Protective packaging and method of making same

Abstract

The present disclosure relates to a method of manufacturing a protective packaging material, and to a protective packaging material manufactured using the method of the disclosure. Such packaging materials can be biodegradable, compostable and / or renewable.

Description

Technical Field

[0001] This disclosure relates to a method for preparing protective packaging materials, and to protective packaging materials prepared using the disclosed method. Background Technology

[0002] Lined envelopes made of kraft paper and foam are popular in today's market. These products meet packaging needs at a reasonable cost; however, they are environmentally harmful because they are not renewable in traditional paper or plastic recycling processes. Therefore, most of these liner envelopes end up in landfills. Lined envelopes containing expandable microspheres offer an option for renewable paper, but their components are not all fully biodegradable, compostable, or renewable.

[0003] There is a need for lightweight, biodegradable, compostable, and / or more renewable lined envelopes that are available at a reasonable market cost. Summary of the Invention

[0004] This disclosure relates to compositions comprising: 1% to 40% by weight of wood fiber, 0.5% to 20% by weight of binder, 0.2% to 10% by weight of surfactant, 10% to 95% by weight of water, and 0% to 30% by weight of additives. Methods for preparing such compositions are also described. This disclosure further relates to methods for preparing wood fiber-containing foams (including intermediate foams and super-expandable foams), which can be used, for example, in the manufacture of cushioning packaging materials, and are also described. Attached Figure Description

[0005] Figure 1A , Figure 1B and Figure 1C The compositions of this disclosure are depicted before mixing (1A), during mixing (1B), and after mixing and aeration to prepare intermediate foam (1C).

[0006] Figure 2 A foam containing a sample of regenerated fibers that had been dried in a conventional oven is depicted. See Example 5.

[0007] Figure 3 An embodiment of the present disclosure is depicted, comprising a 2-inch-long intermediate foam model that has been heated using microwaves to prepare a super-expanded foam (see also Example 7).

[0008] Figure 4A The present disclosure describes a “wet” (“intermediate”) foam composition placed on a paper substrate.

[0009] Figure 4B Depicting Figure 4A An intermediate foam composition, which has been microwave-heated to prepare a super-expanded foam exhibiting expansion in the x, y, and z directions.

[0010] Figure 5A The “wet” (“intermediate”) foam composition of this disclosure is depicted (1 g, 2-inch wet line).

[0011] Figure 5B Depicting Figure 5A An intermediate foam composition, which has been microwave-heated to prepare a super-expanded foam.

[0012] Figure 6 The present disclosure depicts a foam application pattern on a web (paper) substrate, the foam being super-expanded, with long lines (0.56 g of intermediate foam), short lines (0.19 g of intermediate foam), and a lamination thickness of approximately 0.1 to 0.15 inches with the paper.

[0013] Figure 7 An embodiment of the present disclosure is described as a super-expanded foam subjected to microwave treatment (see also Example 5).

[0014] Figure 8 One embodiment of the present disclosure is depicted, which shows a reduction in the overall size of 0.5 g dots of the intermediate foam of the present disclosure, at least in part due to the increased density and degassing of the intermediate foam. (Left - before the addition of NaCl; Right - after the addition of NaCl) (See also Example 6).

[0015] Figure 9 An embodiment of the present disclosure is described, which is a 0.25 g dotted sample of the intermediate foam of the present disclosure after microwave drying (see also Example 8).

[0016] Figure 10A A preferred super-expanded foam of this disclosure, which has been microwave-treated, is described, the super-expanded foam comprising 5% by weight of regenerated fiber and 5% by weight of cork fiber (see also Example 10).

[0017] Figure 10B An embodiment of this disclosure is described, which is treated by convection heat (conventional oven) and comprises 5% by weight of regenerated fiber and 5% by weight of cork fiber (see also Example 10).

[0018] Figure 11A The intermediate foam (0.25 g wet element) of this disclosure is depicted (see also Example 11).

[0019] Figure 11BThe super-expanded foam of this disclosure is depicted (0.25 g element, left: 100% microwave power for 30 seconds; right: 30% microwave power for 60 seconds) (see also Example 11). Detailed Implementation Plan

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. The terminology used in this specification is for describing particular embodiments only and is not intended to limit this disclosure.

[0021] Where a numerical range is provided, it should be understood that every intermediate value between the upper and lower limits of the range, and any other stated or intermediate values ​​within the range, are included in this disclosure unless the context explicitly specifies otherwise (e.g., in the case of a group containing multiple carbon atoms, in which case the number of each carbon atom falling within the range is provided), and the intermediate values ​​are up to one-tenth of the lower limit unit. The upper and lower limits of smaller ranges may be independently included within those smaller ranges, which are also included in this disclosure, but subject to any specific exclusions within the range. Where the range includes one or both of the limitations, the range excluding any or both of the included limitations is also included in this disclosure.

[0022] Unless the context clearly indicates otherwise, the articles “a” and “an” as used herein and in the appended claims refer to one or more (e.g., at least one) of the grammatical objects of the article. For example, “a component” means one element or more elements.

[0023] This disclosure relates to compositions comprising wood fibers, an adhesive, a surfactant, water, and optionally, additives suitable for use in, for example, cushioned packaging materials. Such compositions can be combined with air to form a “wet foam” or “intermediate foam,” terms which are used interchangeably herein. The resulting intermediate foam can be applied to one or more web substrates. Applying dielectric heat to the intermediate foam of this disclosure causes the intermediate foam to expand in each of the x, y, and z planes, i.e., in each of the x, y, and / or z directions, to prepare a “super-expanded foam” or “dry foam,” terms which are used interchangeably herein.

[0024] While not wishing to be bound by any particular theory, it is believed that the expansion is caused by the rapid release of water vapor / steam from the intermediate foam. Surprisingly, expansion in the x, y, and / or z directions cannot be achieved using conventional heating methods. While not wishing to be bound by any particular theory, it is believed that conventional heating methods cannot remove water quickly enough to prepare super-expanded foam. Products containing super-expanded foam can be used to prepare environmentally conscious packaging materials that provide cushioning, protection, and / or insulation. Products that can be prepared according to the disclosed methods include, for example, sleeves, padded envelopes, corrugated packaging, cushioning pads for packaging / protection during transport, all forms of packaging, biodegradable film packaging, insulated packaging, etc.

[0025] In a preferred aspect, the composition disclosed herein comprises: about 1% to about 40% by weight of wood fiber, about 0.5% to about 20% by weight of adhesive, about 0.2% to about 10% by weight of surfactant, about 10% to about 95% by weight of water, and 0% to about 30% by weight of additives.

[0026] In some aspects, the compositions disclosed herein comprise about 1% to about 40% by weight of wood fiber, for example, 1% to 40% by weight of wood fiber. In some aspects, the composition comprises 1% to 5% by weight of wood fiber. In some aspects, the composition comprises 1% to 10% by weight of wood fiber. In some aspects, the composition comprises 1% to 20% by weight of wood fiber. In some aspects, the composition comprises 1% to 30% by weight of wood fiber. In some aspects, the composition comprises 5% to 15% by weight of wood fiber. In some aspects, the composition comprises 15% to 25% by weight of wood fiber. In some aspects, the composition comprises 5% to 40% by weight of wood fiber. In some aspects, the composition comprises 1% to 5% by weight of wood fiber. In some aspects, the composition comprises 10% to 40% by weight of wood fiber. In some aspects, the composition comprises 15% to 40% by weight of wood fiber. In some aspects, the composition comprises 20% to 40% by weight of wood fiber. In some aspects, the composition comprises 25% to 40% by weight of wood fiber. In some aspects, the composition comprises 30% to 40% by weight of wood fiber. In some aspects, the composition comprises 35% to 40% by weight of wood fiber. For example, the compositions disclosed herein may comprise 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35, 36, 37, 38, 39, or 40% by weight of wood fiber.

[0027] The wood fibers used in the compositions of this disclosure can be virgin fibers or regenerated fibers. Virgin or regenerated fibers can be hardwood fibers, such as fibers prepared from deciduous trees. The wood fibers used in the compositions of this disclosure can be softwood fibers, such as fibers prepared from coniferous trees. The wood fibers used in the compositions of this disclosure can be a combination of hardwood fibers and softwood fibers. Preferably, the wood fibers used in the compositions, foams, and methods of this disclosure are softwood virgin wood fibers, particularly softwood virgin kraft pulp. The wood fibers used in the compositions of this disclosure can be kraft pulp fibers, fluff pulp fibers, Northern Bleached Soft kraft (NBSK) pulp fibers, Southern Bleached Soft kraft (SBSK) pulp fibers, virgin pulp fibers, bleached virgin pulp fibers, bleached virgin softwood, newsprint, recycled newsprint, recycled pulp fibers, deinked pulp fibers, bleached pulp fibers, or combinations thereof. In some aspects, the wood fibers used in the compositions of this disclosure comprise kraft pulp fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise fluff pulp fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise NBSK fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise SBSK fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise regenerated fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise deinked fibers. In some aspects, the wood fibers used in the compositions of this disclosure comprise bleached fibers.

[0028] The wood fibers used in the compositions of this invention may include any kind of wood fiber commonly used in the manufacture of paper products. According to this disclosure, wood fibers suitable for use in the disclosed methods and compositions include, for example, spruce fiber, pine fiber, fir fiber, western hemlock fiber, balsam fiber, cedar fiber, or combinations thereof. In some aspects, the wood fibers used in the compositions of this disclosure comprise spruce fiber. In some aspects, the wood fibers used in the methods and compositions of this disclosure are pine fiber. In some aspects, the wood fibers used in the compositions of this disclosure comprise fir fiber. In some aspects, the wood fibers used in the methods and compositions of this disclosure comprise western hemlock fiber. In some aspects, the wood fibers used in the methods and compositions of this disclosure comprise balsam fiber. In some aspects, the wood fibers used in the methods and compositions of this disclosure comprise cedar fiber. In some aspects, synthetic fibers may be additionally added to the wood fibers to form the composition. The synthetic fibers may be made of polymeric materials including, but not limited to, polyester fibers and / or acrylonitrile fibers.

[0029] According to this disclosure, the wood fibers used in the disclosed compositions and methods have a fiber length of about 0.5 mm to about 5 mm, for example, 0.5 mm to 5 mm. Softwood fibers have a length of about 2 to 4 mm (0.08 to 0.16 inches). Hardwood fibers have a length of about 0.5 to 1.5 mm (0.02 to 0.06 inches). Regenerated fibers may have a reduced length of about 0.01 to 5 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 0.5 mm to 4 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 0.5 mm to 3 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 0.5 mm to 2 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 0.5 mm to 1 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 1 mm to 4 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 2 mm to 4 mm. In some aspects, the wood fibers used in the disclosed methods have a fiber length of 3 mm to 4 mm. For example, the wood fibers used in the disclosed methods may have a fiber length of 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9, 3, 3.1, 3.2, 3.3, 3.4, 3.5, 3.6, 3.7, 3.8, 3.9, or 4 mm.

[0030] According to this disclosure, the wood fibers used in the disclosed methods and compositions have a fiber width of about 20 μm to about 35 μm, for example, 20 μm to 25 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 20 μm to 25 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 20 μm to 30 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 25 μm to 30 μm. In some aspects, the wood fibers used in the disclosed methods and compositions have a fiber width of 30 μm to 35 μm. For example, the wood fibers used in the disclosed methods and compositions may have a fiber width of 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32, 33, 34, or 35 mm.

[0031] The wood fibers suitable for use in the disclosed methods and compositions have a weight of about 5 million fibers / g to about 30 million fibers / g, for example, from 5 million fibers / g to 30 million fibers / g. In some aspects, the wood fibers of this disclosure have a weight of 5 million to 10 million fibers / g. In some aspects, the wood fibers of this disclosure have a weight of 10 million to 15 million fibers / g. In some aspects, the wood fibers of this disclosure have a weight of 15 million to 20 million fibers / g. In some aspects, the wood fibers of this disclosure have a weight of 20 million to 25 million fibers / g. In some aspects, the wood fibers of this disclosure have a weight of 25 million to 30 million fibers / g. For example, the wood fibers suitable for use in the disclosed methods and compositions may have a weight of 500, 600, 700, 800, 900, 1,000, 1,100, 1,200, 1,300, 1,400, 1,500, 1,600, 1,700, 1,800, 1,900, 2,000, 2,100, 2,200, 2,300, 2,400, 2,500, 2,600, 2,700, 2,800, 2,900, or 30 million fibers per gram.

[0032] The wood fibers suitable for use in the disclosed methods and compositions may have a fiber coarseness of about 0.05 mg / m to about 0.5 mg / m, for example, 0.05 mg / m to 0.5 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.1 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.15 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.2 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.25 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.3 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.35 mg / m. In some aspects, the wood fibers have a fiber coarseness of 0.05 mg / m to 0.4 mg / m. In some aspects, the wood fibers have a fiber thickness of 0.05 mg / m to 0.45 mg / m. In some aspects, the wood fibers have a fiber thickness of 0.1 mg / m to 0.2 mg / m. In some aspects, the wood fibers have a fiber thickness of 0.2 mg / m to 0.3 mg / m. In some aspects, the wood fibers have a fiber thickness of 0.3 mg / m to 0.4 mg / m. In some aspects, the wood fibers have a fiber thickness of 0.4 mg / m to 0.5 mg / m. For example, the wood fibers used in the disclosed methods and compositions have a fiber thickness of 0.05, 0.1, 0.15, 0.2, 0.25, 0.3, 0.35, 0.4, 0.45, or 0.5 mg / m.

[0033] The wood fibers suitable for use in the disclosed methods and compositions include cork kraft pulp (Mercer PeaceRiver Pulp Ltd.), which comprises white spruce (Picea glauca) (>90%) and black pine (Pinus contorta) (<10%), having a fiber length of 2.39 mm, a fiber width of 27.4 μm, a weight of 8.7 million fibers / gram, and a fiber thickness of 0.14 mg / m.

[0034] The compositions disclosed herein contain an adhesive, preferably from about 0.5 wt% to about 50 wt%, for example, from 0.5 wt% to 40 wt%, for example, from 0.5 wt% to 30 wt%, for example, from 0.5 wt% to 25 wt%, for example, from 0.5 wt% to 20 wt%. In some aspects, the compositions disclosed herein contain 0.5 wt% to 1 wt% of adhesive. In some aspects, the compositions disclosed herein contain 0.5 wt% to 5 wt% of adhesive. In some aspects, the compositions disclosed herein contain 0.5 wt% to 10 wt% of adhesive. In some aspects, the compositions disclosed herein contain 0.5 wt% to 15 wt% of adhesive. In some aspects, the compositions disclosed herein contain 0.5 wt% to 20 wt% of adhesive. In some aspects, the compositions disclosed herein contain 5 wt% to 10 wt% of adhesive. In some aspects, the compositions disclosed herein contain 10 wt% to 15 wt% of adhesive. In some aspects, the compositions disclosed herein contain 15 wt% to 20 wt% of adhesive. For example, the compositions disclosed herein contain 0.5, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5 or 20% by weight of adhesive.

[0035] According to this disclosure, the adhesive may be polyvinyl alcohol (PVOH), ethylene-vinyl alcohol copolymer (EVOH), starch (e.g., cooked or raw starch, including corn starch and tapioca starch), polyvinyl acetate, ethylene-vinyl acetate acrylic acid, dextrin, or combinations thereof. In some aspects, the adhesive comprises polyvinyl alcohol. In some aspects, the adhesive comprises ethylene-vinyl alcohol copolymer. In some aspects, the adhesive comprises starch. In some aspects, the adhesive comprises polyvinyl acetate. In some aspects, the adhesive comprises ethylene-vinyl acetate acrylic acid. In some aspects, the adhesive comprises dextrin. In a preferred aspect of this disclosure, the adhesive is PVOH, EVOH, or combinations thereof. PVOH and / or EVOH are particularly preferred in the manufacture of biodegradable and / or flexible products. In other aspects where a stiffer product is required, the adhesive may comprise starch. Adhesives suitable for use in the disclosed methods may be obtained, for example, from Sekisui Specialty Chemicals America, LLC (Dallas, Texas) and Kuraray Co., Ltd. (Tokyo, Japan). Preferred adhesives include SELVOL. TM Polyvinyl alcohol 840, SELVOL TM Polyvinyl alcohol 540 and SELVOL TMPolyvinyl alcohol 805. The compositions disclosed herein also contain about 0.2 wt% to about 10 wt%, preferably 0.2 wt% to 10 wt% of a surfactant. In some aspects, the composition contains 0.2 wt% to 1 wt% of a surfactant. In some aspects, the composition contains 0.2 wt% to 5 wt% of a surfactant. In some aspects, the composition contains 0.5 wt% to 5 wt% of a surfactant. In some aspects, the composition contains 1 wt% to 5 wt% of a surfactant. In some aspects, the composition contains 5 wt% to 10 wt% of a surfactant. For example, the compositions disclosed herein may contain 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, or 10 wt% of a surfactant.

[0036] The surfactants suitable for use in the disclosed compositions can be anionic surfactants, cationic surfactants, amphoteric surfactants, or combinations thereof. In some aspects, the surfactant comprises anionic surfactants. In some aspects, the surfactant comprises cationic surfactants. In some aspects, the surfactant comprises amphoteric surfactants.

[0037] Surfactants suitable for the disclosed methods include sodium dodecyl sulfate, sodium dioctyl sulfonate, dodecyl dimethylamine oxide (DDAO), octadecyl alcohol, glyceryl laurate, polysorbate, cetearyl alcohol, starch, sucrose, cetyl palmitate, lauryl dimethylamine oxide (LDAO), coamidopropyl betaine (CAPB), ethanolamine, sorbitol, disodium dihydrogen ethylenediaminetetraacetate, sulfosuccinate, or combinations thereof. Preferred surfactants for the method are… OT-75 (Solvay). The preferred surfactant for this method is... (Stepan Company). Another preferred surfactant for the method is... (Stepan Company). Another preferred surfactant for the method is... Lo Special (Stepan Company). Another preferred surfactant for the method is cocoaminopropyl betaine AMPHOSOL. (Stepan Company). Another preferred surfactant for the method is cocoaminopropyl betaine.

[0038] The compositions disclosed herein also comprise water, preferably from about 10% to about 95% by weight, for example, from 10% to 95% by weight. The water can be any water commonly used in the manufacture of paper products and can include fresh water, spring water, purified water, distilled water, reverse osmosis water, etc. Those skilled in the art will understand that the water used in the compositions and methods disclosed herein may contain trace amounts of minerals, inorganic compounds, and organic compounds. In some aspects, the composition comprises 10% to 20% by weight of water. In some aspects, the composition disclosed herein comprises 20% to 30% by weight of water. In some aspects, the composition disclosed herein comprises 30% to 40% by weight of water. In some aspects, the composition disclosed herein comprises 40% to 50% by weight of water. In some aspects, the composition disclosed herein comprises 50% to 60% by weight of water. In some aspects, the composition disclosed herein comprises 60% to 70% by weight of water. In some aspects, the composition disclosed herein comprises 70% to 80% by weight of water. In some aspects, the compositions disclosed herein contain 85% to 95% by weight of water. In some aspects, the compositions disclosed herein contain 10% to 50% by weight of water. In some aspects, the compositions disclosed herein contain 50% to 95% by weight of water. In some aspects, the compositions disclosed herein contain 25% to 50% by weight of water. In some aspects, the compositions disclosed herein contain 50% to 75% by weight of water. For example, the compositions disclosed herein may contain 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95% by weight of water.

[0039] In some aspects, the compositions of this disclosure consist of wood fibers, adhesives, surfactants, and water. In other aspects, the compositions of this disclosure consist essentially of wood fibers, adhesives, surfactants, water, and additional elements that do not materially affect the basic and novel properties of the compositions used to prepare cushioning packaging materials.

[0040] In some aspects, the compositions of this disclosure comprise wood fibers, adhesives, surfactants, water, and additives (i.e., one or more additives). Such compositions comprising additives comprise from a non-zero weight percent to a maximum of 30 weight percent of additives. Additives may include a single additive, or additives may include more than one additive. If the compositions of this disclosure comprise more than one additive, the total combined amount of additives will be from a non-zero weight percent to a maximum of 30 weight percent. In some aspects, the composition comprises up to 30 weight percent of additives. In some aspects, the composition comprises up to 25 weight percent of additives. In some aspects, the composition comprises up to 20 weight percent of additives. In some aspects, the composition comprises up to 15 weight percent of additives. In some aspects, the composition comprises up to 10 weight percent of additives. In some aspects, the composition comprises up to 5 weight percent of additives. In some aspects, the composition comprises up to 2 weight percent of additives. For example, the compositions disclosed herein may contain non-zero weight%, i.e., less than 0.1 weight, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12 0.5, 13, 13.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27.5, 28, 28.5, 29, 29.5 or 30% by weight of additives. The compositions disclosed herein may further comprise up to 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 13. 5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27.5, 28, 28.5, 29, 29.5 or up to 30% by weight of additives.

[0041] Additives suitable for use in the compositions disclosed herein include salts, starches, unexpanded microspheres, expanded microspheres, calcium carbonate, clay, nanocellulose, nanocrystalline cellulose, UV dyes, dyes, pigments, defoamers, humectants, waxes, phase change materials, microencapsulated chemicals, plasticizers, tackifiers, adhesion promoters (e.g., EGDA, PEI), crosslinking agents, polyether compounds, rheology modifiers, preservatives, antimicrobial agents, or combinations thereof.

[0042] Microspheres suitable for use in the products disclosed herein are described in, for example, U.S. Publication No. 20190284438, U.S. Publication No. 20190062028, and U.S. Patent Application No. 10,100,204, the entire contents of which are incorporated herein by reference.

[0043] Rheology modifiers, also known as thickeners or viscosity modifiers, are known in the art and include, for example, waxes, wax dispersions, hydroxyethyl cellulose, methyl cellulose, polyacrylic acid thickeners, xanthan gum, raw starch, cooked starch, or combinations thereof.

[0044] In some respects, the compositions disclosed herein will not contain any additives as inorganic ionic salts, i.e., the compositions disclosed herein may contain about 0% by weight of inorganic ionic salts.

[0045] In some aspects, the compositions of this disclosure contain an additive as an inorganic ionic salt. Such compositions containing an additive as an inorganic ionic salt are particularly preferred in those embodiments of this disclosure, wherein the intermediate foam is heated by microwave. Without wishing to be bound by any particular theory, it is believed that the inorganic ionic salt can promote a rapid temperature rise during microwave heating, thereby preparing the super-expanded foam of this disclosure. In such aspects, the inorganic ionic salt may be present in the composition in an amount of up to 30% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 25% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 20% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 15% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 10% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 5% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 4% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 3% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 2% by weight. In some aspects, the inorganic ionic salt may be present in the composition in an amount of up to 1% by weight. In other aspects, the compositions disclosed herein may contain up to 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, 9.5, 10, 10.5, 11, 11.5, 12, 12.5, 13, 1 3.5, 14, 14.5, 15, 15.5, 16, 16.5, 17, 17.5, 18, 18.5, 19, 19.5, 20, 20.5, 21, 21.5, 22, 22.5, 23, 23.5, 24, 24.5, 26, 26.5, 27, 27.5, 28, 28.5, 29, 29.5, or up to 30% by weight of an inorganic ionic salt. Suitable inorganic ionic salts in the compositions of this disclosure include sodium chloride, calcium chloride, magnesium chloride, aluminum nitrate, zirconium ammonium salts, or combinations thereof. Sodium chloride is a particularly preferred inorganic ionic salt. While not wishing to be limited to any particular theory, it is believed that the addition of a suitable inorganic ionic salt can facilitate the drying of intermediate foams prepared from the compositions of this disclosure by using the methods described herein. It is believed that, without the addition of inorganic ionic salt additives, the RF treatment produces a rapid temperature rise sufficient to prepare the super-expanded foams of this disclosure. However, if desired, the RF-treated composition may contain inorganic ionic salt additives.

[0046] Also within the scope of this disclosure is a dried pulp composition that can be hydrated or rehydrated after the addition of a predetermined amount of water to prepare the desired composition as described herein. This composition comprises 1% to 40% by weight of wood fibers, 0.5% to 20% by weight of a binder, 0.2% to 10% by weight of a surfactant, and up to 30% by weight of optionally present additives. Water can then be added to the dried pulp composition to (re)hydrate and then aerate (or simultaneously (re)hydrate and aerate) to form an intermediate foam. On one hand, wood fibers are rehydrated and aerated more quickly in this manner. On the other hand, a solution comprising (e.g., by spraying, dipping, immersion, etc.) wood fibers or wood chips / blocks containing wood fibers can be applied to form the composition disclosed herein: 0.5% to 20% by weight of a binder, 0.2% to 10% by weight of a surfactant, and up to 30% by weight of optionally present additives. Based on total weight, the final wood fiber content ranges from 1% to 40% by weight.

[0047] In another embodiment, a two-part kit; for example, one part of the kit contains an adhesive, a surfactant, and optionally additives, and this kit can be combined (e.g., by spraying, dipping, immersion, etc.) with another part of the kit containing wood fibers, and the combined kit is inflated with water to prepare an intermediate foam. The components in the two-part kit can be different, thus best meeting transportation and storage requirements. It is also envisioned that three-part or four-part kits can be manufactured to meet transportation and storage requirements. Compositions prepared in this manner can be used in any of the methods described herein.

[0048] The compositions disclosed herein comprise 1% to 40% by weight of wood fibers, 0.5% to 20% by weight of a binder, 0.2% to 10% by weight of a surfactant, 10% to 95% by weight of water, and up to 30% by weight of optional additives. The compositions can be mixed with and combined (i.e., aerated) with air using methods known in the art to form an intermediate foam, thereby incorporating air into the aqueous composition. In one embodiment, the wood fibers are mechanically broken down from their original dense form prior to mixing and aeration. In another embodiment, the mixing and aeration steps also mechanically break down the wood fibers simultaneously, depending on the rate of mixing and aeration. In some aspects, air is added to the material until the total volume percentage of air is 95%. As used herein, the “volume percentage of air” in the formulation is calculated according to the following equation:

[0049] Equation

[0050]

[0051] In some respects, intermediate foam will have the consistency and appearance of commercial shaving cream foam or personal care mousse. In other respects, intermediate foam will have the consistency and appearance of pancake batter.

[0052] The intermediate foam prepared according to this disclosure may contain about 10 vol% to about 95 vol%, for example, 10 vol% to 95 vol% air. In some aspects, the intermediate foam contains 10 vol% to 50 vol% air. In some aspects, the intermediate foam contains 50 vol% to 95 vol% air. In some aspects, the intermediate foam contains 20 vol% to 95 vol% air. In some aspects, the intermediate foam contains 30 vol% to 80 vol% air. In some aspects, the intermediate foam contains 40 vol% to 50 vol% air. In some aspects, the intermediate foam contains 50 vol% to 90 vol% air. In some aspects, the intermediate foam contains 70 vol% to 95 vol% air. For example, the intermediate foam prepared according to this disclosure may contain 10, 15, 20, 25, 30, 35, 40, 45, 50, 55, 60, 65, 70, 75, 80, 85, 90, or 95 vol% air.

[0053] The intermediate foam of this disclosure can be prepared by combining air with the composition of this disclosure using one or more methods known in the art. Suitable methods for combining air include, for example, injection, mixing, shearing, paddle mixing, cowles mixing, frame mixing, spiral mixing, or combinations thereof.

[0054] At temperatures between 25°C and 40°C, the intermediate foam prepared according to the disclosed method has a viscosity of about 3,000 to about 100,000 cPs, for example, 5,000 to 100,000 cPs. Viscosity can be measured using methods known in the art. In some aspects, at 25°C, the intermediate foam prepared according to the disclosed method has a viscosity of 5,000 to 100,000 cPs. In some aspects, at 40°C, the intermediate foam prepared according to the disclosed method has a viscosity of 5,000 to 100,000 cPs. In some aspects, at 25°C, the intermediate foam prepared according to this disclosure has a viscosity of 5,000 to 10,000 cPs. In some aspects, at 25°C, the intermediate foam prepared according to this disclosure has a viscosity of 10,000 to 20,000 cPs. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 20,000 to 30,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 30,000 to 40,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 40,000 to 50,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 60,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 60,000 to 70,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 70,000 to 80,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 80,000 to 90,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 90,000 to 100,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 5,000 to 50,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 100,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 25,000 to 50,000 cPs at 25°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 75,000 cPs at 25°C. In some aspects, at 25°C, the intermediate foam prepared according to this disclosure has a viscosity of 75,000 to 100,000 cPs. In some aspects, at 40°C, the intermediate foam prepared according to this disclosure has a viscosity of 5,000 to 10,000 cPs. In some aspects, at 40°C, the intermediate foam prepared according to this disclosure has a viscosity of 10,000 to 20,000 cPs.In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 20,000 to 30,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 30,000 to 40,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 40,000 to 50,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 60,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 60,000 to 70,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 70,000 to 80,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 80,000 to 90,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 90,000 to 100,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 5,000 to 50,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 100,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 25,000 to 50,000 cPs at 40°C. In some aspects, the intermediate foam prepared according to the present disclosure has a viscosity of 50,000 to 75,000 cPs at 40°C. In some respects, at 40°C, the intermediate foam prepared according to this disclosure will have a viscosity of 75,000 to 100,000 cPs. For example, at 25°C, the intermediate foam prepared according to this disclosure can have a viscosity of 5,000, 10,000, 15,000, 20,000, 25,000, 30,000, 35,000, 40,000, 45,000, 50,000, 55,000, 60,000, 65,000, 70,000, 75,000, 80,000, 85,000, 90,000, 95,000, or 100,000 cPs. In other respects, at 40°C, the intermediate foam prepared according to this disclosure can have a viscosity of 5,000, 10,000, 15,000, 20,000, 25,000, 30,000, 35,000, 40,000, 45,000, 50,000, 55,000, 60,000, 65,000, 70,000, 75,000, 80,000, 85,000, 90,000, 95,000, or 100,000 cPs.

[0055] The intermediate foam prepared according to the method of this disclosure can have a density of about 0.5 lb / gal to about 5 lb / gal, for example, from 0.5 lb / gal to 5 lb / gal. In some aspects, the intermediate foam prepared according to the method of this disclosure has a density of 0.5 lb / gal to 3 lb / gal. In some aspects, the intermediate foam prepared according to the method of this disclosure has a density of 3 lb / gal to 5 lb / gal. For example, the intermediate foam prepared according to the method of this disclosure has a density of 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, or 5 lb / gal.

[0056] As part of the process for manufacturing packaging materials, the intermediate foam of this disclosure can be applied to a first web substrate, which may also be referred to herein as a first layer or a first strip. The first web substrate has a top surface and a bottom surface, as well as a width defining a perimeter.

[0057] Intermediate foam may be applied to a first web substrate using any method known in the art, such as rolling, dripping, discrete application, etc. In some aspects, an nozzle oriented perpendicular to the first web substrate is used to apply the intermediate foam. The intermediate foam may be applied in the form of discrete elements, such as randomly or in patterns (e.g., patterns of dots, lines, squares, triangles, etc.).

[0058] The first web substrate can include any web material suitable for manufacturing packaging materials. For example, the first web substrate can include paper, corrugated paper, compostable polymer films (e.g., Sco Film and Ecoworks from Cortec Corporation; Nativa from Taghleef Industries; Natureflex from Futamura), biodegradable polymer films, bio-based films (e.g., polylactic acid films); cellulosic... TM Polyester film, polypropylene film, polyethylene film, metallized film, renewable paper, recycled paper, renewable coated paper (e.g., Cascades Sonoco's SurfShield; Smartplanet's...). ), renewable metal vapor deposition paper (e.g., Lecta's MetalVac F), or combinations thereof.

[0059] Intermediate foams prepared using the compositions and methods of this disclosure can be treated to remove water. In a preferred aspect, the intermediate foam is treated to convert liquid water present in the intermediate foam into water vapor and / or steam, which is released into the atmosphere. Intermediate foam treated to remove liquid water is also referred to herein as dried intermediate foam, and may be referred to herein as “dry foam” or “super-expanded foam.” This treatment substantially removes all water from the intermediate foam. For example, the treatment removes up to 100% by weight of the water in the intermediate foam of this disclosure. In other aspects, the treatment removes up to 99% by weight of the water in the intermediate foam of this disclosure. In other aspects, the treatment removes up to 95% by weight of the water in the intermediate foam of this disclosure. In other aspects, the treatment removes up to 90% by weight of the water in the intermediate foam of this disclosure. In other aspects, the treatment removes up to 85% by weight of the water in the intermediate foam of this disclosure. In other aspects, the treatment removes up to 80% by weight of the water in the intermediate foam of this disclosure. In other aspects, this treatment removes up to 75% by weight of water from the intermediate foam of this disclosure. In other aspects, this treatment removes up to 70% by weight of water from the intermediate foam of this disclosure. In other aspects, this treatment removes up to 65% by weight of water from the intermediate foam of this disclosure. In other aspects, this treatment removes up to 60% by weight of water from the intermediate foam of this disclosure. In other aspects, this treatment removes up to 55% by weight of water from the intermediate foam of this disclosure. In other aspects, this treatment removes up to 50% by weight of water from the intermediate foam of this disclosure.

[0060] Various methods can be used to remove the liquid water from the intermediate foam disclosed herein (i.e., drying). In some aspects, the intermediate foam of this disclosure is treated with ambient temperature and humidity to remove water. In other aspects, the intermediate foam is treated with conventional heating to remove water. In still other aspects, the drying method does not include conventional heating, such as heating using an oven capable of generating heating temperatures from about 100°C to about 450°C.

[0061] In some respects, intermediate foams prepared using the compositions and methods of this disclosure can be dried by using dielectric heating. In such methods, the intermediate foam is converted into a super-expanded foam. While not wishing to be limited to any particular theory, it is thought that when liquid water bound between the wood fiber layers of the intermediate foam is rapidly converted into water vapor and / or steam, it causes the intermediate foam to expand as the water vapor and / or steam is released from the intermediate foam, thereby producing a super-expanded (dried) foam.

[0062] The percentage increase in total volume of the super-expanded foam disclosed herein can be determined by measuring (e.g., with calipers or a micrometer) in the x, y, and z directions of the super-expanded foam and comparing the measurements in the x, y, and z directions with those of intermediate foam prior to dielectric treatment. Using the measurements obtained with calipers or a micrometer, the volume of the super-expanded foam can be determined according to the following equation:

[0063] X measured value * Y measured value * Z measured value = Foam volume

[0064] The equation for the final increase in foam volume for each element is as follows:

[0065]

[0066] Compared to the volume of the intermediate foam, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 5% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of up to 1000% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 10% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 15% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 20% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 25% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 30% (volume percentage). In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 35% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 40% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 45% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 50% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 55% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 60% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 65% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 70% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 75% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 80% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 85% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 90% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 95% by volume compared to the volume of the intermediate foam.In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 100% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 110% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 120% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 130% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 140% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 150% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 160% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 170% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 180% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 190% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 200% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 210% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 220% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 230% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 240% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 250% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 260% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 270% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 280% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 290% by volume compared to the volume of intermediate foam.In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 300% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 310% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 320% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 330% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 340% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 350% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 360% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 370% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 380% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 390% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 400% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 410% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 420% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 430% by volume compared to the volume of intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 440% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 450% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 460% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 470% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 480% by volume compared to the volume of the intermediate foam. In some aspects, the super-expanded foam of this disclosure exhibits an overall volume increase of at least 490% by volume compared to the volume of the intermediate foam.In some respects, the super-expanded foam of this disclosure will exhibit an overall volume increase of at least 500% compared to the volume of intermediate foam.

[0067] When the intermediate foam of this disclosure is dielectrically heated for a pre-selected duration using a pre-selected frequency, the dielectric heating causes the intermediate foam to expand in each of the x, y, and / or z directions, in order to prepare a super-expanded foam with a lower water content compared to the initial intermediate foam. Treatment of the intermediate foam of this disclosure using non-dielectric heating, or using dielectric heating outside the frequency and time range of this disclosure, does not cause the intermediate foam to expand to form a super-expanded foam.

[0068] Dielectric heating, electronic heating, radio frequency (RF) heating, and high-frequency heating, which are all used interchangeably herein, are processes in which a high-frequency alternating electric field or radio waves heats a dielectric material. Industrial RF frequencies operate between approximately 2 MHz and 300 MHz, with typical wavelengths ranging from approximately 141 to approximately 24 feet (43 to 7.3 meters). Preferred RF frequencies include those less than 100 MHz, such as 13.56, 27.12, and 40.68 MHz.

[0069] In some aspects, the intermediate foam prepared using the compositions and methods of this disclosure can also be dried using dielectric heating as microwave heating to prepare super-expanded foam. Microwave heating causes the intermediate foam to expand in each of the x, y, and / or z directions to prepare super-expanded foam. Industrial microwave systems use frequencies exceeding 300 MHz, with typical wavelengths ranging from about 13 to about 5 inches (33 and 12 cm). Preferred microwave frequencies include 915 MHz and 2750 MHz.

[0070] In other aspects, the intermediate foam is dried using a combination of dielectric heating and conventional heating. For example, the intermediate foam of this disclosure can be treated with dielectric heating in a first processing step to form super-expanded foam, and the resulting super-expanded foam can be treated with conventional heating in a second processing step. In other aspects, the intermediate foam is treated using a combination of dielectric heating, conventional heating, and ambient temperature / humidity. For example, the intermediate foam of this disclosure can be treated with dielectric heating in a first processing step, and the resulting super-expanded foam can be heated with conventional heating in a second processing step, and then the conventionally heated super-expanded foam is treated with ambient temperature / humidity in a third processing step.

[0071] When the intermediate foam of this disclosure is heated using dielectric heating (e.g., RF, microwave) to prepare a super-expanded foam, the intermediate foam of this disclosure expands in each of the x, y, and / or z directions. In some aspects, the intermediate foam of this disclosure expands by at least 20% by volume in the x, y, or z direction to prepare a super-expanded foam. In some aspects, the intermediate foam may expand by up to 200% in the x direction, up to 200% in the y direction, and / or up to 200% in the z direction to prepare a super-expanded foam.

[0072] In some aspects, the intermediate foam can expand by up to 150% in the x-direction to prepare super-expanded foam. In some aspects, the intermediate foam can expand by up to 100% in the x-direction to prepare super-expanded foam. In some aspects, the intermediate foam can expand by up to 50% in the x-direction to prepare super-expanded foam. In some aspects, the intermediate foam expands by 10% to 50% in the x-direction to prepare super-expanded foam. In some aspects, the intermediate foam expands by 20% to 40% in the x-direction to prepare super-expanded foam. For example, the intermediate foam of this disclosure can expand by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the x-direction to prepare super-expanded foam.

[0073] In some aspects, the intermediate foam expands by 5% to 50%, for example, 10% to 50%, in the y-direction to prepare a super-expanded foam. In some aspects, the intermediate foam can expand by up to 200% in the y-direction to prepare a super-expanded foam. In some aspects, the intermediate foam can expand by up to 100% in the y-direction to prepare a super-expanded foam. In some aspects, the intermediate foam can expand by up to 50% in the y-direction to prepare a super-expanded foam. In some aspects, the intermediate foam expands by 15% to 35% in the y-direction to prepare a super-expanded foam. For example, the intermediate foam of this disclosure can expand by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the y-direction to prepare a super-expanded foam.

[0074] In some aspects, the intermediate foam can expand up to 200% in the z-direction to prepare super-expanded foam. In some aspects, the intermediate foam can expand up to 100% in the z-direction to prepare super-expanded foam. In some aspects, the intermediate foam can expand up to 50% in the z-direction to prepare super-expanded foam. In some aspects, the intermediate foam expands from 5% to 50% in the z-direction to prepare super-expanded foam. In some aspects, the intermediate foam expands from 1% to 25% in the z-direction, for example, from 5% to 25%, to prepare super-expanded foam. For example, the intermediate foam of this disclosure can expand by 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 15, 20, 25, 30, 35, 40, 45, or 50% in the z-direction to prepare super-expanded foam.

[0075] In some aspects, when using dielectric heating (e.g., RF or microwave) to prepare super-expanded foam, the intermediate foam expands by approximately 35% in the x-direction, approximately 30% in the y-direction, and approximately 20% in the z-direction. In other aspects, when using dielectric heating (e.g., RF or microwave) to prepare super-expanded foam, the intermediate foam expands by approximately 23% in the x-direction, approximately 99% in the y-direction, and approximately 111% in the z-direction. See, for example... Figure 4A , 4B 5A, 5B.

[0076] Conventional heating of the disclosed intermediate foam does not produce the same degree of super-expansion of the intermediate foam in each of the x, y, and / or z directions as dielectric heating (e.g., RF, microwave). Therefore, conventional heating of the compositions of this disclosure will not produce super-expanded foams within the scope of this disclosure without any treatment using dielectric heating.

[0077] Products prepared by applying the intermediate foam of this disclosure to a first web substrate are within the scope of this disclosure. Also within the scope of this disclosure are products prepared by applying the intermediate foam of this disclosure to a first web substrate and expanding the intermediate foam in each of the x, y, and / or z directions by applying dielectric heat to the intermediate foam or by applying dielectric heat to the intermediate foam and the first web substrate to prepare a super-expanded foam.

[0078] Laminated articles are also within the scope of this disclosure. According to this disclosure, a "laminated" article refers to those products having a foam (e.g., intermediate foam or super-expanded foam) of this disclosure sandwiched between the surfaces of one or more web substrates. Some laminated articles of this disclosure are single-layer laminated articles having a foam (e.g., intermediate foam or super-expanded foam) of this disclosure sandwiched between the surfaces of one web substrate. In other aspects, single-layer laminated articles have a foam (e.g., intermediate foam or super-expanded foam) of this disclosure sandwiched between the surfaces of two different web substrates.

[0079] In some aspects, such single-layer laminated articles comprise: a first web substrate having an intermediate foam of the present disclosure applied to the substrate, wherein an adhesive is applied to the first web substrate; and a second web substrate to which the intermediate foam is applied, the laminated material optionally having been dielectrically heat-treated to prepare a super-expanded foam. An adhesive is applied to at least a portion of the first web substrate, for example, to at least a portion of the periphery of the first web substrate, and the second web substrate is applied to the adhesive to form the laminated article. The single-layer laminated articles may optionally be treated with conventional heat or dielectric heat. Such single-layer laminated articles can be converted into packaging, such as sleeves or pouches.

[0080] In other aspects, a single-layer laminated article can be prepared by providing a first web substrate on which the intermediate foam of this disclosure has been applied. In some aspects, a single-layer laminated article can be prepared by folding the first web substrate at a seam, and the other two edges can be sealed together with an adhesive to form a pouch. It is also envisioned that a pressure-sensitive adhesive strip can be attached to the last remaining edge to seal the pouch to form a sealed package. The pressure-sensitive adhesive may have an inner lining cover, which can be removed at a later point to close and seal the remaining edges. The laminated article comprises an intermediate foam of a composition (which has optionally been dielectrically heated to prepare a super-expanded foam), and the laminated article can be the basis for forming products including sleeves, bags, pouches, boxes, cartons, shells, lids, wraps, flaps, cups, and food containers with adhesive.

[0081] In some aspects, "multilayer laminated" articles can be prepared according to the methods of this disclosure. Multilayer laminated articles are prepared by combining two or more single-layer laminated articles of this disclosure. The multilayer laminated articles may optionally be dielectrically heated. Such multilayer laminated articles can be converted into packaging, such as sleeves or pouches. For example, a pouch can be formed by bonding a first single-layer laminated article to three of the four sides of a second single-layer laminated article using an adhesive. It is also contemplated that a pressure-sensitive adhesive strip can be attached to the last remaining edge to seal the pouch for a sealed package. The pressure-sensitive adhesive may have an inner liner cover, which can be removed at a later point to close and seal the remaining edges. The multilayer laminated article comprises a foam of a composition (which has optionally been dielectrically heated), and the multilayer laminated article can be the base for forming products including sleeves, bags, pouches, boxes, cartons, shells, lids, wraps, flaps, cups, and food containers with adhesives.

[0082] In some aspects, the intermediate foam of this disclosure can be applied to remain in a pre-selected position on the web substrate. The adhesion of the intermediate foam of this disclosure to the web substrate can be adjusted by modifying the type and amount of each component in the intermediate foam. In some aspects, adjusting the type and amount of the adhesive is sufficient to modify the adhesion of the intermediate foam. In some aspects, additives can be modified to include components that increase or decrease adhesion. In other aspects, the adhesion of the intermediate foam to the web substrate is adjusted, for example, by applying an adhesive before or after applying the intermediate foam to the web substrate; by hydrogen bonding between the web substrate and the intermediate foam; or a combination thereof. Ideally, the super-expanded foam maintains adhesion to the web substrate even after compression and / or shearing.

[0083] Products prepared according to the methods of this disclosure may contain adhesives. Adhesives are known in the art and include, for example, water-based adhesives, solvent-based adhesives, hot melt adhesives, and pressure-sensitive adhesives. The adhesives used in the products described herein may also be made from renewable, compostable, or biodegradable materials to further reduce the carbon footprint of the final product. Hot melt adhesives and water-based adhesives are contemplated because they can be processed simultaneously with conventional or dielectric heating of the intermediate foam of this disclosure. During conventional or dielectric heating of the intermediate foam, the hot melt adhesive and water-based adhesive solidify and bond the substrates together. Preferred adhesives suitable for use in said products include, for example, adhesives comprising: ethylene-vinyl acetate (EVA), polyvinyl acetate (PVA), polyvinyl alcohol (PVOH), ethylene-vinyl alcohol copolymer (EVOH), acrylics, acrylates, polyurethanes (PUR), epoxy resins, polyolefins, and combinations thereof.

[0084] Products prepared using the compositions, intermediate foams, super-expanded foams, and methods of this disclosure include lined envelopes and other paper packaging products. Products prepared according to this disclosure can be highly renewable in conventional waste paper streams. Products prepared according to this disclosure can be biodegradable. Standards for biodegradability include OECD 301, 304A, and 306. Products prepared according to this disclosure can be compostable. Standards for compostability include ISO 17088, ISO 18606, ASTM D6400, and ASTM D6868. Products prepared according to the methods of this disclosure may also conform to ASTM D5929-18.

[0085] In some respects, as described herein, concentrated compositions comprising binders, surfactants, and optionally additives and water can be prepared and applied (e.g., by spraying, coating, soaking, impregnation, etc.) to wood fiber-containing substrates, such as pulp sheets or pulp sheet packages containing wood fibers. Such concentrated compositions are also within the scope of this disclosure. The resulting pulp sheets or pulp packages can be dried using conventional methods, on which the concentrated compositions of binders, surfactants, optionally additives, and optionally water have been applied. Pulp sheets and pulp packages treated with the concentrated compositions described herein are also within the scope of this disclosure. The amounts of binders, surfactants, and optionally additives present in such compositions are such that when the dried pulp sheets or pulp packages are added to a certain amount of water for soaking, the resulting composition will contain 1% to 40% by weight of wood fibers, 0.5% to 20% by weight of binders, 0.2% to 10% by weight of surfactants, 10% to 95% by weight of water, and up to 30% by weight of optionally present additives. The resulting composition can be used in any of the methods described herein to generate intermediate and super-expanded foams that can be used in the manufacture of packaging materials.

[0086] The following examples are for illustrative purposes only and should not be construed as limiting the scope of the invention described and claimed herein.

[0087] Example

[0088] Example 1

[0089] Wood fibers are soaked in water, mechanically breaking them down from their original compact form. Binders, surfactants, and optional additives are added. The mixture is mechanically blended and aerated until a predetermined air content is achieved. A blade or blending process can combine appropriate fiber breakdown, blending, and air content. Higher speeds may be required to completely separate the fibers and produce foam with the consistency and appearance typically found in personal care mousses such as shaving cream. Chemical foaming agents or bleaching agents will not be needed.

[0090] After mixing and aeration, additional air can be injected into the foam during transfer. The material can be transferred using, for example, diaphragm pumps, gear pumps, auger systems, rotary tubes, high-shear mixers, gravity feed, vacuum, etc. The resulting intermediate foam is transferred in one or more conveying systems for application to the web substrate.

[0091] Application to the web substrate may or may not occur in contact with the web substrate. Intermediate foam can be extruded using a specific shape or press to achieve elements of the desired size / shape. Intermediate foam can optionally be metered into an open web substrate using a press, extrusion equipment, or open channel, forming a pre-selected shape on the web substrate. Intermediate foam can be applied in the form of strips, stripes, dots, or patterns, or in combination with various element shapes / sizes.

[0092] Intermediate foam is applied in a discontinuous pattern along the direction of the web or orthogonal web. Preferred patterns comprise elements with a minimum dimension less than 0.5 inches and a maximum dimension no greater than 1.5 inches. The spacing between the intermediate foam pattern elements depends on the thickness of the applied intermediate foam. Preferably, the thickness is from about 0.1 inches to about 0.5 inches. See, for example... Figure 6 .

[0093] Example 2

[0094] After applying the intermediate foam to the web substrate, the conversion equipment should not apply excessive pressure to the intermediate foam. If it is laminated, apply minimal compression at the point where the intermediate foam is applied. Optionally, apply pressure to the edges of the web substrate to ensure adequate system closure while maintaining thickness.

[0095] Example 3

[0096] One or more methods are used to dry the intermediate foam. RF and microwave drying parameters are shown in the table in Example 4. Depending on the drying method, super-expanded foams with a larger volume than the intermediate foam can be prepared. The super-expanded foam will be flexible and bend under average hand pressure. After dielectric heat treatment, the initial general shape of the intermediate foam is retained, and most of the super-expanded foam material remains in place during packaging and use.

[0097] Example 4

[0098]

[0099] Example 5

[0100]

[0101] In Example 5, an intermediate foam was prepared by mixing the components for 11 minutes using a manual mixer and a paddle mixer. The resulting intermediate foam of Example 5 had a viscosity of approximately 30,000 cPs and a density of 3.6 psi (wet). A wet dot of 0.5 g of the intermediate foam was applied to a paper substrate and then microwaved at 1000 watts for approximately 5 minutes. When Example 5 was microwaved, a dimensional increase of ≤20% in the x, y, and z directions was observed.

[0102] In a convection oven at 375°F, 0.5 g of wet speckled material from the intermediate foam of Example 5 required 17 minutes to dry. 37 g of wet speckled material from the intermediate foam required 1.5 hours (90 minutes) to dry in the oven at 375°F. See also Figure 2 .

[0103] The material obtained through microwave treatment is rigid and has minimal flexibility. When tested on a texture analyzer, the microwave-treated material requires approximately 140 g / mm to compress. The component maintains its general shape throughout the drying process. See example. Figure 7 .

[0104] Example 6

[0105]

[0106] The intermediate foam prepared according to Example 6 has a viscosity of approximately 20,000 cPs. The intermediate foam has a low foam volume and a density of 6.0 psi. Although Example 6 initially exhibited a higher visible foam peak compared to the unaerated composition, this volume dissipated with the combination of all the raw material components. Before the addition of NaCl, the density of the intermediate foam material was approximately 1.3 psi. See also Figure 8 .

[0107] 0.5g of the intermediate foam from Example 6 was formed into dots on paper and then microwaved for approximately 5 minutes. The wet dots of the 0.5g intermediate foam decreased by 1% in the x-direction, increased by 6% in the y-direction, and increased by 3% in the z-direction. Once dried, the overall % volume increase of the microwaved foam was 4% (volume).

[0108] For a 0.5-gram component, the intermediate foam treatment in Example 6 requires 10 minutes in a conventional oven at 375°F.

[0109] Example 7

[0110]

[0111] The intermediate foam prepared in Example 7 has a viscosity of approximately 20,000 cPs and a wet density of 1.1 psi. The intermediate foam of Example 7 was applied in 0.5 g dots to a paper substrate, which was then microwaved at 1000 watts for approximately 30 seconds to prepare a super-expanded foam. Upon microwave treatment, the volume of the material increases, while the general shape of the elements is maintained within the resulting super-expanded foam. The super-expanded foam exhibits adhesion to the paper substrate and remains stationary during movement. The super-expanded foam is flexible and requires approximately 4 g / mm² for compression.

[0112] For a 2-inch length of yarn with 0.5 g of intermediate foam, once the intermediate foam is processed to prepare a super-expanded foam (e.g., dried), the volume increases by 18% in the x-direction, 84% in the y-direction, and 66% in the z-direction. For a 2-inch length of wet yarn with 1.0 g of intermediate foam, once dried to prepare a super-expanded foam, the volume increases by 23% in the x-direction, 115% in the y-direction, and 87% in the z-direction. See example. Figure 3 .

[0113] When measured in the X, Y, and Z directions using calipers / micrometers and compared to measurements of intermediate foam for a 2-inch line with 0.5 grams of material, the % volume increase of the super-expanded foam showed: a 240% increase in volume compared to the intermediate foam. When compared to the intermediate foam, the % volume increase of the super-expanded foam was 360% of the volume increase. See also Figure 3 .

[0114] Example 8

[0115] Material ％ Fiber – Bleached Spruce Cork Kraft Paper 10 Adhesives – Henkel Intermediate 911-22 7.5 surfactants 2.5 Additive – Raw pearl starch 5 water 75 Air (after foaming, humid) 82% by volume

[0116] The components were uniformly mixed, and the resulting intermediate foam of Example 8 had a final viscosity of 15,000 cPs. The density of the intermediate foam was 1.4 psi. When the intermediate foam was applied to a web substrate as discrete patterned elements, it retained its general shape and structure. Microwave treatment increased the dimensions of the intermediate foam in the x, y, and z directions to prepare a super-expanded foam. When evaluated on a texture analyzer, the super-expanded foam had a stiffness of approximately 68 g / mm². See also Figure 9 .

[0117] Example 9

[0118]

[0119] The components were uniformly mixed, and the resulting intermediate foam of Example 9 had a final viscosity of approximately 4,000 cPs. The final density of the intermediate foam was 1.2 psi. When the intermediate foam was applied to a paper substrate in a discrete pattern, it retained its general shape and structure. After microwave treatment, the intermediate foam generated the super-expanded foam of Example 9. After microwave treatment, the % volume increase from the intermediate foam to the super-expanded foam was ≥4% in each direction. After drying, the super-expanded foam remained flexible.

[0120] 0.5 g of the intermediate foam element from Example 9 was treated in a conventional oven at 375°F for 10 minutes. No dimensional increase was observed when the intermediate foam was dried in the oven. A loss of height (z-direction) was observed once the intermediate foam was dried using a conventional oven. Dimensional increase was only observed when the intermediate foam was microwaved to prepare the super-expanded foam.

[0121] Example 10

[0122]

[0123] The components were uniformly mixed, and the resulting intermediate foam of Example 10 had a final viscosity of approximately 11,000 cPs. The final density of this intermediate foam was 1.4 lb / gallon. During application, the intermediate foam was unstable, and the wood fibers were not uniformly dispersed within it. When the intermediate foam sample was applied to a paper substrate, it dried rapidly, and when applied to the substrate as discrete elements, it retained its general shape and structure. After microwave drying to prepare a super-expanded foam, the super-expanded foam exhibited a slight increase in size in the x, y, and z directions. The overall thickness of the final (dried) laminate was approximately 0.20 inches. Microwave treatment of 0.5 g of the intermediate foam as a wet dot for approximately 3 minutes removed most of the water from the intermediate foam to prepare the super-expanded foam. See also Figure 10A Treating 0.5 g of the wet dotted sheet of the intermediate foam from Example 10 in a conventional oven at 375°F requires 10 minutes and does not produce super-expanded foam. See also Figure 10B .

[0124] Example 11:

[0125] Material ％ Fiber – Bleached Spruce Cork Kraft Paper 12％ Adhesives – Henkel Intermediate 911-22 10％ Surfactant – Amphosol CG-50 1.5％ Additive – NaCl 1.5％ water 75％ Air (after foaming, humid) 86% by volume

[0126] The intermediate foam prepared according to Example 11 has a density of 0.88 psi and a viscosity of about 25,000 cPs. The intermediate foam of Example 11 was placed on a paper substrate as a 0.25 g wet dot and dried in a 1000 W microwave at (i) 100% power and (i) 30% power.

[0127] The intermediate foam was treated in a 1000-watt microwave at 30% power for approximately 60 seconds, generating a super-expanded foam with a moisture content of 10-15% by weight. When preparing the super-expanded foam, a 0.25-gram sample of wet intermediate foam increased in volume by 19% in the x-direction, 24% in the y-direction, and decreased by 22% in the z-direction. Compared to the intermediate foam volume, the overall average volume of the super-expanded foam increased by 46%. See also Figure 11A .

[0128] Treating 0.25 g of wet specks of intermediate foam at 100% power in the same microwave environment for 30 seconds produced super-expanded foam with 10-15% by weight moisture. Compared to intermediate foam, the 0.25 g sample of intermediate foam increased by 43% in the x-direction, 28% in the y-direction, and 5% in the z-direction. The overall average volume of the super-expanded foam increased by 182% compared to the volume of the intermediate foam. See also Figure 11B .

Claims

1. A method for forming super-expanded foam, the method comprising the following steps: (1) Preparing a composition comprising: 1% to 40% by weight of wood fiber; From 5% to 20% by weight of an adhesive, said adhesive being polyvinyl alcohol, ethylene-vinyl alcohol copolymer, polyvinyl acetate, ethylene vinyl acetate acrylic acid, dextrin, vinyl acetate-ethylene copolymer, or a combination thereof; 0.2% to 10% by weight of a surfactant, said surfactant being sodium dioctyl sulfosuccinate, dodecyl dimethylamine oxide, octadecyl alcohol, glyceryl laurate, polysorbate, hexadecyl alcohol, hexadecyl palmitate, lauryl dimethylamine oxide, cocoaminopropyl betaine, ethanolamine, sorbitol, disodium dihydrogen ethylenediaminetetraacetate, or combinations thereof; 10% to 95% by weight of water; and 0% to 30% by weight of additives; (2) The composition is mixed and aerated to form an intermediate foam, the intermediate foam comprising 10% to 95% by volume of air and 90% to 5% by volume of the composition; (3) Apply the intermediate foam to the web substrate; and (4) Heat the intermediate foam to substantially remove the water; Heating the intermediate foam causes it to expand in each of the x, y, and z directions, thereby forming a super-expanded foam. The step (4) is performed by applying dielectric heat to the intermediate foam, wherein the dielectric heat is microwave.

2. The product prepared according to the method of claim 1.

3. The method of claim 1, further comprising applying an adhesive to at least a portion of a first web substrate.

4. The method of claim 3, wherein the first sheet substrate is paper, a compostable polymer film, a biodegradable polymer film, celluloid, polyester film, polypropylene film, polyethylene film, metallized film, or a combination thereof.

5. The method of claim 4, wherein the first sheet substrate is corrugated paper, renewable paper, recycled paper, bio-based film, or a combination thereof.

6. The method of claim 5, wherein the first sheet substrate is renewable coated paper, renewable metal vapor deposition paper, or a combination thereof.

7. The method of claim 3, wherein the adhesive comprises EVA, PVA, PVOH, EVOH, acrylics, acrylates, PUR, epoxy resins, or polyolefins or combinations thereof.

8. The method of claim 3, the method further comprising applying an adhesive to the joint of a second web substrate to form a laminated structure.

9. The method of claim 8, wherein the second sheet substrate is paper, a compostable polymer film, a biodegradable polymer film, celluloid, polyester film, polypropylene film, polyethylene film, metallized film, or a combination thereof.

10. The method of claim 9, wherein the second sheet substrate is corrugated paper, renewable paper, recycled paper, bio-based film, or a combination thereof.

11. The method of claim 10, wherein the second sheet substrate is renewable coated paper, renewable metal vapor deposition paper, or a combination thereof.

12. The product prepared by the method according to claim 9.

13. The product of claim 12, wherein the product is in the form of an adhesive, such as a sleeve, bag, box, container, shell, lid, wrapping, cup, or food container.

14. The product of claim 13, wherein the product is in the form of an adhesive bag or flap.

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