Lignocellulosic and cellulosic products

Abstract

The present disclosure provides lignocellulosic or cellulosic products having physical, chemical, and mechanical properties relevant for various commercial applications (e.g., food containers) and methods of manufacturing the same. In accordance with various embodiments, provided products and methods include use of specially prepared coatings (e.g. CNF-containing coatings). The present disclosure provides a lignocellulosic product including: a substrate comprising of pulp and wood flour and a cellulose nanofibril (CNF) or lignin-containing CNF (LCNF) layer.

Description

LIGNOCELLULOSIC AND CELLULOSIC PRODUCTSCROSS-REFERENCE TO RELATED APPLCIATIONS

[0001] This application claims the benefit of U.S. Provisional Application No. US 63 / 632,817, filed April 11, 2024, the contents of which are incorporated herein in its entirety.BACKGROUND

[0002] The environment faces a grave threat attributable to plastic pollution. Plastic pollution alters ecosystems and negatively contributes to climate change, thereby directly affecting social well-being and the global economy. Non-compostable plastic wastes constitute a significant portion of plastic pollution and are incinerated, landfilled, or make their way into oceans and other marine ecosystems. Single-use plastics (e.g., disposable plates, cups, straws, utensils, etc.) account for about 70% of the total global production of plastics and utilize a large carbon, water, and resource footprint for their manufacture.

[0003] Products (e.g., food containers) made from renewable resources, such as natural fibers (e.g., pulp and paper fibers), are a promising alternative to meet market demands and to reduce the environmental impact of single-use plastics made from fossilbased plastics. However, pulp and paper-based products are not inherently resistant to water and oil / grease and often require additional treatments for usability. The most common method for imparting oil / grease in commercial products is treatments with poly-fluoroalkyl substances (PFAs) which are long-chain polymers that are resistant to environmental degradation and has been reported to be carcinogenic and disruptive to human endocrine and reproductive systems.

[0004] Thus, there is global environmental and health need for substantially rigid oil / grease resistant products that are free from PFAs that are biodegradable, and economical to manufacture.SUMMARY

[0005] The present disclosure provides lignocellulosic and cellulosic products having physical and mechanical properties relevant for various commercial applications (e.g., foodcontainers) and methods of manufacturing the same. In accordance with various embodiments, provided products and methods include use of specially prepared coatings (e.g. CNF-containing coatings).

[0006] In some embodiments, the present disclosure provides a lignocellulosic product including: a substrate comprising about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour; and a cellulose nanofibril (CNF) or lignin-containing CNF (LCNF) layer, wherein the lignocellulosic product comprises at least about 2.5 wt% CNFs.

[0007] In some embodiments, pulp includes bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof.

[0008] In some embodiments, a substrate includes CNFs (e.g., about 2.5 wt% to about 10 wt% CNFs). In some embodiments, CNFs include lignin-free CNFs, LCNFs, delignified CNFs (DCNFs), or a combination thereof.

[0009] In some embodiments, a substrate is molded or formed from a flat sheet. In some embodiments, a substrate is a sheet, a plate, a bowl, a cup, a vessel, a container, a tray, or a pouch.

[0010] In some embodiments, a CNF or LCNF layer has a thickness of about 5 pm to about 80 pm. In some embodiments, a CNF or LCNF layer has a density of about 5 g / m2 to about 40 g / m2. In some embodiments, a CNF or LCNF layer includes one or more additives. In some embodiments, additives include a mineral (e.g., calcium carbonate, talc, clay, or a combination thereof), a cross-linking agent (e.g., polyamide epichlorohydrin resin (PAE)), aluminum sulfate, or a combination thereof. In some embodiments, a CNF or LCNF layer includes about 0.5 wt% to about 2 wt% of a mineral, cross-linking agent, and / or aluminum sulfate.

[0011] In some embodiments, a lignocellulosic product of the present disclosure has: a normalized tensile strength from about 5 mPa / (g / cm3) to about 35 mPa / (g / cm3); a normalized flexural strength from about 10 mPa / (g / cm3) to about 60 mPa / (g / cm3); a normalized tensile modulus from about 1500 mPa / (g / cm3) to about 5500 mPa / (g / cm3); and / or a normalized flexural modulus from about 1500 mPa / (g / cm3) to about 11500mPa / (g / cm3). In some embodiments, a lignocellulosic product of the present disclosure has an oil and grease resistance kit value from about 3 to about 12 as determined by a TAPPI T559 cm-12 standard assay. In some embodiments, a lignocellulosic product of the present disclosure has a water resistance Cobb value from about 20 g / m2 to about 400 g / m2 as determined by a TAPPI T441 standard assay.

[0012] In some embodiments, the present disclosure provides a double-dipping method of manufacturing a lignocellulosic product including steps of: inserting a mold comprising at least one cavity into a substrate slurry; applying a vacuum to the at least one cavity to form a wet substrate layer; removing the mold from the substrate slurry; inserting the mold into a cellulose slurry; applying a vacuum to the at least one cavity to form a wet cellulose layer; pressing the mold against a perforated mold (e.g., at about 3 °C to about 15 °C); applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose layer to form a cold-pressed laminate; detaching the cold-pressed laminate from the perforated mold; and hot-pressing the cold-press laminate to form the cellulosic product (e.g., at about 180 °C to about 250 °C for about 10 seconds to about 30 seconds).

[0013] In other embodiments, the present disclosure provides a wet lamination method of manufacturing a lignocellulosic product including steps of: inserting a mold comprising at least one cavity into a substrate slurry; applying a vacuum to the at least one cavity form a wet substrate layer; placing a wet cellulose film on a perforated mold and removing the mold from the substrate slurry; pressing the mold against the wet cellulose film on the perforated mold (e.g., at about 20 °C to about 25 °C); applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose film to form a cold-pressed laminate; detaching the cold-pressed laminate from the perforated mold; and hot-pressing the cold-press laminate to form the cellulosic product.

[0014] In still other embodiments, the present disclosure provides a spray coating method of manufacturing a lignocellulosic product including steps of: inserting a mold comprising at least one cavity into a substrate slurry; applying a vacuum to the cavity in the mold to form a wet substrate layer; removing the mold from the substrate slurry; spraying the wet substrate layer with a cellulose slurry to form a wet cellulose layer (e.g., using a nozzle spray at a flow rate of about 1 cm3 / s to about 10 cm3 / s); pressing the mold against a perforated mold (e.g., at about 15 °C to about 30 °C); applying a vacuum to the perforatedmold to remove water from the wet substrate layer and wet cellulose layer to form a cold- pressed laminate; detaching the cold-pressed laminate from the perforated mold; and hot- pressing the cold-press laminate to form the cellulosic product.

[0015] In some embodiments, a substrate slurry of any method described herein includes about 0.5% (w / v) to about 2% (w / v) of substrate solids. In some embodiments, substrate solids include about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour. In some embodiments, pulp includes bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof. In some embodiments, substrate solids include about 2.5 wt% to about 10 wt% CNFs.

[0016] In some embodiments, a cellulose slurry of any method described herein includes CNF solids (e.g., lignin-free CNFs, LCNFs, DCNFs, or a combination thereof). In some embodiments, a cellulose slurry includes about 0.3% (w / v) to about 1% (w / v) of CNF solids.

[0017] In some embodiments, a cellulose slurry, or a wet cellulose film of any method described herein includes one or more additives including a mineral (e.g., calcium carbonate, talc, clay, or a combination thereof), a cross-linking agent (e.g., polyamide epichlorohydrin resin (PAE)), aluminum sulfate, or a combination thereof. In some embodiments, a cellulose slurry or a wet cellulose film includes about 0.5 wt% to about 2 wt% of a mineral, crosslinking agent, and / or aluminum sulfate.

[0018] In some embodiments, a wet cellulose layer or wet cellulose film of any method described herein has an area density (coat weight) of about 5 g / m2 to about 40 g / m2.

[0019] In some embodiments, steps of applying a vacuum in any method described herein, includes applying a back vacuum pressure from about -0.5 bar to about -1.0 bar to the at least one cavity for about 5 seconds to about 20 seconds, or about 5 seconds to about 30 seconds.

[0020] In some embodiments, steps of hot-pressing in any method described herein, is at about 180 °C to about 250 °C for about 10 seconds to about 30 seconds.BRIEF DESCRIPTION OF THE DRAWINGS

[0021] FIG. 1 shows a schematic diagram of a lignocellulosic sheet / plate production process. 1 and 2 indicate additional cellulose nanofibril (CNF) lamination steps.

[0022] FIG. 2A shows a bar graph of the normalized tensile modulus and normalized flexural modulus of Formulation 3 (TMP; B45T45C10) and Formulation 2 (WF; B45W45C10) sample sheets / plates.

[0023] FIG. 2B shows a bar graph of the normalized tensile strength and normalized flexural strength of Formulation 3 (TMP; B45T45C10) and Formulation 2 (WF; B45W45C10) sample sheets / plates.

[0024] FIG. 3A shows a line graph of the normalized tensile modulus (left axis) and normalized tensile strength (right axis) of sample sheets / plates having various wt% content of CNF (Formulation 4 (T100C0), Formulation 5 (T90C10), and Formulation 6 (WF;T97.5C2.5)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0025] FIG. 3B shows a line graph of the normalized flexural modulus (left axis) and normalized flexural strength (right axis) of sample sheets / plates having various wt% content of CNF (Formulation 4 (T100C0), Formulation 5 (T90C10), and Formulation 6 (WF; T97.5C2.5)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0026] FIG. 4A shows a line graph of the normalized tensile modulus (left axis) and normalized tensile strength (right axis) of sample sheets / plates having various wt% content of CNF (Formulation 10 (B58.75W38.75C2.5), and Formulation 8 (B65W25C10)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0027] FIG. 4B shows a line graph of the normalized flexural modulus (left axis) and normalized flexural strength (right axis) of sample sheets / plates having various wt% content of CNF (Formulation 10 (B58.75W38.75C2.5), and Formulation 8 (B65W25C10)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0028] FIG. 5A shows a line graph of the normalized tensile modulus (left axis) and normalized tensile strength (right axis) of sample sheets / plates having various wt% content of bleached kraft pulp (BKP) (Formulation 9 (B45W45C10), Formulation 7 (B55W35C10), Formulation 8 (B65W25C10), and Formulation 1 (B100)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0029] FIG. 5B shows a line graph of the normalized flexural modulus (left axis) and normalized flexural strength (right axis) of sample sheets / plates having various wt% content of bleached kraft pulp (BKP) (Formulation 9 (B45W45C10), Formulation 7 (B55W35C10), Formulation 8 (B65W25C10), and Formulation 1 (B100)). Data points having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0030] FIG. 6A shows a bar graph of the normalized tensile strength and normalized flexural strength of Formulation 9 (B45W45C10) sample sheets / plates where: all raw materials were mixed simultaneously (One pot mix); BKP and CNF were mixed first, then WF added (Order 1); BKP and CNF were mixed separately from a mixture of WF and CNF, then the two mixtures were combined (Order 2); or WF and CNF were mixed first, then BKP added (Order 3). Bars having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0031] FIG. 6B shows a bar graph of the normalized tensile modulus and normalized flexural modulus of Formulation 9 (B45W45C10) sample sheets / plates where: all raw materials were mixed simultaneously (One pot mix); BKP and CNF were mixed first, then WF added (Order 1); BKP and CNF were mixed separately from a mixture of WF and CNF, then the two mixtures were combined (Order 2); or WF and CNF were mixed first, then BKP added (Order 3). Bars having the same alphabetic labels do not have statistical difference at 95% confidence level.

[0032] FIG. 7A shows a line graph of the Cobb value for Formulation 7 (B55W35C10) sample sheet / plates laminated with different coat weights of CNF.

[0033] FIG. 7B shows a line graph of the kit number for Formulation 7 (B55W35C10) sample sheet / plates laminated with different coat weights of CNF.

[0034] FIG. 8A shows a scanning electron micrograph (SEM) of the surface of an unlaminated sample sheet / plate of Formulation 7 (B55W35C10).

[0035] FIG. 8B shows a scanning electron micrograph (SEM) of the surface of a sample sheet / plate of Formulation 7 (B55W35C10) laminated with a CNF coat weight of 10 g / m2.

[0036] FIG. 8C shows a scanning electron micrograph (SEM) of the surface of a sample sheet / plate of Formulation 7 (B55W35C10) laminated with a CNF coat weight of 20 g / m2.

[0037] FIG. 8D shows a scanning electron micrograph (SEM) of the surface of a sample sheet / plate of Formulation 7 (B55W35C10) laminated with a CNF coat weight of 40 g / m2.

[0038] FIG. 9A shows a flow chart of an exemplary double dipping process for the manufacture of a lignocellulosic product of the present disclosure.

[0039] FIG. 9B shows a flow chart of an exemplary wet lamination process for the manufacture of a lignocellulosic product of the present disclosure.

[0040] FIG. 9C shows a flow chart of an exemplary spray coating process for the manufacture of a lignocellulosic product of the present disclosure.

[0041] FIG. 10 shows a line graph of tear resistance for uncoated and coated paper sheets for Formulation 7 (B55W35C10) with B100 as a control.DEFINITIONS

[0042] As used herein, the term “exemplary” refers to an example of an embodiment. Unless otherwise indicated, the term “exemplary” is not intended to indicate that an embodiment is a “preferred” or “best” version of an embodiment.

[0043] About'. The term “about”, when used herein in reference to a value, refers to a value that is similar, in context to the referenced value. In general, those skilled in the art, familiar with the context, will appreciate the relevant degree of variance encompassed by “about” in that context. For example, in some embodiments, the term “about” mayencompass a range of values that within 25%, 20%, 19%, 18%, 17%, 16%, 15%, 14%, 13%, 12%, 11%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, or less of the referred value.

[0044] Cellulose nanofibril (CNF): As used herein, the term “cellulose nanofibril” or “CNF” or “cellulose nanofibrils” or “CNFs” refer to nanoscale fibers mainly composed of cellulose molecules. As used herein, these fibers may be referred to as cellulose nanofibers, nanofibrillated cellulose (NFC), or microfibrillated cellulose (MFC).

[0045] Cellulosic: As used herein, the term “cellulosic” refers to a substance, material, product, or formulation comprising cellulose or a derivative thereof.

[0046] Cold-pressed: As used herein, the term “cold-pressed” refers to the application of a compressing force / pressure to a surface, sample, material, formulation, or product at a temperature at or below room temperature (e.g., about -20 °C to about 25 °C, about -15 °C to about 25 °C, about -10 °C to about 25 °C, about -5 °C to about 25 °C, about 0 °C to about 25 °C, about 5 °C to about 25 °C, about 10 °C to about 25 °C, about 15 °C to about 25 °C, about 20 °C to about 25 °C, about -20 °C to about 20 °C, about -15 °C to about 20 °C, about -10 °C to about 20 °C, about -5 °C to about 20 °C, about 0 °C to about 20 °C, about 5 °C to about 20 °C, about 10 °C to about 20 °C, about 15 °C to about 20 °C, about -20 °C to about 15 °C, about -15 °C to about 15 °C, about -10 °C to about 15 °C, about -5 °C to about 15 °C, about 0 °C to about 15 °C, about 5 °C to about 15 °C, about 10 °C to about 15 °C, about -20 °C to about 10 °C, about -15 °C to about 10 °C, about -10 °C to about 10 °C, about -5 °C to about 10 °C, about 0 °C to about 10 °C, about 5 °C to about 10 °C, about -20 °C to about 5 °C, about -15 °C to about 5 °C, about -10 °C to about 5 °C, about -5 °C to about 5 °C, about 0 °C to about 5 °C, about -20 °C to about 0 °C, about -15 °C to about 0 °C, about -10 °C to about 0 °C, about -5 °C to about 0 °C, about -20 °C to about -5 °C, about -15 °C to about -5 °C, about -10 °C to about -5 °C, about -20 °C to about -10 °C, about -15 °C to about -10 °C, or about -20 °C to about -15 °C).

[0047] Comparable'. As used herein, the term “comparable” refers to two or more samples, materials, formulations, entities, situations, sets of conditions, etc., that may not be identical to one another but that are sufficiently similar to permit comparison there between so that one skilled in the art will appreciate that conclusions may reasonably be drawn based on differences or similarities observed. Those of ordinary skill in the art will understand, in context, what degree of identity is required in any given circumstance for two or more suchagents, entities, situations, sets of conditions, etc. to be considered comparable. For example, those of ordinary skill in the art will appreciate that sets of samples, materials, formulations, entities, situations, conditions, etc., are comparable to one another when characterized by a sufficient number and type of substantially identical features to warrant a reasonable conclusion that differences in results obtained or phenomena observed under or with different sets of circumstances, individuals, or populations are caused by or indicative of the variation in those features that are varied.

[0048] Delignified: As used herein, the term “delignified” refers to the removal of lignin polymer from a sample, material, composition, formulation, or product. In some embodiments, “delignification” may be complete removal or partial removal.

[0049] Hot-pressed: As used herein, the term “hot-pressed” refers to the application of a compressing force / pressure to a surface, sample, material, formulation, or product at a temperature at or above 100 °C (e.g., about 100 °C to about 300 °C, about 125 °C to about 300 °C, about 150 °C to about 300 °C, about 175 °C to about 300 °C, about 200 °C to about300 °C, about 225 °C to about 300 °C, about 250 °C to about 300 °C, about 275 °C to about300 °C, about 100 °C to about 275 °C, about 125 °C to about 275 °C, about 150 °C to about275 °C, about 175 °C to about 275 °C, about 200 °C to about 275 °C, about 225 °C to about275 °C, about 250 °C to about 275 °C, about 100 °C to about 250 °C, about 125 °C to about250 °C, about 150 °C to about 250 °C, about 175 °C to about 250 °C, about 200 °C to about250 °C, about 225 °C to about 250 °C, about 100 °C to about 225 °C, about 125 °C to about225 °C, about 150 °C to about 225 °C, about 175 °C to about 225 °C, about 200 °C to about225 °C, about 100 °C to about 200 °C, about 125 °C to about 200 °C, about 150 °C to about200 °C, about 175 °C to about 200 °C, about 100 °C to about 175 °C, about 125 °C to about175 °C, about 150 °C to about 175 °C, about 100 °C to about 150 °C, about 125 °C to about150 °C, or about 100 °C to about 125 °C).

[0050] Increased, Induced, or Reduced'. As used herein, these terms or grammatically comparable comparative terms, indicate values that are relative to a comparable reference measurement. For example, in some embodiments, an assessed value achieved with a provided material or formulation may be “increased” relative to that obtained with a comparable reference composition. Alternatively or additionally, in some embodiments, an assessed value achieved in a subject may be “increased” relative to thatobtained in the same subject under different conditions. In some embodiments, comparative terms refer to statistically relevant differences (e.g., that are of a prevalence and / or magnitude sufficient to achieve statistical relevance). Those skilled in the art will be aware, or will readily be able to determine, in a given context, a degree and / or prevalence of difference that is required or sufficient to achieve such statistical significance. In some embodiments, the term “reduced” or equivalent terms refers to a reduction in the level of an assessed value by at least 5%, at least 10%, at least 20%, at least 50%, at least 75% or higher, as compared to a comparable reference. In some embodiments, the term “reduced” or equivalent terms refers to a complete or essentially complete reduction, i.e., a reduction to zero or essentially to zero. In some embodiments, the term “increased” or “induced” refers to an increase in the level of an assessed value by at least 10%, at least 20%, at least 30%, at least 40%, at least 50%, at least 80%, at least 100%, at least 200%, at least 500%, or higher, as compared to a comparable reference.

[0051] Kraft pulp: As used herein, the term “kraft pulp” refers to pulp produced by the treatment of wood chips with a hot mixture of water, sodium hydroxide (NaOH), and sodium sulfide (Na2S) (i.e., the kraft process).

[0052] Laminate: As used herein, the term “laminate” refers to a layer or overlay on a surface. As understood by those skilled in the art, “lamination” refers to the application of one or more layers onto a surface. In some embodiments a laminate may be uniform or non- uniform. In some embodiments a laminate may completely cover a surface or only partially cover a surface.

[0053] Lignin-Containing Cellulose Nanofibril: As used herein, the term “lignincontaining cellulose nanofibril” or “LCNF” refers to a cellulose nanofibril incorporating a percentage of lignin polymer.

[0054] Mold: As used herein, the term “mold” refers to any container or vessel that gives form and / or shape to a sample, material, composition, formulation, or product.

[0055] Normalized. As used herein, the term “normalized” describes values that are based on the density of a sample, material, composition, formulation, or product. For example, in some embodiments a mechanical property value of a sample, material, composition, formulation or product is normalized by dividing the measured mechanicalproperty value by the corresponding density of the sample, material, composition, formulation, or product. This term is sometimes used interchangeably with the term “specific” as in specific flexural strength.

[0056] Recycled fibers: As used herein, the term “recycled fibers” refers to lignocellulosic fibers that have been previously treated, processed, manufactured, or refined.

[0057] Reference'. As used herein, the term “reference” describes a standard or control relative to which a comparison is performed. In some embodiments, a reference or control is a historical reference or control, optionally embodied in a tangible medium. Typically, as would be understood by those skilled in the art, a reference or control is determined or characterized under comparable conditions or circumstances to those under assessment. Those skilled in the art will appreciate when sufficient similarities are present to justify reliance on and / or comparison to a particular possible reference or control.

[0058] Therinoinechanical pulp'. As used herein, the term “thermomechanical pulp” refers to pulp produced by the preheating of lignocellulosic materials under steam pressure (e.g., 20-40 psi) and temperature (e.g., 115 °C - 155 °C) followed by mechanical refining.DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

[0059] The present disclosure provides lignocellulosic and cellulosic products, and methods of manufacturing the same, that are environmentally and economically advantageous and have physical and mechanical properties optimally suited for commercial uses (e.g., as food containers).I. Lignocellulosic or Cellulosic Products a) Substrate

[0060] In some embodiments, the present disclosure provides lignocellulosic or cellulosic products including a substrate. In some embodiments, the substrate includes pulp, wood flour, or a combination thereof.

[0061] In some embodiments, the substrate incorporates about 40 wt% to about 95 wt% pulp. For example in some embodiments, the substrate incorporates about 40 wt% toabout 95 wt%, about 45 wt% to about 95 wt%, about 50 wt% to about 95 wt%, about 55 wt% to about 95 wt%, about 60 wt% to about 95 wt%, about 65 wt% to about 95 wt%, about 70 wt% to about 95 wt%, about 75 wt% to about 95 wt%, about 80 wt% to about 95 wt%, about 85 wt% to about 95 wt%, about 90 wt% to about 95 wt%, about 40 wt% to about 90 wt%, about 45 wt% to about 90 wt%, about 50 wt% to about 90 wt%, about 55 wt% to about 90 wt%, about 60 wt% to about 90 wt%, about 65 wt% to about 90 wt%, about 70 wt% to about 90 wt%, about 75 wt% to about 90 wt%, about 80 wt% to about 90 wt%, about 85 wt% to about 90 wt%, about 40 wt% to about 85 wt%, about 45 wt% to about 85 wt%, about 50 wt% to about 85 wt%, about 55 wt% to about 85 wt%, about 60 wt% to about 85 wt%, about 65 wt% to about 85 wt%, about 70 wt% to about 85 wt%, about 75 wt% to about 85 wt%, about 80 wt% to about 85 wt%, about 40 wt% to about 80 wt%, about 45 wt% to about 80 wt%, about 50 wt% to about 80 wt%, about 55 wt% to about 80 wt%, about 60 wt% to about 80 wt%, about 65 wt% to about 80 wt%, about 70 wt% to about 80 wt%, about 75 wt% to about 80 wt%, about 40 wt% to about 75 wt%, about 45 wt% to about 75 wt%, about 50 wt% to about 75 wt%, about 55 wt% to about 75 wt%, about 60 wt% to about 75 wt%, about 65 wt% to about 75 wt%, about 70 wt% to about 75 wt%, about 40 wt% to about 70 wt%, about 45 wt% to about 70 wt%, about 50 wt% to about 70 wt%, about 55 wt% to about 70 wt%, about 60 wt% to about 70 wt%, about 65 wt% to about 70 wt%, about 40 wt% to about 65 wt%, about 45 wt% to about 65 wt%, about 50 wt% to about 65 wt%, about 55 wt% to about 65 wt%, about 60 wt% to about 65 wt%, about 40 wt% to about 60 wt%, about 45 wt% to about 60 wt%, about 50 wt% to about 60 wt%, about 55 wt% to about 60 wt%, about 40 wt% to about 55 wt%, about 45 wt% to about 55 wt%, about 50 wt% to about 55 wt%, about 40 wt% to about 50 wt%, about 45 wt% to about 50 wt%, or about 40 wt% to about 45 wt% pulp.

[0062] In some embodiments, the substrate incorporates about 50 wt% to about 75 wt% pulp. For example, in some embodiments the substrate incorporates about 50 wt%, about 51 wt%, about 52 wt%, about 53 wt%, about 54 wt%, about 55 wt%, about 56 wt%, about 57 wt%, about 58 wt%, about 59 wt%, about 60 wt%, about 61 wt%, about 62 wt%, about 63 wt%, about 64 wt%, about 65 wt%, about 66 wt%, about 67 wt%, about 68 wt%, about 69 wt%, about 70 wt%, about 71 wt%, about 72 wt%, about 73 wt%, about 74 wt%, or about 75 wt% pulp.

[0063] In some embodiments, the pulp includes bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, or a combination thereof.

[0064] In some embodiments, a substrate incorporates about 10 wt% to about 60 wt% wood flour. For example, in some embodiments, the substrate incorporates about 10 wt% to about 60%, about 15 wt% to about 60%, about 20 wt% to about 60%, about 25 wt% to about 60%, about 30 wt% to about 60%, about 35 wt% to about 60%, about 40 wt% to about 60%, about 45 wt% to about 60%, about 50 wt% to about 60%, about 55 wt% to about 60%, about 10 wt% to about 55%, about 15 wt% to about 55%, about 20 wt% to about 55%, about 25 wt% to about 55%, about 30 wt% to about 55%, about 35 wt% to about 55%, about 40 wt% to about 55%, about 45 wt% to about 55%, about 50 wt% to about 55%, about 10 wt% to about 50%, about 15 wt% to about 50%, about 20 wt% to about 50%, about 25 wt% to about 50%, about 30 wt% to about 50%, about 35 wt% to about 50%, about 40 wt% to about 50%, about 45 wt% to about 50%, about 10 wt% to about 45%, about 15 wt% to about 45%, about 20 wt% to about 45%, about 25 wt% to about 45%, about 30 wt% to about 45%, about 35 wt% to about 45%, about 40 wt% to about 45%, about 10 wt% to about 40%, about 15 wt% to about 40%, about 20 wt% to about 40%, about 25 wt% to about 40%, about 30 wt% to about 40%, about 35 wt% to about 40%, about 10 wt% to about 35%, about 15 wt% to about 35%, about 20 wt% to about 35%, about 25 wt% to about 35%, about 30 wt% to about 35%, about 10 wt% to about 30%, about 15 wt% to about 30%, about 20 wt% to about 30%, about 25 wt% to about 30%, about 10 wt% to about 25%, about 15 wt% to about 25%, about 20 wt% to about 25%, about 10 wt% to about 20%, about 15 wt% to about 20%, or about 10 wt% to about 15% wood flour.

[0065] In some embodiments, the substrate incorporates about 25 wt% to about 50 wt% wood flour. For example, in some embodiments, the substrate incorporates about 25 wt%, about 26 wt%, about 27 wt%, about 28 wt%, about 29 wt%, about 30 wt%, about 31 wt%, about 32 wt%, about 33 wt%, about 34 wt%, about 35 wt%, about 36 wt%, about 37 wt%, about 38 wt%, about 39 wt%, about 40 wt%, about 41 wt%, about 42 wt%, about 43 wt%, about 44 wt%, about 45 wt%, about 46 wt%, about 47 wt%, about 48 wt%, about 49 wt%, or about 50 wt% wood flour.

[0066] In some embodiments, a substrate further includes cellulose nanofibrils (CNFs) in addition to pulp and wood flour. In some embodiments, the substrate incorporates about 1 wt% to about 20 wt% CNFs. For example, in some embodiments, the substrate incorporates about 1 wt% to about 20 wt%, about 2.5 wt% to about 20 wt%, about 5 wt% to about 20 wt%, about 7.5 wt% to about 20 wt%, about 10 wt% to about 20 wt%, about 12.5wt% to about 20 wt%, about 15 wt% to about 20 wt%, about 17.5 wt% to about 20 wt%, about 1 wt% to about 17.5 wt%, about 2.5 wt% to about 17.5 wt%, about 5 wt% to about 17.5 wt%, about 7.5 wt% to about 17.5 wt%, about 10 wt% to about 17.5 wt%, about 12.5 wt% to about 17.5 wt%, about 15 wt% to about 17.5 wt%, about 1 wt% to about 15 wt%, about 2.5 wt% to about 15 wt%, about 5 wt% to about 15 wt%, about 7.5 wt% to about 15 wt%, about 10 wt% to about 15 wt%, about 12.5 wt% to about 15 wt%, about 1 wt% to about 12.5 wt%, about 2.5 wt% to about 12.5 wt%, about 5 wt% to about 12.5 wt%, about 7.5 wt% to about 12.5 wt%, about 10 wt% to about 12.5 wt%, about 1 wt% to about 10 wt%, about 2.5 wt% to about 10 wt%, about 5 wt% to about 10 wt%, about 7.5 wt% to about 10 wt%, about 1 wt% to about 7.5 wt%, about 2.5 wt% to about 7.5 wt%, about 5 wt% to about 7.5 wt%, about 1 wt% to about 5 wt%, about 2.5 wt% to about 5 wt%, or about 1 wt% to about 2.5 wt% CNFs.

[0067] In some embodiments, a substrate incorporates about 2.5 wt% to about 10 wt% of CNF. For example, in some embodiments, a substrate incorporates about 2.5 wt%, about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 8.5 wt%, about 9 wt%, about 9.5 wt%, or about 10 wt% CNF.

[0068] In some embodiments, the CNFs include lignin-free cellulose nanofibrils, lignin-containing CNFs (LCNFs), delignified CNFs (DCNFs), or a combination thereof.

[0069] In some embodiments, the substrate is molded or formed into a desired shape. For example, in some embodiments, the substrate is molded into the shape of a sheet, a vessel, a container, or a tray. For example, in some embodiments, the substrate is molded into the shape of a sheet, a plate, a bowl, a cup, a vessel, a container, a tray, or a pouch (e.g., a self-standing pouch). b) Cellulose Nanofibril (CNF) or Lignin-Containing Cellulose Nanofibril (LCNF) Layer

[0070] In some embodiments, the present disclosure provides lignocellulosic or cellulosic products including a cellulose nanofibril (CNF) and / or lignin-containing cellulose nanofibril (LCNF) layer. In some embodiments, provided layers may include both CNF and LCNF.

[0071] In some embodiments, a CNF and / or LCNF layer has a thickness of about 1 pm to about 80 pm. For example, in some embodiments, the CNF and / or LCNF layer has a thickness of about 1 pm to about 80 pm, about 10 pm to about 80 pm, about 20 pm to about 80 pm, about 30 pm to about 80 pm, about 40 pm to about 80 pm, about 50 pm to about 80 pm, about 60 pm to about 80 pm, about 70 pm to about 80 pm, about 1 pm to about 70 pm, about 10 pm to about 70 pm, about 20 pm to about 70 pm, about 30 pm to about 70 pm, about 40 pm to about 70 pm, about 50 pm to about 70 pm, about 60 pm to about 70 pm, about 1 pm to about 60 pm, about 10 pm to about 60 pm, about 20 pm to about 60 pm, about 30 pm to about 60 pm, about 40 pm to about 60 pm, about 50 pm to about 60 pm, about 1 pm to about 50 pm, about 10 pm to about 50 pm, about 20 pm to about 50 pm, about 30 pm to about 50 pm, about 40 pm to about 50 pm, about 1 pm to about 40 pm, about 10 pm to about 40 pm, about 20 pm to about 40 pm, about 30 pm to about 40 pm, about 1 pm to about 30 pm, about 10 pm to about 30 pm, about 20 pm to about 30 pm, or about 1 pm to about 20 pm.

[0072] In some embodiments, a CNF and / or LCNF layer has a thickness of about 5 pm to about 40 pm. For example, in some embodiments, a CNF and / or LCNF layer has a thickness of about 5 pm, about 7.5 pm, about 10 pm, about 12.5 pm, about 15 pm, about 17.5 pm, about 20 pm, about 22.5 pm, about 25 pm, about 27.5 pm, about 30 pm, about 32.5 pm, about 35 pm, about 37.5 pm, or about 40 pm.

[0073] In some embodiments, a CNF and / or LCNF layer has an area density (gsm=grams per square meter) of about 1 g / m2to about 50 g / m2. For example, in some embodiments, a CNF and / or LCNF layer has an area density of about 1 g / m2to about 50 g / m2, about 5 g / m2to about 50 g / m2, about 10 g / m2to about 50 g / m2, about 15 g / m2to about 50 g / m2, about 20 g / m2to about 50 g / m2, about 25 g / m2to about 50 g / m2, about 30 g / m2to about 50 g / m2, about 35 g / m2to about 50 g / m2, about 40 g / m2to about 50 g / m2, about 45 g / m2to about 50 g / m2, about 1 g / m2to about 45 g / m2, about 5 g / m2to about 45 g / m2, about 10 g / m2to about 45 g / m2, about 15 g / m2to about 45 g / m2, about 20 g / m2to about 45 g / m2, about 25 g / m2to about 45 g / m2, about 30 g / m2to about 45 g / m2, about 35 g / m2to about 45 g / m2, about 40 g / m2to about 45 g / m2, about 1 g / m2to about 40 g / m2, about 5 g / m2to about 40 g / m2, about 10 g / m2to about 40 g / m2, about 15 g / m2to about 40 g / m2, about 20 g / m2to about 40 g / m2, about 25 g / m2to about 40 g / m2, about 30 g / m2to about 40 g / m2, about 35 g / m2to about 40 g / m2, about 1 g / m2to about 35 g / m2, about 5 g / m2to about 35 g / m2, about10 g / m2to about 35 g / m2, about 15 g / m2to about 35 g / m2, about 20 g / m2to about 35 g / m2, about 25 g / m2to about 35 g / m2, about 30 g / m2to about 35 g / m2, about 1 g / m2to about 30 g / m2, about 5 g / m2to about 30 g / m2, about 10 g / m2to about 30 g / m2, about 15 g / m2to about 30 g / m2, about 20 g / m2to about 30 g / m2, about 25 g / m2to about 30 g / m2, about 1 g / m2to about 25 g / m2, about 5 g / m2to about 25 g / m2, about 10 g / m2to about 25 g / m2, about 15 g / m2to about 25 g / m2, about 20 g / m2to about 25 g / m2, about 1 g / m2to about 20 g / m2, about 5 g / m2to about 20 g / m2, about 10 g / m2to about 20 g / m2, about 15 g / m2to about 20 g / m2, about 1 g / m2to about 15 g / m2, about 5 g / m2to about 15 g / m2, about 10 g / m2to about 15 g / m2, about 1 g / m2to about 10 g / m2, about 5 g / m2to about 10 g / m2, or about 1 g / m2to about 5 g / m2. In some embodiments, a CNF and / or LCNF layer has an area density of about 5 g / m2to about 40 g / m2. For example, in some embodiments, a CNF and / or LCNF layer has an area density of about 5 g / m2, about 7.5 g / m2, about 10 g / m2, about 12.5 g / m2, about 15 g / m2, about 17.5 g / m2, about 20 g / m2, about 22.5 g / m2, about 25 g / m2, about 27.5 g / m2, about 30 g / m2, about 32.5 g / m2, about 35 g / m2, about 37.5 g / m2, or about 40 g / m2.

[0074] In some embodiments, the CNF and / or LCNF layer further incorporates one or more additives. In some embodiments, the one or more additives include a mineral, a crosslinking agent, aluminum sulfate (e.g., alum), or a combination thereof. In some embodiments, an amount of aluminum sulfate between 0.5% to 2% of total dry weight is used. In some embodiments, the one or more additives include a mineral selected from calcium carbonate, talc, or clay. In some embodiments, an amount of mineral between 0.5% to 2% of total dry weight is used. In some embodiments, the one or more additives include a cross-linking agent that is or comprises polyamide epichlorohydrin resin (PAE). In some embodiments, an amount of PAE between 0.5% to 2% of total dry weight is used.

[0075] In some embodiments, a lignocellulosic or cellulosic product includes one or more CNF and / or LCNF layers on a single surface of the substrate. In some embodiments, a lignocellulosic or cellulosic product includes a single CNF and / or LCNF layer on each of two or more surfaces of the substrate. In some embodiments, a lignocellulosic or cellulosic product includes two or more CNF and / or LCNF layers on each of two or more surfaces of the substrate. In some embodiments, a lignocellulosic or cellulosic product includes a substate covered on all surfaces (e.g., encased) by one or more CNF and / or LCNF layer(s).c) Characteristics of Lignocellulosic and / or Cellulosic Products

[0076] Lignocellulosic and / or cellulosic products of the present disclosure have one or more physical, mechanical, and material properties that are conducive for any of a variety of commercial applications, e.g., food containers, packaging, etc.Mechanical Characterization

[0077] As used herein, the term “tensile strength” refers to the maximum stress that a material can withstand when stretched or pulled before breaking.

[0078] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized tensile strength from about 5 MPa / (g / cm3) to about 35 Mpa / (g / cm3). For example, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized tensile strength from about 5 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 5 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 5 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 5 Mpa / (g / cm3) to about 20 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 20 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 20 Mpa / (g / cm3), about 5 Mpa / (g / cm3) to about 15 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 15 Mpa / (g / cm3), or about 5 Mpa / (g / cm3) to about 10 Mpa / (g / cm3).

[0079] As used herein, the term “flexural strength” refers to the maximum stress that a material can withstand when being bended before yielding.

[0080] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized flexural strength from about 10 Mpa / (g / cm3) to about 60 Mpa / (g / cm3). For example, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized flexural strength from about 10 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about60 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 35 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 40 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 45 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 50 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 55 Mpa / (g / cm3) to about 60 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 35 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 40 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 45 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 50 Mpa / (g / cm3) to about 55 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 35 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 40 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 45 Mpa / (g / cm3) to about 50 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 35 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 40 Mpa / (g / cm3) to about 45 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 35 Mpa / (g / cm3) to about 40 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 30 Mpa / (g / cm3) to about 35 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 25 Mpa / (g / cm3) to about 30 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 20 Mpa / (g / cm3) to about 25 Mpa / (g / cm3), about 10 Mpa / (g / cm3) to about 20 Mpa / (g / cm3), about 15 Mpa / (g / cm3) to about 20 Mpa / (g / cm3), or about 10 Mpa / (g / cm3) to about 15 Mpa / (g / cm3).

[0081] As used herein, the term “tensile modulus” refers to the ratio of a material’s tensile stress (force per unit area) to its strain (relative deformation), when being elastically deformed.

[0082] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized tensile modulus from about 1500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3). For example, in some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized tensile modulus from about 1500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 3000 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 4000 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 5000 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 3000 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 4000 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 5000 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 3000 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 4000 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 4000 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 4000 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 4000 Mpa / (g / cm3), about 3000 Mpa / (g / cm3) to about 4000 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 4000 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), about 3000 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 3000 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 3000 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 3000 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 2500 Mpa / (g / cm3), about 2000 Mpa / (g / cm3) to about 2500 Mpa / (g / cm3), or about 1500 Mpa / (g / cm3) to about 2000 Mpa / (g / cm3).

[0083] As used herein, the term “flexural modulus” refers to the ratio of a material’s stress (force per unit area) to its strain (relative deformation), when being flexurally deformed.

[0084] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a normalized flexural modulus from about 1500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3). For example, in some embodiments, a lignocellulosic and / or cellulosicproduct of the present disclosure has a normalized flexural modulus from about 1500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 6500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 7500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 8500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 9500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 10500 Mpa / (g / cm3) to about 11500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 6500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 7500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 8500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 9500 Mpa / (g / cm3) to about 10500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 6500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 7500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 8500 Mpa / (g / cm3) to about 9500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 6500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 7500 Mpa / (g / cm3) to about 8500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 6500 Mpa / (g / cm3) to about 7500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 6500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 6500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 6500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 6500 Mpa / (g / cm3), about 5500 Mpa / (g / cm3) to about 6500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 4500 Mpa / (g / cm3) to about 5500 Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 4500 Mpa / (g / cm3), about 3500 Mpa / (g / cm3) to about 4500Mpa / (g / cm3), about 1500 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), about 2500 Mpa / (g / cm3) to about 3500 Mpa / (g / cm3), or about 1500 Mpa / (g / cm3) to about 2500 Mpa / (g / cm3).Oil and Grease Resistance Characterization

[0085] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has an oil and grease resistance kit value from about 3 to about 12 as determined by a TAPPI T559 cm-12 standard assay. For example in some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has an oil and grease resistance kit value from about 3 to about 12, about 4 to about 12, about 5 to about 12, about 6 to about 12, about 7 to about 12, about 8 to about 12, about 9 to about 12, about 10 to about 12, about 11 to about 12, about 3 to about 11, about 4 to about 11, about 5 to about 11, about 6 to about 11, about 7 to about 11, about 8 to about 11, about 9 to about 11, about 10 to about 11, about 3 to about 10, about 4 to about 10, about 5 to about 10, about 6 to about 10, about 7 to about 10, about 8 to about 10, about 9 to about 10, about 3 to about 9, about 4 to about 9, about 5 to about 9, about 6 to about 9, about 7 to about 9, about 8 to about 9, about 3 to about 8, about 4 to about 8, about 5 to about 8, about 6 to about 8, about 7 to about 8, about 3 to about 7, about 4 to about 7, about 5 to about 7, about 6 to about 7, about 3 to about 6, about 4 to about 6, about 5 to about 6, about 3 to about 5, about 4 to about 5, or about 3 to about 4 as determined by a TAPPI T559 cm-12 standard assay. In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has an oil and grease resistance kit value from about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 11, or about 12 as determined by a TAPPI T559 cm-12 standard assay.Water Resistance Characterization

[0086] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a water resistance Cobb value from about 20 g / m2to about 400 g / m2as determined by a TAPPI T441 standard assay. For example, in some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a water resistance Cobb value from about 20 g / m2to about 400 g / m2, about 40 g / m2to about 400 g / m2, about 60 g / m2to about 400 g / m2, about 80 g / m2to about 400 g / m2, about 100 g / m2to about 400 g / m2, about 120 g / m2to about 400 g / m2, about 140 g / m2to about 400 g / m2, about 160 g / m2to about 400 g / m2, about 180 g / m2to about 400 g / m2, about 200 g / m2to about 400 g / m2, about 220 g / m2toabout 400 g / m2, about 240 g / m2to about 400 g / m2, about 260 g / m2to about 400 g / m2, about 280 g / m2to about 400 g / m2, about 300 g / m2to about 400 g / m2, about 320 g / m2to about 400 g / m2, about 340 g / m2to about 400 g / m2, about 360 g / m2to about 400 g / m2, about 380 g / m2to about 400 g / m2, about 20 g / m2to about 360 g / m2, about 40 g / m2to about 360 g / m2, about 60 g / m2to about 360 g / m2, about 80 g / m2to about 360 g / m2, about 100 g / m2to about 360 g / m2, about 120 g / m2to about 360 g / m2, about 140 g / m2to about 360 g / m2, about 160 g / m2to about 360 g / m2, about 180 g / m2to about 360 g / m2, about 200 g / m2to about 360 g / m2, about 220 g / m2to about 360 g / m2, about 240 g / m2to about 360 g / m2, about 260 g / m2to about 360 g / m2, about 280 g / m2to about 360 g / m2, about 300 g / m2to about 360 g / m2, about 320 g / m2to about 360 g / m2, about 340 g / m2to about 360 g / m2, about 20 g / m2to about 320 g / m2, about 40 g / m2to about 320 g / m2, about 60 g / m2to about 320 g / m2, about 80 g / m2to about 320 g / m2, about 100 g / m2to about 320 g / m2, about 120 g / m2to about 320 g / m2, about 140 g / m2to about 320 g / m2, about 160 g / m2to about 320 g / m2, about 180 g / m2to about 320 g / m2, about 200 g / m2to about 320 g / m2, about 220 g / m2to about 320 g / m2, about 240 g / m2to about 320 g / m2, about 260 g / m2to about 320 g / m2, about 280 g / m2to about 320 g / m2, about 300 g / m2to about 320 g / m2, about 20 g / m2to about 280 g / m2, about 40 g / m2to about 280 g / m2, about 60 g / m2to about 280 g / m2, about 80 g / m2to about 280 g / m2, about 100 g / m2to about 280 g / m2, about 120 g / m2to about 280 g / m2, about 140 g / m2to about 280 g / m2, about 160 g / m2to about 280 g / m2, about 180 g / m2to about 280 g / m2, about 200 g / m2to about 280 g / m2, about 220 g / m2to about 280 g / m2, about 240 g / m2to about 280 g / m2, about 260 g / m2to about 280 g / m2, about 20 g / m2to about 240 g / m2, about 40 g / m2to about 240 g / m2, about 60 g / m2to about 240 g / m2, about 80 g / m2to about 240 g / m2, about 100 g / m2to about 240 g / m2, about 120 g / m2to about 240 g / m2, about 140 g / m2to about 240 g / m2, about 160 g / m2to about 240 g / m2, about 180 g / m2to about 240 g / m2, about 200 g / m2to about 240 g / m2, about 220 g / m2to about 240 g / m2, about 20 g / m2to about 200 g / m2, about 40 g / m2to about 200 g / m2, about 60 g / m2to about 200 g / m2, about 80 g / m2to about 200 g / m2, about 100 g / m2to about 200 g / m2, about 120 g / m2to about 200 g / m2, about 140 g / m2to about 200 g / m2, about 160 g / m2to about 200 g / m2, about 180 g / m2to about 200 g / m2, about 20 g / m2to about 160 g / m2, about 40 g / m2to about 160 g / m2, about 60 g / m2to about 160 g / m2, about 80 g / m2to about 160 g / m2, about 100 g / m2to about 160 g / m2, about 120 g / m2to about 160 g / m2, about 140 g / m2to about 160 g / m2, about 20 g / m2to about 120 g / m2, about 40 g / m2to about 120 g / m2, about 60 g / m2to about 120 g / m2, about 80 g / m2to about 120 g / m2, about 100 g / m2to about 120 g / m2, about 20 g / m2to about 80 g / m2, about 40 g / m2to about 80 g / m2, or about 60 g / m2to about 80 g / m2as determined by a TAPPI T441 standard assay.

[0087] In some embodiments, a lignocellulosic and / or cellulosic product of the present disclosure has a water resistance Cobb value from about 20 g / m2, about 40 g / m2, about 60 g / m2, about 80 g / m2, about 100 g / m2, about 120 g / m2, about 140 g / m2, about 160 g / m2, about 180 g / m2, about 200 g / m2, about 220 g / m2, about 240 g / m2, about 260 g / m2, about 280 g / m2, about 300 g / m2, about 320 g / m2, about 340 g / m2, about 360 g / m2, about 380 g / m2, or about 400 g / m2as determined by a TAPPI T441 standard assay.II. Methods of Producing Lignocellulosic and / or Cellulosic Products

[0088] In some embodiments, the present disclosure provides methods of producing a lignocellulosic and / or cellulosic product as described herein.

[0089] In some embodiments, methods of producing a lignocellulosic and / or cellulosic product of the present disclosure include inserting a mold comprising at least one cavity into a substrate slurry.

[0090] In some embodiments, a mold comprises at least one cavity. In some embodiments, a mold comprises at least two cavities. In some embodiments, a mold comprises at least three cavities. In some embodiments, a mold comprises at least four cavities. In some embodiments, a mold comprises at least five cavities. In some embodiments, a mold comprises one cavity. In some embodiments, a mold comprises two cavities. In some embodiments, a mold comprises three cavities. In some embodiments, a mold comprises four cavities. In some embodiments, a mold comprises five cavities.

[0091] In some embodiments, a mold comprising at least one cavity is shaped to form a sheet, plate, a bowl, a cup, a vessel, a container, a tray, or a pouch (e.g., a self-standing pouch).

[0092] In some embodiments, a substrate slurry into which a mold is inserted includes about 0.1% (w / v) to about 10% (w / v) substrate solids. For example, in some embodiments, a substrate slurry includes about 0.1% (w / v) to about 10% (w / v), about 0.5% (w / v) to about 10% (w / v), about 2% (w / v) to about 10% (w / v), about 2.5% (w / v) to about 10% (w / v), about 3% (w / v) to about 10% (w / v), about 3.5% (w / v) to about 10% (w / v), about 4% (w / v) to about10% (w / v), about 4.5% (w / v) to about 10% (w / v), about 5% (w / v) to about 10% (w / v), about 5.5% (w / v) to about 10% (w / v), about 6% (w / v) to about 10% (w / v), about 6.5% (w / v) to about 10% (w / v), about 7% (w / v) to about 10% (w / v), about 7.5% (w / v) to about 10% (w / v), about 8% (w / v) to about 10% (w / v), about 8.5% (w / v) to about 10% (w / v), about 9% (w / v) to about 10% (w / v), about 9.5% (w / v) to about 10% (w / v), about 0.1% (w / v) to about 9% (w / v), about 0.5% (w / v) to about 9% (w / v), about 2% (w / v) to about 9% (w / v), about 2.5% (w / v) to about 9% (w / v), about 3% (w / v) to about 9% (w / v), about 3.5% (w / v) to about 9% (w / v), about 4% (w / v) to about 9% (w / v), about 4.5% (w / v) to about 9% (w / v), about 5% (w / v) to about 9% (w / v), about 5.5% (w / v) to about 9% (w / v), about 6% (w / v) to about 9% (w / v), about 6.5% (w / v) to about 9% (w / v), about 7% (w / v) to about 9% (w / v), about 7.5% (w / v) to about 9% (w / v), about 8% (w / v) to about 9% (w / v), about 8.5% (w / v) to about 9% (w / v), about 0.1% (w / v) to about 8% (w / v), about 0.5% (w / v) to about 8% (w / v), about 2% (w / v) to about 8% (w / v), about 2.5% (w / v) to about 8% (w / v), about 3% (w / v) to about 8% (w / v), about 3.5% (w / v) to about 8% (w / v), about 4% (w / v) to about 8% (w / v), about 4.5% (w / v) to about 8% (w / v), about 5% (w / v) to about 8% (w / v), about 5.5% (w / v) to about 8% (w / v), about 6% (w / v) to about 8% (w / v), about 6.5% (w / v) to about 8% (w / v), about 7% (w / v) to about 8% (w / v), about 7.5% (w / v) to about 8% (w / v), about 0.1% (w / v) to about 7% (w / v), about 0.5% (w / v) to about 7% (w / v), about 2% (w / v) to about 7% (w / v), about 2.5% (w / v) to about 7% (w / v), about 3% (w / v) to about 7% (w / v), about 3.5% (w / v) to about 7% (w / v), about 4% (w / v) to about 7% (w / v), about 4.5% (w / v) to about 7% (w / v), about 5% (w / v) to about 7% (w / v), about 5.5% (w / v) to about 7% (w / v), about 6% (w / v) to about 7% (w / v), about 6.5% (w / v) to about 7% (w / v), about 0.1% (w / v) to about 6% (w / v), about 0.5% (w / v) to about 6% (w / v), about 2% (w / v) to about 6% (w / v), about 2.5% (w / v) to about 6% (w / v), about 3% (w / v) to about 6% (w / v), about 3.5% (w / v) to about 6% (w / v), about 4% (w / v) to about 6% (w / v), about 4.5% (w / v) to about 6% (w / v), about 5% (w / v) to about 6% (w / v), about 5.5% (w / v) to about 6% (w / v), about 0.1% (w / v) to about 5% (w / v), about 0.5% (w / v) to about 5% (w / v), about 2% (w / v) to about 5% (w / v), about 2.5% (w / v) to about 5% (w / v), about 3% (w / v) to about 5% (w / v), about 3.5% (w / v) to about 5% (w / v), about 4% (w / v) to about 5% (w / v), about 4.5% (w / v) to about 5% (w / v), about 0.1% (w / v) to about 4% (w / v), about 0.5% (w / v) to about 4% (w / v), about 2% (w / v) to about 4% (w / v), about 2.5% (w / v) to about 4% (w / v), about 3% (w / v) to about 4% (w / v), about 3.5% (w / v) to about 4% (w / v), about 0.1% (w / v) to about 3% (w / v), about 0.5% (w / v) to about 3% (w / v), about 2% (w / v) to about 3% (w / v), about 2.5% (w / v) to about 3% (w / v), about 0.1% (w / v) to about 2% (w / v), orabout 0.1% (w / v) to about 1% (w / v) substrate solids. In some embodiments, the substrate slurry includes about 0.5% (w / v) to about 2% (w / v) substrate solids. For example, in some embodiments, a substrate slurry includes about 0.5% (w / v), about 0.6% (w / v), about 0.7% (w / v), about 0.8% (w / v), about 0.9% (w / v), about 1% (w / v), about 1.1% (w / v), about 1.2% (w / v), about 1.3% (w / v), about 1.4% (w / v), about 1.5% (w / v), about 1.6% (w / v), about 1.7% (w / v), about 1.8% (w / v), about 1.9% (w / v), or about 2% (w / v) substrate solids.

[0093] In some embodiments, the substrate solids include about 40 wt% to about 95 wt% pulp. For example in some embodiments, substrate solids include about 40 wt% to about 95 wt%, about 45 wt% to about 95 wt%, about 50 wt% to about 95 wt%, about 55 wt% to about 95 wt%, about 60 wt% to about 95 wt%, about 65 wt% to about 95 wt%, about 70 wt% to about 95 wt%, about 75 wt% to about 95 wt%, about 80 wt% to about 95 wt%, about 85 wt% to about 95 wt%, about 90 wt% to about 95 wt%, about 40 wt% to about 90 wt%, about 45 wt% to about 90 wt%, about 50 wt% to about 90 wt%, about 55 wt% to about 90 wt%, about 60 wt% to about 90 wt%, about 65 wt% to about 90 wt%, about 70 wt% to about 90 wt%, about 75 wt% to about 90 wt%, about 80 wt% to about 90 wt%, about 85 wt% to about 90 wt%, about 40 wt% to about 85 wt%, about 45 wt% to about 85 wt%, about 50 wt% to about 85 wt%, about 55 wt% to about 85 wt%, about 60 wt% to about 85 wt%, about 65 wt% to about 85 wt%, about 70 wt% to about 85 wt%, about 75 wt% to about 85 wt%, about 80 wt% to about 85 wt%, about 40 wt% to about 80 wt%, about 45 wt% to about 80 wt%, about 50 wt% to about 80 wt%, about 55 wt% to about 80 wt%, about 60 wt% to about 80 wt%, about 65 wt% to about 80 wt%, about 70 wt% to about 80 wt%, about 75 wt% to about 80 wt%, about 40 wt% to about 75 wt%, about 45 wt% to about 75 wt%, about 50 wt% to about 75 wt%, about 55 wt% to about 75 wt%, about 60 wt% to about 75 wt%, about 65 wt% to about 75 wt%, about 70 wt% to about 75 wt%, about 40 wt% to about 70 wt%, about 45 wt% to about 70 wt%, about 50 wt% to about 70 wt%, about 55 wt% to about 70 wt%, about 60 wt% to about 70 wt%, about 65 wt% to about 70 wt%, about 40 wt% to about 65 wt%, about 45 wt% to about 65 wt%, about 50 wt% to about 65 wt%, about 55 wt% to about 65 wt%, about 60 wt% to about 65 wt%, about 40 wt% to about 60 wt%, about 45 wt% to about 60 wt%, about 50 wt% to about 60 wt%, about 55 wt% to about 60 wt%, about 40 wt% to about 55 wt%, about 45 wt% to about 55 wt%, about 50 wt% to about 55 wt%, about 40 wt% to about 50 wt%, about 45 wt% to about 50 wt%, or about 40 wt% to about 45 wt% pulp.

[0094] In some embodiments, substrate solids include about 50 wt% to about 75 wt% pulp. For example, in some embodiments substrate solids include about 50 wt%, about 51 wt%, about 52 wt%, about 53 wt%, about 54 wt%, about 55 wt%, about 56 wt%, about 57 wt%, about 58 wt%, about 59 wt%, about 60 wt%, about 61 wt%, about 62 wt%, about 63 wt%, about 64 wt%, about 65 wt%, about 66 wt%, about 67 wt%, about 68 wt%, about 69 wt%, about 70 wt%, about 71 wt%, about 72 wt%, about 73 wt%, about 74 wt%, or about 75 wt% pulp.

[0095] In some embodiments, pulp includes bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof.

[0096] In some embodiments, substrate solids include about 10 wt% to about 60 wt% wood flour. For example, in some embodiments, substrate solids include about 10 wt% to about 60%, about 15 wt% to about 60%, about 20 wt% to about 60%, about 25 wt% to about 60%, about 30 wt% to about 60%, about 35 wt% to about 60%, about 40 wt% to about 60%, about 45 wt% to about 60%, about 50 wt% to about 60%, about 55 wt% to about 60%, about 10 wt% to about 55%, about 15 wt% to about 55%, about 20 wt% to about 55%, about 25 wt% to about 55%, about 30 wt% to about 55%, about 35 wt% to about 55%, about 40 wt% to about 55%, about 45 wt% to about 55%, about 50 wt% to about 55%, about 10 wt% to about 50%, about 15 wt% to about 50%, about 20 wt% to about 50%, about 25 wt% to about 50%, about 30 wt% to about 50%, about 35 wt% to about 50%, about 40 wt% to about 50%, about 45 wt% to about 50%, about 10 wt% to about 45%, about 15 wt% to about 45%, about 20 wt% to about 45%, about 25 wt% to about 45%, about 30 wt% to about 45%, about 35 wt% to about 45%, about 40 wt% to about 45%, about 10 wt% to about 40%, about 15 wt% to about 40%, about 20 wt% to about 40%, about 25 wt% to about 40%, about 30 wt% to about 40%, about 35 wt% to about 40%, about 10 wt% to about 35%, about 15 wt% to about 35%, about 20 wt% to about 35%, about 25 wt% to about 35%, about 30 wt% to about 35%, about 10 wt% to about 30%, about 15 wt% to about 30%, about 20 wt% to about 30%, about 25 wt% to about 30%, about 10 wt% to about 25%, about 15 wt% to about 25%, about 20 wt% to about 25%, about 10 wt% to about 20%, about 15 wt% to about 20%, or about 10 wt% to about 15% wood flour.

[0097] In some embodiments, substrate solids include about 25 wt% to about 50 wt% wood flour. For example, in some embodiments, substrate solids include about 25 wt%,about 26 wt%, about 27 wt%, about 28 wt%, about 29 wt%, about 30 wt%, about 31 wt%, about 32 wt%, about 33 wt%, about 34 wt%, about 35 wt%, about 36 wt%, about 37 wt%, about 38 wt%, about 39 wt%, about 40 wt%, about 41 wt%, about 42 wt%, about 43 wt%, about 44 wt%, about 45 wt%, about 46 wt%, about 47 wt%, about 48 wt%, about 49 wt%, or about 50 wt% wood flour.

[0098] In some embodiments, substrate solids include cellulose nanofibrils (CNFs). In some embodiments, substrate solids include about 1 wt% to about 20 wt% CNFs. For example, in some embodiments, substrate solids include about 1 wt% to about 20 wt%, about2.5 wt% to about 20 wt%, about 5 wt% to about 20 wt%, about 7.5 wt% to about 20 wt%, about 10 wt% to about 20 wt%, about 12.5 wt% to about 20 wt%, about 15 wt% to about 20 wt%, about 17.5 wt% to about 20 wt%, about 1 wt% to about 17.5 wt%, about 2.5 wt% to about 17.5 wt%, about 5 wt% to about 17.5 wt%, about 7.5 wt% to about 17.5 wt%, about 10 wt% to about 17.5 wt%, about 12.5 wt% to about 17.5 wt%, about 15 wt% to about 17.5 wt%, about 1 wt% to about 15 wt%, about 2.5 wt% to about 15 wt%, about 5 wt% to about 15 wt%, about 7.5 wt% to about 15 wt%, about 10 wt% to about 15 wt%, about 12.5 wt% to about 15 wt%, about 1 wt% to about 12.5 wt%, about 2.5 wt% to about 12.5 wt%, about 5 wt% to about 12.5 wt%, about 7.5 wt% to about 12.5 wt%, about 10 wt% to about 12.5 wt%, about 1 wt% to about 10 wt%, about 2.5 wt% to about 10 wt%, about 5 wt% to about 10 wt%, about 7.5 wt% to about 10 wt%, about 1 wt% to about 7.5 wt%, about 2.5 wt% to about7.5 wt%, about 5 wt% to about 7.5 wt%, about 1 wt% to about 5 wt%, about 2.5 wt% to about 5 wt%, or about 1 wt% to about 2.5 wt% CNFs.

[0099] In some embodiments, substrate solids include about 2.5 wt% to about 10 wt% of CNF. For example, in some embodiments, substrate solids incorporate about 2.5 wt%, about 3 wt%, about 3.5 wt%, about 4 wt%, about 4.5 wt%, about 5 wt%, about 5.5 wt%, about 6 wt%, about 6.5 wt%, about 7 wt%, about 7.5 wt%, about 8 wt%, about 8.5 wt%, about 9 wt%, about 9.5 wt%, or about 10 wt% CNF.

[0100] In some embodiments, CNFs include lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

[0101] In some embodiments, methods of producing a lignocellulosic and / or cellulosic product of the present disclosure include applying back vacuum pressure to at least one cavity in a mold to form a wet substrate layer. In some embodiments, back vacuumpressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar to about -0.5 bar. In some embodiments, back vacuum pressure is from about -0.5 bar to about -1.0 bar. For example, in some embodiments, back vacuum pressure is about -0.5 bar, about -0.6 bar, about -0.7 bar, - 0.8 bar, -0.9 bar, or about -1.0 bar.

[0102] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 secondsto about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds. In some embodiments, the back vacuum pressure is applied for about 5 seconds to about 20 seconds. For example, in some embodiments, back vacuum pressure is applied for about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, or about 20 seconds.CNF / LCNF Layer

[0103] In accordance with various embodiments, any of a variety of application- appropriate methods for creating and / or applying a CNF and / or LCNF layer may be used. a) Double-Dipping Method

[0104] In some embodiments, the present disclosure provides double-dipping methods of producing lignocellulosic and / or cellulosic products, or portions thereof (e.g., CNF and / or LCNF layer) as described herein, including the steps of:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the at least one cavity to form a wet substrate layer;(iii) removing the mold from the substrate slurry;(iv) inserting the mold into a cellulose slurry;(v) applying a vacuum to the cavity to form a wet cellulose layer;(vi) pressing the mold against a perforated mold;(vii) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose layer to form a cold-pressed laminate;(viii) detaching the cold-pressed laminate from the perforated mold; and(ix) hot-pressing the cold-press laminate to form the cellulosic product.

[0105] In some embodiments a cellulose slurry includes cellulose nanofibril (CNF) solids. In some embodiments, a cellulose slurry includes about 0.1% (w / v) to about 5% (w / v) CNF solids. For example, in some embodiments, a cellulose slurry includes about 0.1% (w / v) to about 5% (w / v), about 0.5% (w / v) to about 5% (w / v), about 1% (w / v) to about 5% (w / v), about 1.5% (w / v) to about 5% (w / v), about 2% (w / v) to about 5% (w / v), about 2.5% (w / v) to about 5% (w / v), about 3% (w / v) to about 5% (w / v), about 3.5% (w / v) to about 5% (w / v), about 4% (w / v) to about 5% (w / v), about 4.5% (w / v) to about 5% (w / v), about 0.1% (w / v) to about 4.5% (w / v), about 0.5% (w / v) to about 4% (w / v), about 1% (w / v) to about 4% (w / v), about 1.5% (w / v) to about 4% (w / v), about 2% (w / v) to about 4% (w / v), about 2.5% (w / v) to about 4% (w / v), about 3% (w / v) to about 4% (w / v), about 3.5% (w / v) to about 4% (w / v), about 0.1% (w / v) to about 3.5% (w / v), about 0.5% (w / v) to about 3.5% (w / v), about 1% (w / v) to about 3.5% (w / v), about 1.5% (w / v) to about 3.5% (w / v), about 2% (w / v) to about 3.5% (w / v), about 2.5% (w / v) to about 3.5% (w / v), about 3% (w / v) to about 3.5% (w / v), about 0.1% (w / v) to about 3% (w / v), about 0.5% (w / v) to about 3% (w / v), about 1% (w / v) to about 3% (w / v), about 1.5% (w / v) to about 3% (w / v), about 2% (w / v) to about 3% (w / v), about 2.5% (w / v) to about 3% (w / v), about 0.1% (w / v) to about 2.5% (w / v), about 0.5% (w / v) to about 2.5% (w / v), about 1% (w / v) to about 2.5% (w / v), about 1.5% (w / v) to about 2.5% (w / v), about 2% (w / v) to about 2.5% (w / v), about 0.1% (w / v) to about 2% (w / v), about 0.5% (w / v) to about 2% (w / v), about 1% (w / v) to about 2% (w / v), about 1.5% (w / v) to about 2% (w / v), about 0.1% (w / v) to about 1.5% (w / v), about 0.5% (w / v) to about 1.5% (w / v), about 1% (w / v) to about 1.5% (w / v), about 0.1% (w / v) to about 1% (w / v), about 0.5% (w / v) to about 1% (w / v), or about 0.1% (w / v) to about 0.5% (w / v) CNF solids. In some embodiments, a cellulose slurry includes about 0.3% (w / v) to about 1% (w / v) CNF solids. For example, in some embodiments, a cellulose slurry includes about 0.3% (w / v), 0.35% (w / v), about 0.4% (w / v), about 0.45% (w / v), about 0.5% (w / v), about 0.55% (w / v), about 0.6% (w / v), about 0.65% (w / v), about 0.7% (w / v), about 0.75% (w / v), about 0.8% (w / v), about 0.85% (w / v), about 0.9% (w / v), about 0.95% (w / v), or about 1% (w / v) CNF solids.

[0106] In some embodiments, CNF solids in a cellulose slurry include lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

[0107] In some embodiments, a cellulose slurry further incorporates one or more additives. In some embodiments, one or more additives include a mineral, a cross-linking agent, aluminum sulfate (e.g., alum), or a combination thereof. In some embodiments, an amount of aluminum sulfate between 0.5% to 2% of total dry weight is used. In some embodiments, one or more additives include a mineral selected from calcium carbonate, talc, or clay. In some embodiments, an amount of mineral between 0.5% to 2% of total dry weight is used. In some embodiments, one or more additives include a cross-linking agent that is or comprises polyamide epichlorohydrin resin (PAE). In some embodiments, an amount of PAE between 0.5% to 2% of total dry weight is used.

[0108] In some embodiments, step (v) of a double-dipping method includes applying back vacuum pressure to at least one cavity of a mold to form a wet cellulose layer. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar toabout -0.5 bar. In some embodiments, back vacuum pressure is from about -0.5 bar to about -1.0 bar. For example, in some embodiments, back vacuum pressure is about -0.5 bar, about -0.6 bar, about -0.7 bar, -0.8 bar, -0.9 bar, or about -1.0 bar.

[0109] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds. In some embodiments, the back vacuum pressure is applied for about 5 seconds to about 20 seconds. For example, in some embodiments, the back vacuum pressure is applied for about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, or about 20 seconds.

[0110] In some embodiments, a wet cellulose layer has an area density of about 1 g / m2to about 50 g / m2. For example, in some embodiments, a wet cellulose layer has an area density of about 1 g / m2to about 50 g / m2, about 5 g / m2to about 50 g / m2, about 10 g / m2to about 50 g / m2, about 15 g / m2to about 50 g / m2, about 20 g / m2to about 50 g / m2, about 25 g / m2to about 50 g / m2, about 30 g / m2to about 50 g / m2, about 35 g / m2to about 50 g / m2, about 40 g / m2to about 50 g / m2, about 45 g / m2to about 50 g / m2, about 1 g / m2to about 45 g / m2, about 5 g / m2to about 45 g / m2, about 10 g / m2to about 45 g / m2, about 15 g / m2to about 45 g / m2, about 20 g / m2to about 45 g / m2, about 25 g / m2to about 45 g / m2, about 30 g / m2to about 45 g / m2, about 35 g / m2to about 45 g / m2, about 40 g / m2to about 45 g / m2, about 1 g / m2to about 40 g / m2, about 5 g / m2to about 40 g / m2, about 10 g / m2to about 40 g / m2, about 15 g / m2to about 40 g / m2, about 20 g / m2to about 40 g / m2, about 25 g / m2to about 40 g / m2, about 30 g / m2to about 40 g / m2, about 35 g / m2to about 40 g / m2, about 1 g / m2to about 35 g / m2, about 5 g / m2to about 35 g / m2, about 10 g / m2to about 35 g / m2, about 15 g / m2to about 35 g / m2,about 20 g / m2to about 35 g / m2, about 25 g / m2to about 35 g / m2, about 30 g / m2to about 35 g / m2, about 1 g / m2to about 30 g / m2, about 5 g / m2to about 30 g / m2, about 10 g / m2to about 30 g / m2, about 15 g / m2to about 30 g / m2, about 20 g / m2to about 30 g / m2, about 25 g / m2to about 30 g / m2, about 1 g / m2to about 25 g / m2, about 5 g / m2to about 25 g / m2, about 10 g / m2to about 25 g / m2, about 15 g / m2to about 25 g / m2, about 20 g / m2to about 25 g / m2, about 1 g / m2to about 20 g / m2, about 5 g / m2to about 20 g / m2, about 10 g / m2to about 20 g / m2, about15 g / m2to about 20 g / m2, about 1 g / m2to about 15 g / m2, about 5 g / m2to about 15 g / m2, about 10 g / m2to about 15 g / m2, about 1 g / m2to about 10 g / m2, about 5 g / m2to about 10 g / m2, or about 1 g / m2to about 5 g / m2. In some embodiments, a wet cellulose layer has an area density of about 5 g / m2to about 40 g / m2. For example, in some embodiments, a wet cellulose layer has an area density of about 5 g / m2, about 7.5 g / m2, about 10 g / m2, about 12.5 g / m2, about 15 g / m2, about 17.5 g / m2, about 20 g / m2, about 22.5 g / m2, about 25 g / m2, about 27.5 g / m2, about 30 g / m2, about 32.5 g / m2, about 35 g / m2, about 37.5 g / m2, or about 40 g / m2.[OHl] In some embodiments, step (v) of a double-dipping method of the present disclosure is performed at about 1 °C to about 20 °C. For example, in some embodiments, step (v) of a double-dipping method is performed at about 1 °C to about 20 °C, about 2 °C to about 20 °C, about 3 °C to about 20 °C, about 4 °C to about 20 °C, about 5 °C to about 20 °C, about 6 °C to about 20 °C, about 7 °C to about 20 °C, about 8 °C to about 20 °C, about 9 °C to about 20 °C, about 10 °C to about 20 °C, about 11 °C to about 20 °C, about 12 °C to about 20 °C, about 13 °C to about 20 °C, about 14 °C to about 20 °C, about 15 °C to about 20 °C, about16 °C to about 20 °C, about 17 °C to about 20 °C, about 18 °C to about 20 °C, about 19 °C to about 20 °C, about 1 °C to about 18 °C, about 2 °C to about 18 °C, about 3 °C to about 18 °C, about 4 °C to about 18 °C, about 5 °C to about 18 °C, about 6 °C to about 18 °C, about 7 °C to about 18 °C, about 8 °C to about 18 °C, about 9 °C to about 18 °C, about 10 °C to about 18 °C, about 11 °C to about 18 °C, about 12 °C to about 18 °C, about 13 °C to about 18 °C, about 14 °C to about 18 °C, about 15 °C to about 18 °C, about 16 °C to about 18 °C, about 17 °C to about 18 °C, about 1 °C to about 16 °C, about 2 °C to about 16 °C, about 3 °C to about 16 °C, about 4 °C to about 16 °C, about 5 °C to about 16 °C, about 6 °C to about 16 °C, about 7 °C to about 16 °C, about 8 °C to about 16 °C, about 9 °C to about 16 °C, about 10 °C to about 16 °C, about 11 °C to about 16 °C, about 12 °C to about 16 °C, about 13 °C to about 16 °C, about 14 °C to about 16 °C, about 15 °C to about 16 °C, about 1 °C to about 14 °C, about 2 °C to about 14 °C, about 3 °C to about 14 °C, about 4 °C to about 14 °C, about 5 °C to about 14 °C,about 6 °C to about 14 °C, about 7 °C to about 14 °C, about 8 °C to about 14 °C, about 9 °C to about 14 °C, about 10 °C to about 14 °C, about 11 °C to about 14 °C, about 12 °C to about 14 °C, about 13 °C to about 14 °C, about 1 °C to about 12 °C, about 2 °C to about 12 °C, about 3 °C to about 12 °C, about 4 °C to about 12 °C, about 5 °C to about 12 °C, about 6 °C to about 12 °C, about 7 °C to about 12 °C, about 8 °C to about 12 °C, about 9 °C to about 12 °C, about 10 °C to about 12 °C, about 11 °C to about 12 °C, about 1 °C to about 10 °C, about 2 °C to about 10 °C, about 3 °C to about 10 °C, about 4 °C to about 10 °C, about 5 °C to about 10 °C, about 6 °C to about 10 °C, about 7 °C to about 10 °C, about 8 °C to about 10 °C, about 9 °C to about 10 °C, about 1 °C to about 8 °C, about 2 °C to about 8 °C, about 3 °C to about 8 °C, about 4 °C to about 8 °C, about 5 °C to about 8 °C, about 6 °C to about 8 °C, about 7 °C to about 8 °C, about 1 °C to about 6 °C, about 2 °C to about 6 °C, about 3 °C to about 6 °C, about 4 °C to about 6 °C, about 5 °C to about 6 °C, about 1 °C to about 4 °C, about 2 °C to about 4 °C, about 3 °C to about 4 °C, or about 1 °C to about 2 °C. In some embodiments, step (v) of a double-dipping method of the present application is performed at about 3 °C to about 15 °C. For example, in some embodiments, step (v) of a double-dipping method is performed at about 3 °C, about 4 °C, about 5 °C, about 6 °C, about 7 °C, about 8 °C, about 9 °C, about 10 °C, about 11 °C, about 12 °C, about 13 °C, about 14 °C, or about 15 °C.

[0112] In some embodiments, a perforated mold is a silicon mold, a rubber mold, or a soft plastic mold. For example, in some embodiments, a perforated mold is a perforated silicon mold.

[0113] In some embodiments, step (vii) of a double-dipping method includes applying back vacuum pressure to a perforated mold to remove water from a wet substrate layer and a wet cellulose layer to form a cold-pressed laminate. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 barto about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar to about -0.5 bar.

[0114] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds.

[0115] In some embodiments, step (viii) of a double-dipping method includes detaching a cold-pressed laminate from a perforated mold by applying pressure to the cold- pressed laminate. In some embodiments, pressure applied to a cold-pressed laminate is air pressure. In some embodiments, a cold-pressed laminate is detached from a perforated mold but maintains attachment to a mold comprising at least one cavity.

[0116] In some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate for about 1 second to about 60 seconds. For example, in some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-presslaminate for about 1 second to about 60 seconds, about 5 seconds to about 60 seconds, about 10 seconds to about 60 seconds, about 15 seconds to about 60 seconds, about 20 seconds to about 60 seconds, about 25 seconds to about 60 seconds, about 30 seconds to about 60 seconds, about 35 seconds to about 60 seconds, about 40 seconds to about 60 seconds, about 45 seconds to about 60 seconds, about 50 seconds to about 60 seconds, about 55 seconds to about 60 seconds, about 1 second to about 50 seconds, about 5 seconds to about 50 seconds, about 10 seconds to about 50 seconds, about 15 seconds to about 50 seconds, about 20 seconds to about 50 seconds, about 25 seconds to about 50 seconds, about 30 seconds to about 50 seconds, about 35 seconds to about 50 seconds, about 40 seconds to about 50 seconds, about 45 seconds to about 50 seconds, about 1 second to about 40 seconds, about 5 seconds to about 40 seconds, about 10 seconds to about 40 seconds, about 15 seconds to about 40 seconds, about 20 seconds to about 40 seconds, about 25 seconds to about 40 seconds, about 30 seconds to about 40 seconds, about 35 seconds to about 40 seconds, about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 10 seconds, or about 5 seconds to about 10 seconds. In some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate for about 10 seconds to about 30 seconds. For example, in some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate for about 10 seconds, about 12 seconds, about 14 seconds, about 16 seconds, about 18 seconds, about 20 seconds, about 22 seconds, about 24 seconds, about 26 seconds, about 28 seconds, or about 30 seconds.

[0117] In some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C. For example, in some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C, about 160 °C to about 300 °C, about 170 °C to about 300 °C, about 180 °C to about 300 °C, about 190 °C to about300 °C, about 200 °C to about 300 °C, about 210 °C to about 300 °C, about 220 °C to about300 °C, about 230 °C to about 300 °C, about 240 °C to about 300 °C, about 250 °C to about300 °C, about 260 °C to about 300 °C, about 270 °C to about 300 °C, about 280 °C to about300 °C, about 290 °C to about 300 °C, about 150 °C to about 250 °C, about 160 °C to about250 °C, about 170 °C to about 250 °C, about 180 °C to about 250 °C, about 190 °C to about250 °C, about 200 °C to about 250 °C, about 210 °C to about 250 °C, about 220 °C to about250 °C, about 230 °C to about 250 °C, about 240 °C to about 250 °C, about 250 °C to about250 °C, about 260 °C to about 250 °C, about 270 °C to about 250 °C, about 280 °C to about250 °C, about 290 °C to about 250 °C, about 150 °C to about 200 °C, about 160 °C to about200 °C, about 170 °C to about 200 °C, about 180 °C to about 200 °C, or about 190 °C to about 200 °C. In some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate at a temperature of about 180 °C to about 250 °C. For example, in some embodiments, step (ix) of a double-dipping method includes hot pressing a cold-press laminate at a temperature of about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, or about 250 °C. b) Wet Lamination Method

[0118] In some embodiments, the present disclosure provides wet lamination methods of producing lignocellulosic and / or cellulosic products, or portions thereof (e.g., CNF and / or LCNF layer) as described herein, including the steps of:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the at least one cavity form a wet substrate layer;(iii) placing a wet cellulose film on a perforated mold and removing the mold from the substrate slurry;(iv) pressing the mold against the wet cellulose film on the perforated mold;(v) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose film to form a cold-pressed laminate;(vi) detaching the cold-pressed laminate from the perforated mold; and(vii) hot-pressing the cold-press laminate to form the cellulosic product.

[0119] In some embodiments, a wet cellulose film includes about 1 g / m2to about 50 g / m2of lignin-free CNFs, LCNFs, DCNFs, or a combination thereof. For example, in some embodiments, a wet cellulose film includes about 1 g / m2to about 50 g / m2, about 5 g / m2to about 50 g / m2, about 10 g / m2to about 50 g / m2, about 15 g / m2to about 50 g / m2, about 20 g / m2to about 50 g / m2, about 25 g / m2to about 50 g / m2, about 30 g / m2to about 50 g / m2, about 35 g / m2to about 50 g / m2, about 40 g / m2to about 50 g / m2, about 45 g / m2to about 50 g / m2, about 1 g / m2to about 45 g / m2, about 5 g / m2to about 45 g / m2, about 10 g / m2to about 45 g / m2, about 15 g / m2to about 45 g / m2, about 20 g / m2to about 45 g / m2, about 25 g / m2to about 45 g / m2, about 30 g / m2to about 45 g / m2, about 35 g / m2to about 45 g / m2, about 40 g / m2to about 45 g / m2, about 1 g / m2to about 40 g / m2, about 5 g / m2to about 40 g / m2, about 10 g / m2to about 40 g / m2, about 15 g / m2to about 40 g / m2, about 20 g / m2to about 40 g / m2, about 25 g / m2to about 40 g / m2, about 30 g / m2to about 40 g / m2, about 35 g / m2to about 40 g / m2, about 1 g / m2to about 35 g / m2, about 5 g / m2to about 35 g / m2, about 10 g / m2to about 35 g / m2, about 15 g / m2to about 35 g / m2, about 20 g / m2to about 35 g / m2, about 25 g / m2to about 35 g / m2, about 30 g / m2to about 35 g / m2, about 1 g / m2to about 30 g / m2, about 5 g / m2to about 30 g / m2, about 10 g / m2to about 30 g / m2, about 15 g / m2to about 30 g / m2, about 20 g / m2to about 30 g / m2, about 25 g / m2to about 30 g / m2, about 1 g / m2to about 25 g / m2, about 5 g / m2to about 25 g / m2, about 10 g / m2to about 25 g / m2, about 15 g / m2to about 25 g / m2, about 20 g / m2to about 25 g / m2, about 1 g / m2to about 20 g / m2, about 5 g / m2to about 20 g / m2, about 10 g / m2to about 20 g / m2, about 15 g / m2to about 20 g / m2, about 1 g / m2to about 15 g / m2, about 5 g / m2to about 15 g / m2, about 10 g / m2to about 15 g / m2, about 1 g / m2to about 10 g / m2, about 5 g / m2to about 10 g / m2, or about 1 g / m2to about 5 g / m2of lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

[0120] In some embodiments, a wet cellulose film includes about 5 g / m2to about 40 g / m2of lignin-free CNFs, LCNFs, DCNFs, or a combination thereof. For example, in some embodiments, a wet cellulose film includes about 5 g / m2, about 10 g / m2, about 15 g / m2, about 20 g / m2, about 25 g / m2, about 30 g / m2, about 35 g / m2, or about 40 g / m2of lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

[0121] In some embodiments, a wet cellulose film further incorporates one or more additives. In some embodiments, one or more additives include a mineral, a cross-linking agent, aluminum sulfate (e.g., alum), or a combination thereof. In some embodiments, an amount of aluminum sulfate between 0.5% to 2% of total dry weight is used. In someembodiments, one or more additives include a mineral selected from calcium carbonate, talc, or clay. In some embodiments, an amount of mineral between 0.5% to 2% of total dry weight is used. In some embodiments, one or more additives include a cross-linking agent that is or comprises polyamide epichlorohydrin resin (PAE). In some embodiments, an amount of PAE between 0.5% to 2% of total dry weight is used.

[0122] In some embodiments, step (iii) of a wet lamination method includes placing a wet cellulose film on a perforated mold before removing a mold from a substrate slurry. In some embodiments, step (iii) of a wet lamination method includes placing a wet cellulose film on a perforated mold concurrently with removing a mold from a substrate slurry. In some embodiments, step (iii) of a wet lamination method includes placing a wet cellulose film on a perforated mold after removing a mold from a substrate slurry.

[0123] In some embodiments, a perforated mold is a silicon mold, a rubber mold, or a soft plastic mold. For example, in some embodiments, a perforated mold is a perforated silicon mold.

[0124] In some embodiments, step (iv) of a wet lamination method is performed at about 15 °C to about 30 °C. For example, in some embodiments, step (iv) of a wet lamination method is performed at about 15 °C to about 30 °C, about 17.5 °C to about 30 °C, about 20 °C to about 30 °C, about 22.5 °C to about 30 °C, about 25 °C to about 30 °C, about 275 °C to about 30 °C, about 15 °C to about 25 °C, about 17.5 °C to about 25 °C, about 20 °C to about 25 °C, about 22.5 °C to about 25 °C, about 15 °C to about 20 °C, or about 17.5 °C to about 20 °C. In some embodiments, step (iv) of a wet lamination method is performed at about 20 °C to about 25 °C. For example, in some embodiments, step (iv) of a wet lamination method is performed at about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, or about 25 °C.

[0125] In some embodiments, step (v) of a wet lamination method includes applying back vacuum pressure to a perforated mold to remove water from a wet substrate layer and a wet cellulose film to form a cold-pressed laminate. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 barto about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar to about -0.5 bar. In some embodiments, the back vacuum pressure is from about -0.5 bar to about -1.0 bar. For example, in some embodiments, the back vacuum pressure is about -0.5 bar, about -0.6 bar, about -0.7 bar, -0.8 bar, -0.9 bar, or about -1.0 bar.

[0126] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds. In some embodiments, the back vacuum pressure is applied for about 5 seconds to about 20 seconds. For example, in some embodiments, the back vacuum pressure is applied for about 5 seconds, about 6seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, or about 20 seconds.

[0127] In some embodiments, step (vi) of a wet lamination method includes detaching a cold-pressed laminate from a perforated mold by applying pressure to the cold-pressed laminate. In some embodiments, pressure applied to a cold-pressed laminate is air pressure.

[0128] In some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate for about 1 second to about 60 seconds. For example, in some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate for about 1 second to about 60 seconds, about 5 seconds to about 60 seconds, about 10 seconds to about 60 seconds, about 15 seconds to about 60 seconds, about 20 seconds to about 60 seconds, about 25 seconds to about 60 seconds, about 30 seconds to about 60 seconds, about 35 seconds to about 60 seconds, about 40 seconds to about 60 seconds, about 45 seconds to about 60 seconds, about 50 seconds to about 60 seconds, about 55 seconds to about 60 seconds, about 1 second to about 50 seconds, about 5 seconds to about 50 seconds, about 10 seconds to about 50 seconds, about 15 seconds to about 50 seconds, about 20 seconds to about 50 seconds, about 25 seconds to about 50 seconds, about 30 seconds to about 50 seconds, about 35 seconds to about 50 seconds, about 40 seconds to about 50 seconds, about 45 seconds to about 50 seconds, about 1 second to about 40 seconds, about 5 seconds to about 40 seconds, about 10 seconds to about 40 seconds, about 15 seconds to about 40 seconds, about 20 seconds to about 40 seconds, about 25 seconds to about 40 seconds, about 30 seconds to about 40 seconds, about 35 seconds to about 40 seconds, about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 10 seconds, or about 5 seconds to about 10 seconds. In some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate for about 10 seconds to about 30 seconds. For example, in some embodiments, step (vii) of a wet lamination method includes hot-pressing a cold-press laminate for about 10 seconds, about 12 seconds, about 14 seconds, about 16 seconds, about18 seconds, about 20 seconds, about 22 seconds, about 24 seconds, about 26 seconds, about 28 seconds, or about 30 seconds.

[0129] In some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C. For example, in some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C, about 160 °C to about 300 °C, about 170 °C to about 300 °C, about 180 °C to about 300 °C, about 190 °C to about300 °C, about 200 °C to about 300 °C, about 210 °C to about 300 °C, about 220 °C to about300 °C, about 230 °C to about 300 °C, about 240 °C to about 300 °C, about 250 °C to about300 °C, about 260 °C to about 300 °C, about 270 °C to about 300 °C, about 280 °C to about300 °C, about 290 °C to about 300 °C, about 150 °C to about 250 °C, about 160 °C to about250 °C, about 170 °C to about 250 °C, about 180 °C to about 250 °C, about 190 °C to about250 °C, about 200 °C to about 250 °C, about 210 °C to about 250 °C, about 220 °C to about250 °C, about 230 °C to about 250 °C, about 240 °C to about 250 °C, about 250 °C to about250 °C, about 260 °C to about 250 °C, about 270 °C to about 250 °C, about 280 °C to about250 °C, about 290 °C to about 250 °C, about 150 °C to about 200 °C, about 160 °C to about200 °C, about 170 °C to about 200 °C, about 180 °C to about 200 °C, or about 190 °C to about 200 °C. In some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate at a temperature of about 180 °C to about 250 °C. For example, in some embodiments, step (vii) of a wet lamination method includes hot pressing a cold-press laminate at a temperature of about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, or about 250 °C. c) Spray Coating Method

[0130] In some embodiments, the present disclosure provides spray coating methods of producing lignocellulosic and / or cellulosic products, or portions thereof (e.g., CNF and / or LCNF layer) as described herein, including the steps of:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the at least one cavity to form a wet substrate layer;(iii) removing the mold from the substrate slurry;(iv) spraying the wet substrate layer with a cellulose slurry to form a wet cellulose layer;(v) pressing the mold against a perforated mold;(vi) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose layer to form a cold-pressed laminate;(vii) detaching the cold-pressed laminate from the perforated mold; and(viii) hot-pressing the cold-press laminate to form the cellulosic product.

[0131] In some embodiments, step (ii) of a spray coating method includes applying back vacuum pressure to at least one cavity in the mold to form a wet substrate layer. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about - 0.1 bar to about -0.5 bar. In some embodiments, back vacuum pressure is from about -0.5 bar to about -1.0 bar. For example, in some embodiments, back vacuum pressure is about -0.5 bar, about -0.6 bar, about -0.7 bar, -0.8 bar, -0.9 bar, or about -1.0 bar.

[0132] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds. In some embodiments, back vacuum pressure is applied for about 5 seconds to about 20 seconds. For example, in some embodiments, back vacuum pressure is applied for about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, or about 20 seconds.

[0133] In some embodiments a cellulose slurry includes cellulose nanofibril (CNF) solids. In some embodiments, a cellulose slurry includes about 0.1% (w / v) to about 5% (w / v) CNF solids. For example, in some embodiments, a cellulose slurry includes about 0.1% (w / v) to about 5% (w / v), about 0.5% (w / v) to about 5% (w / v), about 1% (w / v) to about 5% (w / v), about 1.5% (w / v) to about 5% (w / v), about 2% (w / v) to about 5% (w / v), about 2.5% (w / v) to about 5% (w / v), about 3% (w / v) to about 5% (w / v), about 3.5% (w / v) to about 5% (w / v), about 4% (w / v) to about 5% (w / v), about 4.5% (w / v) to about 5% (w / v), about 0.1% (w / v) to about 4.5% (w / v), about 0.5% (w / v) to about 4% (w / v), about 1% (w / v) to about 4% (w / v), about 1.5% (w / v) to about 4% (w / v), about 2% (w / v) to about 4% (w / v), about 2.5% (w / v) to about 4% (w / v), about 3% (w / v) to about 4% (w / v), about 3.5% (w / v) to about 4%(w / v), about 0.1% (w / v) to about 3.5% (w / v), about 0.5% (w / v) to about 3.5% (w / v), about 1% (w / v) to about 3.5% (w / v), about 1.5% (w / v) to about 3.5% (w / v), about 2% (w / v) to about 3.5% (w / v), about 2.5% (w / v) to about 3.5% (w / v), about 3% (w / v) to about 3.5% (w / v), about 0.1% (w / v) to about 3% (w / v), about 0.5% (w / v) to about 3% (w / v), about 1% (w / v) to about 3% (w / v), about 1.5% (w / v) to about 3% (w / v), about 2% (w / v) to about 3% (w / v), about 2.5% (w / v) to about 3% (w / v), about 0.1% (w / v) to about 2.5% (w / v), about 0.5% (w / v) to about 2.5% (w / v), about 1% (w / v) to about 2.5% (w / v), about 1.5% (w / v) to about 2.5% (w / v), about 2% (w / v) to about 2.5% (w / v), about 0.1% (w / v) to about 2% (w / v), about 0.5% (w / v) to about 2% (w / v), about 1% (w / v) to about 2% (w / v), about 1.5% (w / v) to about 2% (w / v), about 0.1% (w / v) to about 1.5% (w / v), about 0.5% (w / v) to about 1.5% (w / v), about 1% (w / v) to about 1.5% (w / v), about 0.1% (w / v) to about 1% (w / v), about 0.5% (w / v) to about 1% (w / v), or about 0.1% (w / v) to about 0.5% (w / v) CNF solids. In some embodiments, a cellulose slurry includes about 0.3% (w / v) to about 1% (w / v) CNF solids. For example, in some embodiments, a cellulose slurry includes about 0.3% (w / v), 0.35% (w / v), about 0.4% (w / v), about 0.45% (w / v), about 0.5% (w / v), about 0.55% (w / v), about 0.6% (w / v), about 0.65% (w / v), about 0.7% (w / v), about 0.75% (w / v), about 0.8% (w / v), about 0.85% (w / v), about 0.9% (w / v), about 0.95% (w / v), or about 1% (w / v) CNF solids.

[0134] In some embodiments, CNF solids in a cellulose slurry include lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

[0135] In some embodiments, a cellulose slurry further incorporates one or more additives. In some embodiments, one or more additives include a mineral, a cross-linking agent, aluminum sulfate (e.g., alum), or a combination thereof. In some embodiments, an amount of aluminum sulfate between 0.5% to 2% of total dry weight is used. In some embodiments, one or more additives include a mineral selected from calcium carbonate, or clay. In some embodiments, an amount of mineral between 0.5% to 2% of total dry weight is used. In some embodiments, one or more additives include a cross-linking agent that is or comprises polyamide epichlorohydrin resin (PAE). In some embodiments, an amount of PAE between 0.5% to 2% of total dry weight is used.

[0136] In some embodiments, step (iv) of a spray coating method includes spraying a cellulose slurry using a nozzle onto a wet substrate layer. In some embodiments, a cellulose slurry is sprayed through a nozzle at a flow rate of about 0.1 cm3 / s to about 15 cm3 / s. Forexample, in some embodiments, a cellulose slurry is sprayed through a nozzle at a flow rate of about 0.1 cm3 / s to about 15 cm3 / s, about 0.5 cm3 / s to about 15 cm3 / s, about 1 cm3 / s to about 15 cm3 / s, about 1.5 cm3 / s to about 15 cm3 / s, about 2 cm3 / s to about 15 cm3 / s, about 2.5 cm3 / s to about 15 cm3 / s, about 3 cm3 / s to about 15 cm3 / s, about 3.5 cm3 / s to about 15 cm3 / s, about 4 cm3 / s to about 15 cm3 / s, about 4.5 cm3 / s to about 15 cm3 / s, about 5 cm3 / s to about 15 cm3 / s, about 5.5 cm3 / s to about 15 cm3 / s, about 6 cm3 / s to about 15 cm3 / s, about 6.5 cm3 / s to about 15 cm3 / s, about 7 cm3 / s to about 15 cm3 / s, about 7.5 cm3 / s to about 15 cm3 / s, about 8 cm3 / s to about 15 cm3 / s, about 8.5 cm3 / s to about 15 cm3 / s, about 9 cm3 / s to about 15 cm3 / s, about 9.5 cm3 / s to about 15 cm3 / s, about 10 cm3 / s to about 15 cm3 / s, about 10.5 cm3 / s to about 15 cm3 / s, about 11 cm3 / s to about 15 cm3 / s, about 11.5 cm3 / s to about 15 cm3 / s, about 12 cm3 / s to about 15 cm3 / s, about 12.5 cm3 / s to about 15 cm3 / s, about 13 cm3 / s to about 15 cm3 / s, about 13.5 cm3 / s to about 15 cm3 / s, about 14 cm3 / s to about 15 cm3 / s, about 14.5 cm3 / s to about 15 cm3 / s, about 0.1 cm3 / s to about 12.5 cm3 / s, about 0.5 cm3 / s to about 12.5 cm3 / s, about 1 cm3 / s to about 12.5 cm3 / s, about 1.5 cm3 / s to about 12.5 cm3 / s, about 2 cm3 / s to about12.5 cm3 / s, about 2.5 cm3 / s to about 12.5 cm3 / s, about 3 cm3 / s to about 12.5 cm3 / s, about 3.5 cm3 / s to about 12.5 cm3 / s, about 4 cm3 / s to about 12.5 cm3 / s, about 4.5 cm3 / s to about 12.5 cm3 / s, about 5 cm3 / s to about 12.5 cm3 / s, about 5.5 cm3 / s to about 12.5 cm3 / s, about 6 cm3 / s to about 12.5 cm3 / s, about 6.5 cm3 / s to about 12.5 cm3 / s, about 7 cm3 / s to about 12.5 cm3 / s, about 7.5 cm3 / s to about 12.5 cm3 / s, about 8 cm3 / s to about 12.5 cm3 / s, about 8.5 cm3 / s to about 12.5 cm3 / s, about 9 cm3 / s to about 12.5 cm3 / s, about 9.5 cm3 / s to about 12.5 cm3 / s, about 10 cm3 / s to about 12.5 cm3 / s, about 10.5 cm3 / s to about 12.5 cm3 / s, about 11 cm3 / s to about 12.5 cm3 / s, about 11.5 cm3 / s to about 12.5 cm3 / s, about 12 cm3 / s to about 12.5 cm3 / s, about 0.1 cm3 / s to about 10 cm3 / s, about 0.5 cm3 / s to about 10 cm3 / s, about 1 cm3 / s to about 10 cm3 / s, about 1.5 cm3 / s to about 10 cm3 / s, about 2 cm3 / s to about 10 cm3 / s, about 2.5 cm3 / s to about 10 cm3 / s, about 3 cm3 / s to about 10 cm3 / s, about 3.5 cm3 / s to about 10 cm3 / s, about 4 cm3 / s to about 10 cm3 / s, about 4.5 cm3 / s to about 10 cm3 / s, about 5 cm3 / s to about 10 cm3 / s, about 5.5 cm3 / s to about 10 cm3 / s, about 6 cm3 / s to about 10 cm3 / s, about 6.5 cm3 / s to about 10 cm3 / s, about 7 cm3 / s to about 10 cm3 / s, about 7.5 cm3 / s to about 10 cm3 / s, about 8 cm3 / s to about 10 cm3 / s, about 8.5 cm3 / s to about 10 cm3 / s, about 9 cm3 / s to about 10 cm3 / s, about 9.5 cm3 / s to about 10 cm3 / s, about 0.1 cm3 / s to about 7.5 cm3 / s, about 0.5 cm3 / s to about 7.5 cm3 / s, about 1 cm3 / s to about 7.5 cm3 / s, about 1.5 cm3 / s to about 7.5 cm3 / s, about 2 cm3 / s to about 7.5 cm3 / s, about 2.5 cm3 / s to about 7.5 cm3 / s, about 3 cm3 / s to about 7.5 cm3 / s, about3.5 cm3 / s to about 7.5 cm3 / s, about 4 cm3 / s to about 7.5 cm3 / s, about 4.5 cm3 / s to about 7.5cm3 / s, about 5 cm3 / s to about 7.5 cm3 / s, about 5.5 cm3 / s to about 7.5 cm3 / s, about 6 cm3 / s to about 7.5 cm3 / s, about 6.5 cm3 / s to about 7.5 cm3 / s, about 7 cm3 / s to about 7.5 cm3 / s, about 0.1 cm3 / s to about 5 cm3 / s, about 0.5 cm3 / s to about 5 cm3 / s, about 1 cm3 / s to about 5 cm3 / s, about 1.5 cm3 / s to about 5 cm3 / s, about 2 cm3 / s to about 5 cm3 / s, about 2.5 cm3 / s to about 5 cm3 / s, about 3 cm3 / s to about 5 cm3 / s, about 3.5 cm3 / s to about 5 cm3 / s, about 4 cm3 / s to about 5 cm3 / s, about 4.5 cm3 / s to about 5 cm3 / s, about 0.1 cm3 / s to about 2.5 cm3 / s, about 0.5 cm3 / s to about 2.5 cm3 / s, about 1 cm3 / s to about 2.5 cm3 / s, about 1.5 cm3 / s to about 2.5 cm3 / s, or about 2 cm3 / s to about 2.5 cm3 / s.

[0137] In some embodiments, a cellulose slurry is sprayed through a nozzle at a flow rate of about 1 cm3 / s to about 15 cm3 / s. For example, in some embodiments, a cellulose slurry is sprayed through a nozzle at a flow rate of about 1 cm3 / s, about 2 cm3 / s, about 3 cm3 / s, about 4 cm3 / s, about 5 cm3 / s, about 6 cm3 / s, about 7 cm3 / s, about 8 cm3 / s, about 9 cm3 / s, about 10 cm3 / s, about 11 cm3 / s, about 12 cm3 / s, about 13 cm3 / s, about 14 cm3 / s, or about 15 cm3 / s.

[0138] In some embodiments, step (v) of a double-dipping method includes applying back vacuum pressure to at least one cavity in a mold to form a wet cellulose layer. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar toabout -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar to about -0.5 bar. In some embodiments, back vacuum pressure is from about -0.5 bar to about -1.0 bar. For example, in some embodiments, back vacuum pressure is about -0.5 bar, about -0.6 bar, about -0.7 bar, -0.8 bar, -0.9 bar, or about -1.0 bar.

[0139] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds. In some embodiments, back vacuum pressure is applied for about 5 seconds to about 20 seconds. For example, in some embodiments, back vacuum pressure is applied for about 5 seconds, about 6 seconds, about 7 seconds, about 8 seconds, about 9 seconds, about 10 seconds, about 11 seconds, about 12 seconds, about 13 seconds, about 14 seconds, about 15 seconds, about 16 seconds, about 17 seconds, about 18 seconds, about 19 seconds, or about 20 seconds.

[0140] In some embodiments, a wet cellulose layer has an area density of about 1 g / m2to about 50 g / m2. For example, in some embodiments, a wet cellulose layer has an area density of about 1 g / m2to about 50 g / m2, about 5 g / m2to about 50 g / m2, about 10 g / m2to about 50 g / m2, about 15 g / m2to about 50 g / m2, about 20 g / m2to about 50 g / m2, about 25 g / m2to about 50 g / m2, about 30 g / m2to about 50 g / m2, about 35 g / m2to about 50 g / m2, about 40 g / m2to about 50 g / m2, about 45 g / m2to about 50 g / m2, about 1 g / m2to about 45 g / m2, about 5 g / m2to about 45 g / m2, about 10 g / m2to about 45 g / m2, about 15 g / m2to about 45 g / m2, about 20 g / m2to about 45 g / m2, about 25 g / m2to about 45 g / m2, about 30 g / m2to about45 g / m2, about 35 g / m2to about 45 g / m2, about 40 g / m2to about 45 g / m2, about 1 g / m2to about 40 g / m2, about 5 g / m2to about 40 g / m2, about 10 g / m2to about 40 g / m2, about 15 g / m2to about 40 g / m2, about 20 g / m2to about 40 g / m2, about 25 g / m2to about 40 g / m2, about 30 g / m2to about 40 g / m2, about 35 g / m2to about 40 g / m2, about 1 g / m2to about 35 g / m2, about 5 g / m2to about 35 g / m2, about 10 g / m2to about 35 g / m2, about 15 g / m2to about 35 g / m2, about 20 g / m2to about 35 g / m2, about 25 g / m2to about 35 g / m2, about 30 g / m2to about 35 g / m2, about 1 g / m2to about 30 g / m2, about 5 g / m2to about 30 g / m2, about 10 g / m2to about 30 g / m2, about 15 g / m2to about 30 g / m2, about 20 g / m2to about 30 g / m2, about 25 g / m2to about 30 g / m2, about 1 g / m2to about 25 g / m2, about 5 g / m2to about 25 g / m2, about 10 g / m2to about 25 g / m2, about 15 g / m2to about 25 g / m2, about 20 g / m2to about 25 g / m2, about 1 g / m2to about 20 g / m2, about 5 g / m2to about 20 g / m2, about 10 g / m2to about 20 g / m2, about 15 g / m2to about 20 g / m2, about 1 g / m2to about 15 g / m2, about 5 g / m2to about 15 g / m2, about 10 g / m2to about 15 g / m2, about 1 g / m2to about 10 g / m2, about 5 g / m2to about 10 g / m2, or about 1 g / m2to about 5 g / m2. In some embodiments, a wet cellulose layer has an area density of about 5 g / m2to about 40 g / m2. For example, in some embodiments, a wet cellulose layer has an area density of about 5 g / m2, about 7.5 g / m2, about 10 g / m2, about 12.5 g / m2, about 15 g / m2, about 17.5 g / m2, about 20 g / m2, about 22.5 g / m2, about 25 g / m2, about 27.5 g / m2, about 30 g / m2, about 32.5 g / m2, about 35 g / m2, about 37.5 g / m2, or about 40 g / m2.

[0141] In some embodiments, step (v) of a spray coating method is performed at about 15 °C to about 30 °C. For example, in some embodiments, step (v) of a spray coating method is performed at about 15 °C to about 30 °C, about 17.5 °C to about 30 °C, about 20 °C to about 30 °C, about 22.5 °C to about 30 °C, about 25 °C to about 30 °C, about 275 °C to about 30 °C, about 15 °C to about 25 °C, about 17.5 °C to about 25 °C, about 20 °C to about 25 °C, about 22.5 °C to about 25 °C, about 15 °C to about 20 °C, or about 17.5 °C to about 20 °C. In some embodiments, step (v) of a spray coating method is performed at about 20 °C to about 25 °C. For example, in some embodiments, step (v) of a spray coating method is performed at about 20 °C, about 21 °C, about 22 °C, about 23 °C, about 24 °C, or about 25 °C.

[0142] In some embodiments, a perforated mold is a silicon mold, a rubber mold, or a soft plastic mold. For example, in some embodiments, a perforated mold is a perforated silicon mold.

[0143] In some embodiments, step (vi) of a spray coating method includes applying back vacuum pressure to a perforated mold to remove water from a wet substrate layer and a wet cellulose layer to form a cold-pressed laminate. In some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar. For example, in some embodiments, back vacuum pressure is from about -0.1 bar to about -5.0 bar, about -0.5 bar to about -5.0 bar, about -1.0 bar to about -5.0 bar, about -1.5 bar to about -5.0 bar, about -2.0 bar to about -5.0 bar, about -2.5 bar to about -5.0 bar, about -3.0 bar to about -5.0 bar, about -3.5 bar to about -5.0 bar, about -4.0 bar to about -5.0 bar, about -4.5 bar to about -5.0 bar, about -0.1 bar to about -4.5 bar, about -0.5 bar to about -4.5 bar, about -1.0 bar to about -4.5 bar, about -1.5 bar to about -4.5 bar, about -2.0 bar to about -4.5 bar, about -2.5 bar to about -4.5 bar, about -3.0 bar to about -4.5 bar, about -3.5 bar to about -4.5 bar, about -4.0 bar to about -4.5 bar, -0.1 bar to about -4.0 bar, about -0.5 bar to about -4.0 bar, about -1.0 bar to about -4.0 bar, about -1.5 bar to about -4.0 bar, about -2.0 bar to about -4.0 bar, about -2.5 bar to about -4.0 bar, about -3.0 bar to about -4.0 bar, about -3.5 bar to about -4.0 bar, about -0.1 bar to about -3.5 bar, about -0.5 bar to about -3.5 bar, about -1.0 bar to about -3.5 bar, about -1.5 bar to about -3.5 bar, about -2.0 bar to about -3.5 bar, about -2.5 bar to about -3.5 bar, about -3.0 bar to about -3.5 bar, about -0.1 bar to about -3.0 bar, about -0.5 bar to about -3.0 bar, about -1.0 bar to about -3.0 bar, about -1.5 bar to about -3.0 bar, about -2.0 bar to about -3.0 bar, about -2.5 bar to about -3.0 bar, about -0.1 bar to about -2.5 bar, about -0.5 bar to about -2.5 bar, about -1.0 bar to about -2.5 bar, about -1.5 bar to about -2.5 bar, about -2.0 bar to about -2.5 bar, about -0.1 bar to about -2.0 bar, about -0.5 bar to about -2.0 bar, about -1.0 bar to about -2.0 bar, about -1.5 bar to about -2.0 bar, about -0.1 bar to about -1.5 bar, about -0.5 bar to about -1.5 bar, about -1.0 bar to about -1.5 bar, about -0.1 bar to about -1.0 bar, about -0.5 bar to about -1.0 bar, or about -0.1 bar to about -0.5 bar.

[0144] In some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds. For example, in some embodiments, back vacuum pressure is applied for about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 25 seconds, about 5 seconds to about 25 seconds, about 10 seconds to about 25 seconds, about 15 seconds to about 25 seconds, about 20 seconds to about 25 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 secondsto about 20 seconds, about 1 second to about 15 seconds, about 5 seconds to about 15 seconds, about 10 seconds to about 15 seconds, about 1 second to about 10 seconds, about 5 seconds to about 10 seconds, or about 1 second to about 5 seconds.

[0145] In some embodiments, step (vii) of a spray coating method includes detaching a cold-pressed laminate from a perforated mold by applying pressure to the cold-pressed laminate. In some embodiments, pressure applied to a cold-pressed laminate is air pressure.

[0146] In some embodiments, step (viii) of a spray coating method includes hot- pressing a cold-press laminate for about 1 second to about 60 seconds. For example, in some embodiments, step (viii) of a spray coating method includes hot-pressing a cold-press laminate for about 1 second to about 60 seconds, about 5 seconds to about 60 seconds, about 10 seconds to about 60 seconds, about 15 seconds to about 60 seconds, about 20 seconds to about 60 seconds, about 25 seconds to about 60 seconds, about 30 seconds to about 60 seconds, about 35 seconds to about 60 seconds, about 40 seconds to about 60 seconds, about 45 seconds to about 60 seconds, about 50 seconds to about 60 seconds, about 55 seconds to about 60 seconds, about 1 second to about 50 seconds, about 5 seconds to about 50 seconds, about 10 seconds to about 50 seconds, about 15 seconds to about 50 seconds, about 20 seconds to about 50 seconds, about 25 seconds to about 50 seconds, about 30 seconds to about 50 seconds, about 35 seconds to about 50 seconds, about 40 seconds to about 50 seconds, about 45 seconds to about 50 seconds, about 1 second to about 40 seconds, about 5 seconds to about 40 seconds, about 10 seconds to about 40 seconds, about 15 seconds to about 40 seconds, about 20 seconds to about 40 seconds, about 25 seconds to about 40 seconds, about 30 seconds to about 40 seconds, about 35 seconds to about 40 seconds, about 1 second to about 30 seconds, about 5 seconds to about 30 seconds, about 10 seconds to about 30 seconds, about 15 seconds to about 30 seconds, about 20 seconds to about 30 seconds, about 25 seconds to about 30 seconds, about 1 second to about 20 seconds, about 5 seconds to about 20 seconds, about 10 seconds to about 20 seconds, about 15 seconds to about 20 seconds, about 1 second to about 10 seconds, or about 5 seconds to about 10 seconds. In some embodiments, step (viii) of a spray coating method includes hot-pressing a cold-press laminate for about 10 seconds to about 30 seconds. For example, in some embodiments, step (viii) of a spray coating method includes hot-pressing the cold-press laminate for about 10 seconds, about 12 seconds, about 14 seconds, about 16 seconds, about18 seconds, about 20 seconds, about 22 seconds, about 24 seconds, about 26 seconds, about 28 seconds, or about 30 seconds.

[0147] In some embodiments, step (viii) of a spray coating method includes hot- pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C. For example, in some embodiments, step (viii) of a spray coating method includes hot-pressing a cold-press laminate at a temperature of about 150 °C to about 300 °C, about 160 °C to about 300 °C, about 170 °C to about 300 °C, about 180 °C to about 300 °C, about 190 °C to about300 °C, about 200 °C to about 300 °C, about 210 °C to about 300 °C, about 220 °C to about300 °C, about 230 °C to about 300 °C, about 240 °C to about 300 °C, about 250 °C to about300 °C, about 260 °C to about 300 °C, about 270 °C to about 300 °C, about 280 °C to about300 °C, about 290 °C to about 300 °C, about 150 °C to about 250 °C, about 160 °C to about250 °C, about 170 °C to about 250 °C, about 180 °C to about 250 °C, about 190 °C to about250 °C, about 200 °C to about 250 °C, about 210 °C to about 250 °C, about 220 °C to about250 °C, about 230 °C to about 250 °C, about 240 °C to about 250 °C, about 250 °C to about250 °C, about 260 °C to about 250 °C, about 270 °C to about 250 °C, about 280 °C to about250 °C, about 290 °C to about 250 °C, about 150 °C to about 200 °C, about 160 °C to about200 °C, about 170 °C to about 200 °C, about 180 °C to about 200 °C, or about 190 °C to about 200 °C. In some embodiments, step (viii) of a spray coating method includes hot-pressing a cold-press laminate at a temperature of about 180 °C to about 250 °C. For example, in some embodiments, step (viii) of a spray coating method includes hot pressing a cold-press laminate at a temperature of about 180 °C, about 190 °C, about 200 °C, about 210 °C, about 220 °C, about 230 °C, about 240 °C, or about 250 °C.EXAMPLES

[0148] The following examples are provided so as to describe to the skilled artisan how to make and use methods and compositions described herein and are not intended to limit the scope of the present disclosure.Example 1: Initial Lignocellulosic Material Preparations

[0149] The present example describes the composition and method of producing various exemplary lignocellulosic material preparations.Materials

[0150] Cellulose nanofibril (CNF) suspensions produced from softwood bleached kraft pulp (BKP) containing 3 wt% solids with a 90% fines content were obtained from the Process Development Center (PDC) at the University of Maine. Maple wood flour (WF) was obtained from Lignetics (Broomfield, CO). These wood particles had an average length of 1.0 ±0.4 mm, an aspect ratio of 4.2 ± 2.1, and an average moisture content of 9.5%. BKP in the form of dried sheets was also obtained from the PDC at the University of Maine. Thermomechanical pulp (TMP) was obtained from TimberHP (Madison, ME). The solid content of the CNF suspension was determined using a moisture analyzer (Ohaus MB45 Corporation, Parsippany, NJ), while fines content, defined as the percentage of fibers with lengths smaller than 200 micrometers, was measured using a MorFi analyzer (MorFi, Tecpap Inc., France).Initial Screening for Raw Materials

[0151] Different formulations were prepared for an initial screening of raw materials. TABLE 1 shows exemplary formulations that were initially tested to analyze the impact of different lignocellulosic materials on the overall mechanical properties of a lignocellulosic product and to identify the composite system that would be most functionally and commercially viable as a food-serving container in terms of both material strength and expected cost.TABLE 1: Initial Formulations Prepared Using Different Lignocellulosic Materials

[0152] FIG. 1 shows a general exemplary scheme for a laboratory-scale fabrication process for CNF / lignocellulosic sheets. To prepare the sample sheet, all lignocellulosic materials, including CNF, WF, BKP, and TMP, were weighed according to the formulation composition and simultaneously mixed in a beaker. The initial solids content of CNFs was 3 wt%, WF and TMP fibers had 90 wt% solids. The solids content of the formulation mixturewas adjusted to 1 wt% by the addition of water. The mixture was blended for 30 seconds using a kitchen blender (Waring, Stamford, CT). Vacuum filtration was performed using a Buchner funnel, with a plastic filter screen having a pore size of 70 pm. The vacuum pressure was maintained at 30 inHg. The filtration was stopped after the interval between two consecutive drops decreased to a drop occurring every 10 seconds. Once the filtration was completed, the wet sheet was removed from the funnel. The wet sample was then placed between two stainless steel plates. The steel plates, along with the wet material, were pressed using a Carver Inc. hot press (Wabash, IN) at a temperature of 150 °C and a pressure of 1.5 MPa for 3 minutes. The diameter of the sheet was 11 cm with an area of 95 cm2. All sheets were prepared at a target basis weight (grammage) of 600 g / m2.Example 2: Optimization of Wood Flour Formulations

[0153] The present example describes the optimization of various exemplary wood flour formulations of the present disclosure.

[0154] After the evaluation of the preliminary formulations listed in TABLE 1, various formulations containing wood flour (WF) were further optimized by first keeping the CNF content at 10% and varying the proportion of WF and BKP, and then by reducing the CNF content (formulations shown in TABLE 2). The production process for these formulations were performed as previously described in Example 1.TABLE 2: Secondary Formulations Prepared Using Different Lignocellulosic MaterialsExample 3: Mechanical Characterization

[0155] The present example describes the characterization of the mechanical properties of exemplary formulations of the present disclosure.

[0156] The mechanical properties of all formulations were analyzed by conducting tensile and flexural tests on the samples using an Instron mechanical testing machine (Model 5942, Instron Instruments, Norwood, MA) equipped with a 500 N load cell. For these tests, each formulation sample sheet was cut into 8 cm * 1.5 cm strips using a Muse 3D laser cutter (Full Spectrum, Las Vegas, NV).

[0157] Before testing, all samples were preconditioned in a humidity chamber at 23 ± 2 °C and 50 ± 3% relative humidity (RH) for 24 hours. For both tensile and flexural tests, a total of eight strips were tested for each formulation. The densities of the samples were measured prior to testing and the results were normalized based on density by dividing mechanical property values by corresponding sample density.

[0158] A three-point bending test was conducted, with a sample strip positioned horizontally over two supports. The span length of the Instron fixture for the flexural test was adjusted to 60 mm leaving 10 mm on each side. Force was applied to the center of the material at a crosshead speed of 2 mm per minute. The flexural modulus was computed from the slope of the stress and strain curve, while the maximum force determined the maximum stress or flexural strength of the sample.

[0159] In the tensile test, the sample was securely gripped within the fixture grips. Tensile force was applied at a crosshead speed of 2 mm per minute, pulling one side of the sample upwards while the other side remained firmly attached to the fixture. An extensometer was mounted in the middle of the sample to precisely measure the strain over a gauge length of 10 mm as force was applied. The test proceeded until the sample was either broken or torn apart.

[0160] As shown in FIG. 2A and FIG. 2B, sample lignocellulosic sheets / plates of Formulation 3 (B45T45C10) and Formulation 2 (B45W45C10) had comparable normalized tensile modulus values and comparable normalized flexural modulus values.

[0161] As shown in FIG. 3A and FIG. 4A, normalized tensile strength values generally increased as % CNF content increased in a formulation. Similarly, as shown in FIG. 3B and FIG. 4B, normalized flexural modulus and normalized flexural strength increased as % CNF content increased in a formulation.

[0162] As shown in FIG. 5A, formulations having some percentages of wood flour and cellulose nanofibrils had greater normalized tensile modulus values and normalized tensile strength than formulations having 100% bleached kraft pulp. Similarly, formulations having some percentages of wood flour and cellulose nanofibrils had greater normalized flexural modulus values and normalized flexural strength than formulations having 100% bleached kraft pulp.Statistical Analysis

[0163] One-way analysis of variance (ANOVA) on the data was conducted on the data from flexural and tensile tests. To analyze the significance of the variance among group means, Duncan’s Multiple Range Test (DMRT) was done. All statistical procedures were carried out with a confidence level of 95% using IBM SPSS Statistics version 28 (IBM Corp., Armonk, NY).Example 4: Evaluation of Order of Addition

[0164] The present example describes experiments investigating the effect that the order of addition of lignocellulosic materials to a mixture has on the mechanical properties of the sheet.

[0165] Formulation 9 (B45W45C10) was selected for this series of experiments. In a simultaneously mixed formulation (B45W45C10), all raw materials, i.e., BKP, WF, and CNF, were blended altogether.

[0166] In a first order of addition (B45W45C10-O1), BKP was added to the CNF suspension and mixed in a blender for 30 seconds. WF was then added to the mixture and blended for another 30 seconds.

[0167] In a second order of addition (B45W45C 10-02), BKP was mixed with half of the CNF content for 30 seconds in a blender and WF was separately mixed with the other half of the CNF content for 30 seconds in a blender. The two resulting mixtures were then combined and mixed with a stirring rod to obtain the final suspension.

[0168] In a third order of addition (B45W45C 10-03), WF was added to the CNF suspension and mixed in a blender for 30 seconds. BKP was then added to the mixture andblended for an additional 30 seconds. The production of the lignocellulosic sheets was performed as previously described in Example 1.

[0169] As shown in FIG. 6A and FIG. 6B, all orders of addition had comparable normalized tensile strengths, normalized flexural strengths, normalized tensile modulus values, and normalized flexural modulus values. These data indicate that the order of addition of raw materials in the manufacture of lignocellulosic products of the present disclosure do not significantly affect the mechanical properties of the products.Example 5: CNF Lamination

[0170] The present example describes the lamination of exemplary lignocellulosic materials of the present disclosure with a CNF layer.

[0171] A sheet / plate of Formulation 7 (B55W35C10) was laminated with 5, 10, 20, 40, 50, and 60 g / m2CNF coat weight using the deposition method after the formation of the wet base layer as described above. The CNF suspension, initially containing 3 wt% solids, was diluted to 0.2 wt%. The desired CNF suspension was directly deposited onto the wet base plate after flipping it to the uniform side in the Buchner funnel. The suspension was allowed to filter at 30 inHg. After the filtration was completed, the wet sample was then placed between two stainless steel plates and pressed similar to uncoated samples.Example 6: Evaluation of Water Resistance

[0172] The present example describes experiments characterizing the water resistance properties of exemplary lignocellulosic materials of the present disclosure.

[0173] A Cobb test, TAPPI T441 standard (TAPPI 2009) assay was performed to test the water resistance of products laminated with different CNF coat weights (5, 10, 20, 40, 50, and 60 g / m2). After conditioning, each sample, with an area of 77.8 cm2, was carefully weighed and placed inside a Cobb tester, with the coated surface facing upward. A soft rubber gasket ring was used to ensure a secure seal and prevent any leakage, we employed a soft rubber gasket ring. 77.8 mL of deionized water was added to the Cobb tester ring on the sample sheet. After 120 seconds, the water was drained from the Cobb tester, and the samples were sandwiched between two blotting papers and pressed using a 10 kg roller toremove excess water. The weight of the wet sample was promptly measured, and the difference between the dry and wet weights allowed for the calculation of the amount of water absorbed through the coated surface of the samples. Each test was performed in triplicate.

[0174] Absorptiveness values (e.g., Cobb values) of the samples were calculated using Equation (1) below.. , Weight of the wet sample (g)— Weight of the conditioned samples ( a)Cobb value ( / m ) = - — - - - - — - - (1)Area of the test surf ace (m2)

[0175] As shown in FIG. 7A, increasing CNF coat weights laminated onto exemplary sheet / plates of Formulation 7 resulted in lowered Cobb values (i.e., increased water resistance).Example 7: Evaluation of Oil and Grease Resistance

[0176] The present Example describes experiments characterizing the oil and grease resistant properties of exemplary lignocellulosic materials of the present disclosure.

[0177] Oil and grease resistance was tested using a TAPPI T559 cm-12 standard assay (TAPPI 1996) for products laminated with various coat weights of CNF (5, 10, 20, 40, 50, and 60 g / m2), and for an uncoated control sample. In brief, a drop of reagent (oils with varying viscosities) was placed onto the sample surface from a height of 13 mm. After 15 seconds, the reagent was wiped off using a Kim wipe. If a dark stain was visible on the sample surface, the test was considered failed. Conversely, the absence of any spot indicated a passed kit value. Reagents such as castor oil, n-heptane, and toluene were employed in this evaluation, with kit values ranging from 1 to 12, where 12 represented the highest kit number.

[0178] As shown in FIG. 7B, increasing CNF coat weights laminated onto exemplary sheet / plates of Formulation 7 resulted in increased kit values (i.e., increased oil and grease resistance).Example 8: Scanning Electron Microscope Imaging

[0179] The present Example describes scanning electron microscopy (SEM) experiments performed on exemplary lignocellulosic materials of the present disclosure.

[0180] SEM images of coated and uncoated sample plates were taken to analyze the surface morphology of the plates. SEM images were obtained using a Zeiss Nvision 40 FIB- SEM at an acceleration voltage of 5.0 kV. The sample plates were prepared as previously described in Example 1 and laminated as previously described in Example 2. Samples for imaging were further sputter coated with gold-palladium (Au:Pd) with a thickness of 6 nm and kept in a desiccator for at least 24 hours prior to imaging.

[0181] As shown in in the SEM micrographs of FIGs. 8B-8D, the CNF-laminated surface of sample sheets / plates of Formulation 7 (B55W35C10) appear smoother and more uniform than an unlaminated control FIG. 8A.Example 9: Evaluation of Tear Resistance

[0182] The present Example describes experiments characterizing the tear resistance properties of exemplary lignocellulosic materials of the present disclosure.

[0183] A tear test was performed using an Instron mechanical testing machine (Model5942, Instron Instruments, Norwood, MA) equipped with a 500 N load cell. A tensile fixture was mounted on the instrument to perform this test. Test samples were prepared using the same sample preparation process and formulation (e.g., Formulation 7) as described in Examples 1, 2, and 5. Test samples are cut into 6 cm x 2.5 cm strips using a laser cutter.

[0184] To conduct the tear test, samples were cut halfway in length from the center all the way up to 1 cm. The crosshead speed was set to 2 mm / min. The sample was clamped directly from the top and bottom of the cut, ensuring that the cut was positioned precisely in the middle where the force was applied. The test was conducted until the sample was completely torn or broken.

[0185] As is shown in FIG. 10, the tear resistance of CNF-coated sheets showed statistically the same results as that of Bl 00, which is often used as standard food serving material. The tear resistance of sheets laminated with different coat weights of CNF (e.g., Formulation 7 (B55W35C10)) were measured. The uncoated sheet and 10 g / m2CNF coated sheet showed statistically low tear resistance values of 12 ± 3.90 (N / mm) and 10 ± 1.74 (N / mm), respectively, as of B100, which showed tear resistance of 17 ± 3.3 (N / mm). The sheets laminated with CNF coat weight of 20g / m2and 40 g / m2showed tear resistance of 13 ±1.3 (N / mm) and 14 ± 3.5 (N / mm), respectively, which is statistically the same as B100. It can be inferred from the results that increasing CNF coat weights can improve the tear resistance of the sheets. Similar tear index of CNF and softwood BKP samples for CNF 0% to 20% ranging between 11.36 to 12.46 mNm2 / g have been reported (Kumar et al., 2016).Example 10: Double Dipping Process

[0186] The present Example describes an exemplary double dipping process for the manufacture of a lignocellulosic product of the present disclosure.

[0187] For the double dipping process, a molded-fiber mold is inserted into a substrate slurry containing between 0.5% (w / v) to 2% (w / v) solids followed by applying back vacuum pressure for a period of time ranging from 5 to 20 seconds to form a wet layer of substrate material inside the mold cavity. The mold is then removed from the substrate slurry and is re-inserted into a slurry of CNFs and / or LCNFs with or without additives at a solids content ranging from 0.3% (w / v) to 1% (w / v) followed by applying a second back vacuum pressure for 5-20 seconds. This forms a wet layer of CNF and / or LCNF on top of the substrate layer which may have a final thickness of 5 pm to 40 pm or 5 g / m2to 40 g / m2. The entire assembly is then pressed against a perforated silicon mold at room temperature while vacuum is applied to drain extra water. Air pressure from below is applied to detach the cold- pressed laminated structure from the silicon mold. Finally, the cold-pressed structure is hot- pressed for 10 to 20 seconds at a temperature of 200 °C to 240 °C until dried. This process is shown in the flow chart of FIG. 9A.Example 11: Wet Lamination Process

[0188] The present Example describes an exemplary wet lamination process for the manufacture of a lignocellulosic product of the present disclosure.

[0189] For the wet lamination process, a molded-fiber mold is inserted into a substrate slurry containing between 0.5% (w / v) to 2% (w / v) solids followed by applying back vacuum pressure for a period of time ranging from 5 to 20 seconds to form a wet layer of substrate material inside the mold cavity. A wet film of CNFs already prepared at the target grammage ranging from 5 to 40 g / m2is then placed on the surface of silicon cold press. The mold is then removed from the substrate slurry and pressed against a perforated silicon moldcovered with the wet CNF film at room temperature while vacuum is applied to drain extra water. Air pressure from below is applied to detach the cold-pressed laminated structure from the silicon mold. Finally, the cold-pressed structure is hot-pressed for 10 to 20 seconds at a temperature of 200 °C to 240 °C until dried. This process is shown in the flow chart of FIG. 9BExample 12: Spray Coating Process

[0190] The present Example describes an exemplary spray coating process for the manufacture of a lignocellulosic product of the present disclosure.

[0191] For the spray coating process, a molded-fiber mold is inserted into a substrate slurry containing between 0.5% (w / v) to 2% (w / v) solids followed by applying back vacuum pressure for a period of time ranging from 5 to 20 seconds to form a wet layer of substrate material inside the mold cavity. The mold is then removed from the substrate slurry and a nozzle sprays a thin coat of CNF and / or LCNF suspension onto the inner side of the wet- formed substrate. The solids content of the slurry ranges from 0.3% (w / v) to 1.5% (w / v) leading to a coat weight of 5 to 40 g / m2. The entire assembly is then pressed against a perforated silicon mold at room temperature while vacuum is applied to drain extra water. Air pressure from below is applied to detach the cold-pressed laminated structure from the silicon mold. Finally, the cold-pressed structure is hot-pressed for 10 to 20 seconds at a temperature of 200 °C to 240 °C until dried. This process is shown in the flow chart of FIG. 9C.EQUIVALENTS

[0192] Those skilled in the art will recognize or be able to ascertain using no more than routine experimentation, many equivalents to the specific embodiments of technologies described herein. The scope of the present disclosure is not intended to be limited to the above Description, but rather is as set forth in the following claims.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. A lignocellulosic product comprising:(i) a substrate comprising about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour; and(ii) a cellulose nanofibril (CNF) or lignin-containing CNF (LCNF) layer, wherein the lignocellulosic product comprises at least about 2.5 wt% CNFs.

2. The product of claim 1, wherein the pulp comprises bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof.

3. The product of claim 1 or 2, wherein the substrate comprises CNFs.

4. The product of claim 3, wherein the substrate comprises about 2.5 wt% to about 10 wt% CNFs.

5. The product of any one of claims 1 to 4, wherein the CNFs comprise lignin-free CNFs, LCNFs, delignified CNFs (DCNFs), or a combination thereof.

6. The product of any one of claims 1 to 5, wherein the substrate is molded or formed from a flat sheet.

7. The product of any one of claims 1 to 6, wherein the substrate is a sheet, a plate, a bowl, a cup, a vessel, a container, a tray, or a pouch.

8. The product of any one of claims 1 to 7, wherein the CNF or LCNF layer comprises a thickness of about 5 pm to about 80 pm.

9. The product of any one of claims 1 to 8, wherein the CNF or LCNF layer comprises an area density of about 5 g / m2to about 40 g / m2.

10. The product of any one of claims 1 to 9, wherein the CNF or LCNF layer further comprises one or more additives.

11. The product of claim 10, wherein the one or more additives comprise a mineral, a crosslinking agent, aluminum sulfate, or a combination thereof.

12. The product of claim 11, wherein the mineral comprises calcium carbonate, talc, clay, or a combination thereof.

13. The product of claim 11 or 12, wherein the CNF or LCNF layer comprises about 0.5 wt% to about 0.02 wt% of the mineral.

14. The product of any one of claims 11 to 13, wherein the cross-linking agent comprises polyamide epichlorohydrin resin (PAE).

15. The product of any one of claims 11 to 14, wherein the CNF or LCNF layer comprises about 0.5 wt% to about 2 wt% of the cross-linking agent.

16. The product of any one of claims 11 to 15, wherein the CNF or LCNF layer comprises about 0.5 wt% to about 2 wt% of aluminum sulfate.

17. The product of any one of claims 1 to 16, wherein the product comprises a normalized tensile strength from about 5 mPa / (g / cm3) to about 35 mPa / (g / cm3).

18. The product of any one of claims 1 to 17, wherein the product comprises a normalized flexural strength from about 10 mPa / (g / cm3) to about 60 mPa / (g / cm3).

19. The product of any one of claims 1 to 18, wherein the product comprises a normalized tensile modulus from about 1500 mPa / (g / cm3) to about 5500 mPa / (g / cm3).

20. The product of any one of claims 1 to 19, wherein the product comprises a normalized flexural modulus from about 1500 mPa / (g / cm3) to about 11500 mPa / (g / cm3).

21. The product of any one of claims 1 to 20, wherein the product comprises an oil and grease resistance kit value from about 3 to about 12 as determined by a TAPPI T559 cm-12 standard assay.

22. The product of any one of claims 1 to 21, wherein the product comprises a water resistance Cobb value from about 20 g / m2to about 400 g / m2as determined by a TAPPI T441 standard assay.

23. A method of manufacturing a lignocellulosic product comprising:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the at least one cavity to form a wet substrate layer;(iii) removing the mold from the substrate slurry;(iv) inserting the mold into a cellulose slurry;(v) applying a vacuum to the at least one cavity to form a wet cellulose layer;(vi) pressing the mold against a perforated mold;(vii) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose layer to form a cold-pressed laminate;(viii) detaching the cold-pressed laminate from the perforated mold; and(ix) hot-pressing the cold-press laminate to form the cellulosic product.

24. The method of claim 23 wherein the substrate slurry comprises about 0.5% (w / v) to about 2% (w / v) of substrate solids.

25. The method of claim 24 wherein the substrate solids comprise about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour.

26. The method of claim 25, wherein the pulp comprises bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof.

27. The method of any one of claims 24 to 26 wherein the substrate solids comprise CNFs.

28. The method of claim 27, wherein the substrate solids comprise about 2.5 wt% to about 10 wt% CNFs.

29. The method of claim 27 or 28, wherein the CNFs comprise lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

30. The method of any one of claims 23 to 29, wherein step (ii) applying the vacuum comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar to the at least one cavity for about 5 seconds to about 20 seconds.

31. The method of any one of claims 23 to 30, wherein the cellulose slurry comprises CNF solids.

32. The method of claim 31, wherein the cellulose slurry comprises about 0.3% (w / v) to about 1% (w / v) of CNF solids.

33. The method of claim 31 or 32, wherein the CNF solids comprise lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

34. The method of any one of claims 23 to 33, wherein the cellulose slurry comprises one or more additives.

35. The method of claim 34, wherein the one or more additives comprise a mineral, a crosslinking agent, aluminum sulfate, or a combination thereof.

36. The method of claim 35, wherein the mineral comprises calcium carbonate, talc, clay, or a combination thereof.

37. The method of claim 35 or 36, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of the mineral.

38. The method of any one of claims 35 to 37, wherein the cross-linking agent comprises polyamide epichlorohydrin resin (PAE).

39. The method of any one of claims 35 to 38, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of the cross-linking agent.

40. The method of any one of claims 35 to 39, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of aluminum sulfate.

41. The method of any one of claims 23 to 40, wherein step (v) comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar to the at least one cavity for about 5 seconds to about 20 seconds.

42. The method of any one of claims 23 to 41, wherein the wet cellulose layer comprises an area density (coat weight) of about 5 g / m2to about 40 g / m2.

43. The method of any one of claims 23 to 42, wherein step (vi) is performed at about 3 °C to about 15 °C.

44. The method of any one of claims 23 to 43, wherein the perforated mold is a silicon mold, a rubber mold, or a soft plastic mold.

45. The method of any one of claims 23 to 44, wherein step (vii) applying the vacuum comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar for about 5 seconds to about 30 seconds.

46. The method of any one of claims 23 to 45, wherein step (ix) pressing comprises hot- pressing the cold-pressed laminate for about 10 seconds to about 30 seconds.

47. The method of claim 46, wherein the hot-pressing is performed at about 180 °C to about 250°C.

48. A method of manufacturing a lignocellulosic product comprising:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the at least one cavity form a wet substrate layer;(iii) placing a wet cellulose film on a perforated mold and removing the mold from the substrate slurry;(iv) pressing the mold against the wet cellulose film on the perforated mold;(v) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose film to form a cold-pressed laminate;(vi) detaching the cold-pressed laminate from the perforated mold; and(vii) hot-pressing the cold-press laminate to form the cellulosic product.

49. The method of claim 48, wherein the substrate slurry comprises about 0.5% (w / v) to about 2% (w / v) of substrate solids.

50. The method of claim 49, wherein the substrate solids comprise about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour.

51. The method of claim 50 wherein the pulp comprises bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers, or a combination thereof.

52. The method of any one of claims 49 to 51, wherein the substrate solids comprise CNFs.

53. The method of claim 52, wherein the substrate solids comprise about 2.5 wt% to about 10wt% CNFs.

54. The method of claim 52 or 53, wherein the CNFs comprise lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

55. The method of any one of claims 48 to 54, wherein step (ii) applying the vacuum comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar to the cavity for about 5 seconds to about 20 seconds.

56. The method of any one of claims 48 to 55, wherein the wet cellulose film comprises about 5 g / m2to about 40 g / m2of lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

57. The method of any one of claims 48 to 56, wherein the wet cellulose film comprises one or more additives.

58. The method of claim 57, wherein the one or more additives comprise a mineral, a crosslinking agent, aluminum sulfate, or a combination thereof.

59. The method of claim 58, wherein the mineral comprises calcium carbonate, talc, clay, or a combination thereof.

60. The method of claim 58 or 59, wherein the wet cellulose film comprises about 0.5 wt% to about 2 wt% of the mineral.

61. The method of any one of claims 58 to 60, wherein the cross-linking agent comprises polyamide epichlorohydrin resin (PAE).

62. The method of any one of claims 58 to 61, wherein the wet cellulose film comprises about 0.5 wt% to about 2 wt% of the cross-linking agent.

63. The method of any one of claims 58 to 62, wherein the wet cellulose film comprises about 0.5 wt% to about 2 wt% of aluminum sulfate.

64. The method of any one of claims 48 to 63, wherein step (iv) is performed at about 20 °C to about 25 °C.

65. The method of any one of claims 48 to 64, wherein step (v) comprises applying a back vacuum pressure from about -0.5 bar to about -1 bar to the cavity for about 5 seconds to about 20 seconds.

66. The method of any one of claims 48 to 65, wherein step (vii) comprises hot-pressing the cold-pressed laminate for about 10 seconds to about 30 seconds.

67. The method of claim 66, wherein the hot-pressing is performed at about 180 °C to about 250 °C.

68. A method of manufacturing a lignocellulosic product comprising:(i) inserting a mold comprising at least one cavity into a substrate slurry;(ii) applying a vacuum to the cavity in the mold to form a wet substrate layer;(iii) removing the mold from the substrate slurry;(iv) spraying the wet substrate layer with a cellulose slurry to form a wet cellulose layer;(v) pressing the mold against a perforated mold;(vi) applying a vacuum to the perforated mold to remove water from the wet substrate layer and wet cellulose layer to form a cold-pressed laminate;(vii) detaching the cold-pressed laminate from the perforated mold; and (viii) hot-pressing the cold-press laminate to form the cellulosic product.

69. The method of claim 68, wherein the substrate slurry comprises about 0.5% (w / v) to about 2% (w / v) of substrate solids.

70. The method of claim 69, wherein the substrate solids comprise about 50 wt% to about 75 wt% of pulp and about 25 wt% to about 50 wt% wood flour.

71. The method of claim 70, wherein the pulp comprises bleached Kraft pulp, unbleached Kraft pulp, thermomechanical pulp, recycled fibers or a combination thereof.

72. The method of any one of claims 69 to 71, wherein the substrate solids comprise CNFs.

73. The method of claim 72, wherein the substrate solids comprise about 2.5 wt% to about 10 wt% CNFs.

74. The method of claim 72 or 73, wherein the CNFs comprise lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

75. The method of any one of claims 68 to 74, wherein step (ii) applying the vacuum comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar to the at least one cavity for about 5 seconds to about 30 seconds.

76. The method of cany one of claims 68 to 75, wherein the cellulose slurry comprises CNF solids.

77. The method of claim 76, wherein the cellulose slurry comprises about 0.3% (w / v) to about 1% (w / v) of CNF solids.

78. The method of claim 76 or 77, wherein the CNF solids comprise lignin-free CNFs, LCNFs, DCNFs, or a combination thereof.

79. The method of any one of claims 68 to 78, wherein the cellulose slurry comprises one or more additives.

80. The method of claim 79, wherein the one or more additives comprise a mineral, a crosslinking agent, aluminum sulfate, or a combination thereof.

81. The method of claim 80, wherein the mineral comprises calcium carbonate, talc, clay, or a combination thereof.

82. The method of claim 80 or 81, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of the mineral.

83. The method of any one of claims 80 to 82, wherein the cross-linking agent comprises polyamide epichlorohydrin resin (PAE).

84. The method of any one of claims 80 to 83, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of the cross-linking agent.

85. The method of any one of claims 80 to 84, wherein the cellulose slurry comprises about 0.5 wt% to about 2 wt% of aluminum sulfate.

86. The method of any one of claims 68 to 85, wherein step (iv) spraying the wet substrate layer comprises using a nozzle to spray the cellulose slurry at a flow rate of about 1 cm3 / s to about 10 cm3 / s.

87. The method of any one of claims 68 to 86, wherein the wet cellulose layer comprises an area density of about 5 g / m2to about 40 g / m2.

88. The method of any one of claims 68 to 87, wherein step (v) is performed at about 15 °C to about 30 °C.

89. The method of any one of claims 68 to 88, wherein in step (vi) applying the vacuum comprises applying a back vacuum pressure from about -0.5 bar to about -1.0 bar for about 5 seconds to about 30 seconds.

90. The method of any one of claims 68 to 89, wherein step (viii) comprises hot-pressing the cold-pressed laminate for about 10 seconds to about 30 seconds.

91. The method of claim 90, wherein the hot-pressing is performed at about 180 °C to about 250 °C.

Images