the latest by hot pressing.

[0294] The layered fibrous structure can be formed in an optional layered order. In other words, formation can begin from any of the inner layers or from any of the surface layers.

[0295] The bonding of layers to each other can be initiated by dehydration through layer interfaces.

[0296] The bonding of the layers continues or, at most, occurs in the subsequent hot pressing stage, in which the heat and steam generated in the fibrous structure and the steam conducted through the layers also reinforce the bonding of the layers to each other.

[0297] Lamination can be performed with the same fibers, but different additives can be used in different layers. Petition 870260042878, dated 07 / 05 / 2026, p. 62 / 147 58 / 62

[0298] Hot pressing may comprise a plurality of separate hot pressing stages. Hot air or radiation heating or impulse drying may be applied to hot press and / or dry the fibrous structure.

[0299] After the hot pressing stage, an optional additional high-temperature drying stage may follow.

[0300] The method involves generating a foam from fibers, water, air, and a foaming chemical. The properties of the foam can vary as described previously. In addition, the method involves using a pair of molds with variable mutual distance. In other words, the distance between the molds can be varied. In practice, after feeding the foam, the molds are pressed against each other to remove water and air, thus forming the fibrous structure.

[0301] In addition, the method also includes feeding foam between the molds to form a layer. A single layer can constitute the fibrous structure, but advantageously the fibrous structure can include multiple layers. Foam can be fed even when the molds are far apart and also when moving the pair relative to each other. This shortens the process cycle and offers more options for adapting the process and the final product.

[0302] The method involves creating a closed mold space and feeding a volume of foam into the mold space, which is like a closed cavity. The molded fibrous structure is removed from the mold and transferred for hot pressing. Petition 870260042878, dated 07 / 05 / 2026, p. 63 / 147 59 / 62

[0303] Advantageously, the pair includes an upper mold and a lower mold. The upper mold is movable while the lower mold is arranged stationary, or alternatively the lower mold is movable while the upper mold is arranged stationary, or alternatively both molds are movable.

[0304] With the mold space closed, the molds can be spaced apart from each other during forming. After they separate, the pair makes room for more foam.

[0305] In practice, the distance between the molds is 10 to 100 mm, preferably 20 to 80 mm. In one embodiment, the distance between the molds is at least 5 mm. Generally, the thicker the layer, the greater the distance. The foam flow rate remains moderate. In practice, the flow rate is 1 to 3 meters per second.

[0306] As mentioned earlier, several identical fibrous structures can be obtained in parallel by a forming method in which each mold of the pair comprises several identical partial molds or submolds.

[0307] Each partial or sub-mold is filled uniformly with foam. This ensures that the molded fibrous structures are uniform and the process is fast.

[0308] After the mold space is filled with foam, the water and air are removed by pressing. Water and air can permeate the mold surface as fibers accumulate on the mold surface. Water removal can be aided by vacuum. Water removal can also be aided by overpressure exerted by the opposing mold.

[0309] It should be understood that the embodiments of the invention disclosed are not limited to structures, Petition 870260042878, dated 07 / 05 / 2026, page 64 / 147 60 / 62 process steps or particular materials disclosed herein, but are extended to equivalents thereof, as would be recognized by those normally versed in the relevant techniques. It should also be understood that the terminology employed herein is used only for the purpose of describing particular embodiments and is not intended to be limiting.

[0310] The reference throughout this descriptive report to “an embodiment” or “an embodiment” means that a specific feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of the phrases “in an embodiment” or “in an embodiment” in various places throughout this descriptive report do not necessarily refer to the same embodiment.

[0311] As used herein, a plurality of items, structural elements, compositional elements and / or materials may be presented in a common list for convenience. However, these lists should be interpreted as if each member of the list were individually identified as a separate and unique member. Thus, no individual member of this list should be interpreted as being equivalent in fact to any other member of the same list solely on the basis of its presentation in a common group, without indication to the contrary. Furthermore, various embodiments and examples of the present invention may be referred to herein together with alternatives for the various components thereof. It is understood that such embodiments, examples and alternatives should not be interpreted as equivalent. Petition 870260042878, dated 07 / 05 / 2026, p. 65 / 147 61 / 62 are in fact different from each other, but should be considered as separate and autonomous representations of the present invention.

[0312] Furthermore, the features, structures, or characteristics described can be combined in any suitable manner in one or more embodiments. In the following description, numerous specific details are provided, such as examples of lengths, widths, shapes, etc., to provide a complete understanding of the embodiments of the invention. A person skilled in the relevant art will recognize, however, that the invention can be practiced without one or more of the specific details, or with other methods, components, materials, etc. In other cases, well-known structures, materials, or operations are not shown or described in detail to avoid obscuring aspects of the invention.

[0313] Although the preceding examples are illustrative of the principles of the present invention in one or more specific applications, it will be evident to those skilled in the art that numerous modifications in form, use, and implementation details can be made without exercising inventive faculty and without departing from the principles and concepts of the invention. Consequently, the invention is not intended to be limited except by the claims set forth below.

[0314] The verbs “understand” and “include” are used in this document as open-ended limitations that neither exclude nor require the existence of features not explicitly stated. The features mentioned in the dependent claims are mutually combinable, unless explicitly stated otherwise. Furthermore, it should be understood that Petition 870260042878, dated 07 / 05 / 2026, page 66 / 147 62 / 62 The use of "um" or "uma," that is, a singular form, throughout this document does not exclude a plurality. INDUSTRIAL APPLICABILITY

[0315] The present invention is industrially applicable at least in the manufacture of powder-coated molded fibrous products. REFERENCE SIGNS first fibrous layer second fibrous layer inner fibrous layer intermediate layer lining Petition 870260042878, dated 07 / 05 / 2026, page 67 / 147

Claims

1 / 5 CLAIMS l. Product, characterized in that it comprises: - a fibrous structure comprising a cellulosic and / or lignocellulosic fibrous material and obtained by a molding process; and - a coating, such as at least one coating layer, on at least one surface of the fibrous structure, wherein the coating was obtained by a powder coating process, wherein the fibrous structure to be coated or part thereof was obtained using foaming, wherein the density of the fibrous structure to be coated is in the range of 300 to 1000 kg / m3, calculated as weight of dry solids per volume, wherein the surface smoothness of the fibrous structure to be coated is in the range of 50 to 3000 ml / min, measured by the ISO 8791-2 Bendtsen method.

2. Product according to claim 1, characterized in that the coating forms an upper layer or a lower layer of the product.

3. Product, according to any of the preceding claims, characterized in that the product comprises at least two coating layers that are located on different surfaces of the fibrous structure, such as on opposite sides of a flat fibrous structure.

4. Product, according to any of the preceding claims, characterized in that the coating is a non-fibrous coating and comprises or consists of a thermoplastic polymeric material or a thermoset polymeric material, such as polyolefin, polyester, polyethylene terephthalate (PET), polyhydroxyalkanoate or polylactic acid.

5. Product, according to any of the preceding claims, characterized in that the coating comprises at least 50% by weight, such as at least 80% by weight, or at least 90% by weight of a thermoplastic polymeric material or a thermosetting polymeric material.

6. Product, according to any of the preceding claims, characterized in that the product has a dry basis weight in the range of 5 to 900 g / m2, for example, in the range of 100 to 800 g / m2, such as in the range of 200 to 600 g / m2.

7. Product, according to any of the preceding claims, characterized in that the coating has a dry basis weight in the range of 2 to 80 g / m2, for example, 10 to 35 g / m2, and in that the coating thickness is at least 1 µm, such as in the range of 2 to 50 µm, for example, 5 to 30 µm.

8. Product, according to any of the preceding claims, characterized in that the fibrous structure is a multi-layered fibrous structure and comprises at least a first fibrous layer and a second fibrous layer, each comprising a cellulosic and / or lignocellulosic fibrous material. Petition 870260042878, dated 07 / 05 / 2026, page 69 / 147 3 / 5 9. Product, according to any of the preceding claims, characterized in that it further comprises, between the first and second fibrous layers, one or more inner fibrous layers, each comprising a cellulosic and / or lignocellulosic fibrous material, preferably comprising mechanical pulp, such as chemimechanical pulp (CTMP) or bleached chemimechanical pulp (BCTMP) and / or waste.

10. Product, according to any of the preceding claims, characterized in that the entire fibrous structure was obtained by foaming.

11. Product, according to any of the preceding claims, characterized in that the fibrous structure is a multi-layered fibrous structure comprising at least two fibrous layers, wherein all the fibrous layers of the fibrous structure were obtained by a foaming method in a mold.

12. Use of the product, as defined in any of the preceding claims, characterized in that it serves as packaging or a container for food, such as dairy products, fish or meat, or as packaging for medicines or cosmetics, or as a part thereof for storing, handling, preparing or cooking food.

13. Method, characterized in that it comprises: - providing at least one fibrous composition comprising cellulosic and / or lignocellulosic fibers and water; Petition 870260042878, dated 07 / 05 / 2026, page 70 / 147 4 / 5 - in a mold, forming a fibrous structure from said at least one fibrous composition; - applying a coating, such as at least one coating layer, to at least part of a surface of the molded fibrous structure by a powder coating process, wherein the forming step comprises foaming, wherein the density of the fibrous structure to be coated is in the range of 300 to 1000 kg / m3, calculated as weight of dry solids by volume, wherein the surface smoothness of the fibrous structure to be coated is in the range of 50 to 3000 ml / min, measured by the ISO 8791-2 Bendtsen method.

14. Method according to claim 13, characterized in that said forming step comprises forming a three-dimensional fibrous structure from said at least one fibrous composition using a three-dimensional mold.

15. Method, according to claim 13 or 14, characterized in that said powder coating process comprises electrostatically applying a dry powder to said surface of the fibrous structure, and curing or melting the applied powder, preferably by heating and / or hot pressing with or without contact, to form a film.

16. Method, according to any one of claims 13 to 15, characterized in that the fibrous structure to be coated has a dry matter content of at least 90%, such as 90 to 96%. Petition 870260042878, dated 07 / 05 / 2026, p. 71 / 147 5 / 5 17. Method, according to any one of claims 13 to 16, characterized in that it further comprises, after the aforementioned forming step and before applying the coating: - dehydrating the structure; - hot pressing the dehydrated structure to obtain the molded three-dimensional fibrous structure, in which said hot pressing produces a surface that is directly suitable for dry coating, for example, powder coating.

18. Method, according to any one of claims 13 to 17, characterized in that the fibrous structure to be coated has a dry matter content of at least 60%, and in that after applying the coating, the coated structure is hot-pressed, such as hot-pressed a second time.

19. Method, according to any one of claims 13 to 18, characterized in that the density of the fibrous structure to be coated is at least 700 kg / m3.

20. Method, according to any one of claims 13 to 19, characterized in that the fibrous structure is a multi-layered fibrous structure comprising at least two fibrous layers, wherein each fibrous layer of the fibrous structure is obtained by foaming from a respective fibrous composition in a mold. Petition 870260042878, dated 07 / 05 / 2026, p. 72 / 147

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