Foam materials and uses thereof

Abstract

Compositions, processes for their preparation, and uses thereof as protective packaging materials are provided. These protective packaging materials compositions may be biodegradable, compostable and / or recyclable.

Description

Attorney Docket No.: 2024PF00301WO_stFOAM MATERIALS AND USES THEREOFTECHNICAL FIELD

[0001] The present disclosure relates to compositions, processes for their preparation, and uses thereof as protective packaging materials in, e.g., paper packaging applications. These protective packaging materials may be biodegradable, compostable and / or recyclable.BACKGROUND

[0002] Expanded polystyrene (EPS) foams dominate markets such as cold chain insulation packaging due to their light weight, low cost, and availability. These materials, however, have environmental issues such as carbon emissions, dependence on fossil fuels, and waste proliferation.

[0003] Recyclable paper packaging materials (e.g., molded cellulose and corrugated boxes) eliminate many environmental issues, but are heavier (resulting in higher transportation costs and emissions) and more costly. Recyclable paper packaging material do not compete effectively with EPS foams in structural performance or stiffness. For example, EPS can be used to cushion heavy electronics and metal parts, whereas traditional cellulose foams do not have the structural capability for these heavy items.

[0004] What is needed are biodegradable foams that have high structural support.SUMMARY

[0005] In some aspects, the disclosure provides compositions comprising (a) a foaming agent; and (b) cyanobacteria, microalgae, or a combination thereof. In some embodiments, the composition is a powder.

[0006] In other aspects, the disclosure provides compositions comprising (a) cellulose fibers; (b) a foaming agent; and (c) cyanobacteria, microalgae, or a combination thereof. Such compositions further comprise “wet” compositions, z.e., compositions having greater than or equal to 20 wt% of water, including wet foam compositions wherein air is introduced into the composition. Moreover, such wet compositions may be dried to provide a dry composition, z.e., a composition comprising less than 20 wt% water.

[0007] In further aspects, the disclosure provides processes for preparing foamed compositions, comprising (i) incorporating air into the compositions disclosed herein; and (ii)Attorney Docket No.: 2024PF00301WO_st removing some or all of the water from the product of (i) to form the foamed composition. In some embodiments, the processes further include applying the compositions onto one or more substrates and laminating, molding, and / or folding the compositions and / or such substrates to form packaging materials.

[0008] In yet other aspects, the disclosure provides foamed compositions prepared according to the process described herein. In some embodiments, the foamed compositions are used in articles, such as paper packaging products. In some embodiments, the article is compostable, recyclable, and / or renewable.BRIEF DESCRIPTION OF FIGURES

[0009] Figures 1 and 2 are photographs of expanded and dried foam material in between two Kraft papers.

[0010] Figure 3 is a photograph of molded foam material, forming a corner brace / protector.DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

[0011] As used herein, the term “about” when referring to a number or a numerical range means that the number or numerical range referred to is an approximation within experimental variability (or within statistical experimental error), and thus the number or numerical range may vary from, e.g., 1% to 10% of the stated number or numerical range.

[0012] As used herein, the term “comprising” (and related terms such as “comprise” or “comprises” or “having” or “including”) includes, but is not limited to, those embodiments, e.g., an embodiment of any composition of matter, composition, method, or process, or the like, that “consist of’ or “consist essentially of’ the described features.

[0013] Any use of the word “or” herein is intended to be inclusive and is equivalent to the expression “and / or,” unless the context clearly dictates otherwise. As such, e.g., the expression “A or B” means A, or B, or both A and B. Similarly, e.g., the expression “A, B, or C” means A, or B, or C, or any combination thereof.

[0014] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (e.g., the range of “2 to 10” is inclusive of the endpoints, 2 and 10, and all the intermediate values). The endpoints of the ranges and any values disclosed herein are not limited to the precise range or value; they are sufficiently imprecise to include values approximating these ranges and / or values. As used herein, approximating language may be applied to modify any quantitative representation that may vary without resulting in a changeAttorney Docket No.: 2024PF00301WO_st in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about,” may not be limited to the precise value specified, in some cases. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. The modifier “about” should also be considered as disclosing the range defined by the absolute values of the two endpoints. For example, the expression “about 2 to about 4” also discloses the range “2 to 4.” The term “about” may refer to plus or minus 10% of the indicated number. For example, “about 10%” may indicate a range of “9% to 11” and “about 1” may mean “0.9-1.1.” Other meanings of “about” may be apparent from the context, such as rounding off, so, e.g., “about 1” may also mean “0.5 to 1.4.”

[0015] The disclosure provides fully bio-based foam composites that can be made and used for packaging applications. These are superior to the cellulose based foams in the art, which have lower compressive strength compared to synthetic polymer foams. In looking for strong, compressible, and environmentally friendly foams, the inventors found that the addition of cyanobacteria and / or microalgae to the compositions described herein resulted in such foams. Moreover, the compressive strength of the foams were comparable to synthetic polymer foams like EPS, and EPE (expanded polyethylene), among others. Thus, the inventors found environmentally friendly foams that can compete in the rigid protective foam packaging space.

[0016] As set forth herein, a higher density foam with greater compressive strength can be achieved using the compositions disclosed herein. This is achieved without extensive pre-processing steps for the cellulose fibers, use of hazardous reagents in crosslinking, constraints on production scalability, or health and environmental concerns.

[0017] According to the disclosure, the compositions described herein contain cyanobacteria and / or microalgae. In some embodiments, the compositions contain cyanobacteria. In other embodiments, the compositions contain microalgae. In further embodiments, the compositions contain cyanobacteria and microalgae. Desirably, the cyanobacteria and / or microalgae are photosynthetic. In other words, the cyanobacteria and / or microalgae are capable of performing photosynthesis and using sunlight to convert carbon dioxide and water into sugar and oxygen.

[0018] In some embodiments, the compositions described herein contain cyanobacteria. In some embodiments, the cyanobacteria is Anabaena, Aphanizomenon flos- aquae, Arthrospira (e.g., A. platensis, A. fusiformis, or A. maxima), Chroococcus, Cyanophyceae, Fat choy, Gloeocapsa, Lyngbya, Microcystis, Oscillatoria, Phormidium, Prochlorococcus, Synechococcus, Nostoc, Spirulina, Suizenji nori platensis, SynechocystisAttorney Docket No.: 2024PF00301WO_st sp. PCC 6803, or Trichodesmium, or a combination thereof. In other embodiments, the cyanobacteria is a Spirulina. In further embodiments, the cyanobacteria is Spirulina abbreviate, Spirulina agilis, Spirulina agilissima, Spirulina albida, Spirulina ardissoni, Spirulina baltica, Spirulina bayannurensis, Spirulina breviarticulata, Spirulina cabrerae, Spirulina caldaria, Spirulina cavanillesiana, Spirulina condensate, Spirulina corakiana, Spirulina flavovirens, Spirulina funiformis, Spirulina gessneri, Spirulina gomontiana, Spirulina gomontii, Spirulina gordiana, Spirulina gracilis, Spirulina innatans, Spirulina labyrinthiformis, Spirulina laxa, Spirulina laxissima, Spirulina legitima, Spirulina magnifica, Spirulina major, Spirulina margaritae, Spirulina mariae, Spirulina massartii, Spirulina maxima, Spirulina miniate, Spirulina minima, Spirulina mukdensis, Spirulina nodosa, Spirulina nordstedtii, Spirulina okensis, Spirulina oscillarioides, Spirulina platensis, Spirulina princeps, Spirulina pseudotenuissima, Spirulina robusta, Spirulina rosea, Spirulina schroederi, Spirulina sigmoidea, Spirulina socialis, Spirulina spirulinoides, Spirulina subsalsa, Spirulina subtilissima, Spirulina supersalsa, Spirulina tenerrima, Spirulina tenuior, Spirulina tenuis, Spirulina tenuissima, Spirulina thermalis, Spirulina turfosa, Spirulina versicolor, Spirulina weissii, or Spirulina spp. In yet other embodiments, the cyanobacteria is Arthrospira platensis. In certain embodiments, the cyanobacteria are in the form of a powder. In some embodiments, the cyanobacteria are non-irradiated.

[0019] In some embodiments, the compositions contain microalgae. In other embodiments, the microalgae is Chlorella, Haematococcus, Dunaliella, Pediastrum, Phaeodactylum tricornutum, Nostoc commune, Aphanizomenon flosaquae, Porphyridium sp, Isochrysis, Pavlova spp, Nannochloropsis sp, Chaetoceros sp, Schizotrichium, or Ulkenia spp. In further embodiments, the microalgae is a Chlorella. In yet other embodiments, the microalgae is Chlorella autotrophica, Chlorella colonials, Chlorella lewinii, Chlorella minutissima, Chlorella pituita, Chlorella pulchelloides, Chlorella pyrenoidosa, Chlorella regularis, Chlorella rotunda, Chlorella sacchar ophila, Chlorella singularis, Chlorella sorokiniana, Chlorella variabilis, Chlorella volutis, or Chlorella vulgaris. In still further embodiments, the microalgae is Chlorella pyrenoidosa. In other embodiments, the microalgae is Chlorella vulgaris. In certain embodiments, the microalgae are in the form of a powder. In some embodiments, the microalgae are non-irradiated.Compositions

[0020] According to the disclosures, compositions are provided. In some embodiments, the compositions are dry. For example, a dry composition may be any composition comprising less than 20 wt% of water. In some embodiments, a dry compositionAttorney Docket No.: 2024PF00301WO_st contains less than about 15, about 10, about 5, about 4, about 3, about 2, about 1, about 0.5, about 0.1, about 0.01, or about 0.001 wt% of water. In other embodiments, a dry composition contains 0 wt% water. In further embodiments, a dry composition contains less than about 1 wt% water. In yet other embodiments, a dry composition contains less than about 5 wt% water. In still further embodiments, a dry composition contains less than about 10 wt% water. In other embodiments, a dry composition contains less than about 15 wt% water. In yet other embodiments, a dry composition contains about 0.001 to about 20, 0.001 to about 15, about 0.001 to about 10, about 0.001 to about 5, about 0.001 to about 4, about 0.001 to about 3, about 0.001 to about 2, about 0.001 to about 1, about 0.001 to about 0.5, about 0.001 to about 0.1, about 0.001 to about 0.01, about 0.01 to about 20, about 0.01 to about 15, about 0.01 to about 10, about 0.01 to about 5, about 0.01 to about 4, about 0.01 to about 3, about 0.01 to about 2, about 0.01 to about 1, about 0.01 to about 0.5, about 0.01 to about 0.1, about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 4, about 0.1 to about 3, about 0.1 to about 2, about 0.1 to about 1, about 0.1 to about 0.5, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 4, about 0.5 to about 3, about 0.5 to about 2, about 0.5 to about 1, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 1 to about 4, about 1 to about 3, or about 1 to about 2 wt% water.A. Composition I

[0021] In some embodiments, the disclosure provides composition I comprising a foaming agent and cyanobacteria, microalgae, or a combination thereof. In some aspects, composition I is dry. In other aspects, composition l is a powder.

[0022] According to the disclosure, composition I contains about 4 to about 98 wt% of the cyanobacteria, microalgae, or a combination thereof. In some embodiments, composition I contains about 4, about 5, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 95, or about 98 wt% of the cyanobacteria, microalgae, or a combination thereof. In other embodiments, composition I contains about 4 to about 95, about 4 to about 90, about 4 to about 80, about 4 to about 70, about 4 to about 60, about 4 to about 60, about 4 to about 50, about 4 to about 40, about 4 to about 30, about 4 to about 20, about 4 to about 10, about 10 to about 95, about 10 to about 90, about 10 to about 80, about 10 to about 70, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 95, about 15 to about 90, about 15 to about 80, about 15 to about 70, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 95, about 20 to about 90, about 20 toAttorney Docket No.: 2024PF00301WO_st about 80, about 20 to about 70, about 20 to about 60, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 95, about 30 to about 90, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 95, about 40 to about 90, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 95, about 50 to about 90, about 50 to about 80, about 50 to about 70, about 50 to about 60, about 60 to about 95, about 60 to about 90, about 60 to about 80, about 60 to about 70, about 70 o about 95, about 70 to about 90, about 70 to about 80, about 80 to about 95, about 80 to about 90, or about 90 to about 95 wt% of the cyanobacteria, microalgae, or a combination thereof. In further embodiments, composition I contains about 15 to about 65 wt% of the cyanobacteria, microalgae, or a combination thereof.

[0023] According to the disclosure, composition I contains about 1 to about 25 wt% of the foaming agent. Examples of suitable foaming agents are described herein. In some embodiments, composition I contains about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 17, about 18, about 19, about 20, about 21, about 22, about 23, about 24 or about 25 wt% of the foaming agent. In other embodiments, composition I contains 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 7, about 1 to about 5, about 5 to about 25, about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 25, about 15 to about 20, or about 20 to about 25 wt% of the foaming agent. In further embodiments, composition I contains about 1 to about 7 wt% of the foaming agent.

[0024] According to the disclosure, composition I optionally contains a binder. Examples of suitable binder are described herein. In some embodiments, composition I contains about 0.1 to about 90 wt% of the binder. In other embodiments, composition I contains about 0.1, about 1, about 5, about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, or about 90 wt% of the binder. In other embodiments, composition I contains about 0.1 to about 80, about 0.1 to about 70, about 0.1 to about 60, about 0.1 to about 50, about 0.1 to about 40, about 0.1 to about 30, about 0.1 to about 20, about 0.1 to about 10, about 0.1 to about 1, about 1 to about 90, about 1 to about 80, about 1 to about 70, about 1 to about 60, about 1 to about 50, about 1 to about 40, about 1 to about 30, about 1 to about 20, about 1 to about 10, about 1 to about 5, about 5 to about 90, about 5 to about 80, about 5 to about 70, about 5 to about 60, about 5 to about 60, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 90,Attorney Docket No.: 2024PF00301WO_st about 10 to about 80, about 10 to about 70, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 90, about 15 to about 80, about 15 to about 70, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 90, about 20 to about 80, about 20 to about 70, about 20 to about 60, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 90, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 90, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 90, about 50 to about 80, about 50 to about 70, about 50 to about 60, about 60 to about 90, about 60 to about 80, about 60 to about 70, about 70 to about 90, about 70 to about 80, or about 80 to about 90 wt% of the binder. In further embodiments, composition I contains about 20 to about 90 wt% of the binder.

[0025] According to the disclosure, composition I optionally contains one or more additives. Examples of suitable additives are described herein. In some embodiments, composition I contains about 0.1 to about 35 wt% of the additives. In other embodiments, composition I contains about 0.1, about 0.5, about 1, about 5, about 10, about 15, about 20, about 25, about 30, or about 35 wt% of the one or more additives. In further embodiments, composition I contains about 0.1 to about 30, about 0.1 to about 25, about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 0.5, about 0.5 to about 35, about 0.5 to about 30, about 0.5 to about 25, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 1, about1 to about 35, about 1 to about 30, about 1 to about 25, about 1 to about 20, about 1 to about15, about 1 to about 10, about 1 to about 5, about 5 to about 35, about 5 to about 30, about 5 to about 25, about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 35, about 10 to about 30, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 35, about 15 to about 30, about 15 to about 25, about 15 to about 20, about 20 to about 35, about 20 to about 30, about 20 to about 25, about 25 to about 35, about 25 to about 30, or about 30 to about 35 wt% of the one or more additives. In further, embodiments, composition I contains about 0.1 to about 5 wt% of the one or more additives.B. Composition II

[0026] In some embodiments, the disclosure provides a composition II, comprising cellulose fibers, a foaming agent, and cyanobacteria, microalgae, or a combination thereof. In some aspects, composition II is dry, where water was not added to this composition.Attomey Docket No.: 2024PF00301WO_stAmbient moisture may be present in composition II, due to the nature of the cellulose fibers, foaming agent, and proteins; but additional water was not purposefully added.

[0027] According to the disclosure, composition II contains about 10 to about 95 wt% of the cellulose fibers. Examples of suitable cellulose fibers are described herein. In some embodiments, composition II contains about 10, about 20, about 30, about 40, about 50, about 60, about 70, about 80, about 90, or about 95 wt% of the cellulose fibers. In other embodiments, composition II contains about 10 to about 95, about 10 to about 90, about 10 to about 80, about 10 to about 70, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 95, about 15 to about 90, about 15 to about 80, about 15 to about 70, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 95, about 20 to about 90, about 20 to about 80, about 20 to about 70, about 20 to about 60, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 95, about 30 to about 90, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 95, about 40 to about 90, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 95, about 50 to about 90, about 50 to about 80, about 50 to about 70, about 50 to about 60, about 60 to about 95, about 60 to about 90, about 60 to about 80, about 60 to about 70, about 70 o about 95, about 70 to about 90, about 70 to about 80, about 80 to about 95, about 80 to about 90, or about 90 to about 95 wt% of the cellulose fibers. In further embodiments, composition II contains about 20 to about 90 wt% of the cellulose fibers.

[0028] According to the disclosure, composition II contains about 2 to about 80 wt% of the cyanobacteria, microalgae, or a combination thereof. Examples of suitable cyanobacteria and microalgae are described herein. In some embodiments, composition II contains about 4, about 5, about 10, about 20, about 30, about 40, about 50, about 60, about 70, or about 80 wt% of the cyanobacteria, microalgae, or a combination thereof. In other embodiments, composition II contains about 2 to about 70, about 2 to about 60, about 2 to about 60, about 2 to about 50, about 2 to about 40, about 2 to about 30, about 2 to about 20, about 2 to about 10, about 5 to about 80, about 5 to about 70, about 5 to about 60, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 80, about 10 to about 70, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 80, about 15 to about 70, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 80, about 20 to about 70, about 20 to about 60, about 20 to about 50,Attorney Docket No.: 2024PF00301WO_st about 20 to about 40, about 20 to about 30, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 80, about 50 to about 70, about 50 to about 60, about 60 to about 80, about 60 to about 70, or about 70 to about 80 wt% of the cyanobacteria, microalgae, or a combination thereof. In further embodiments, composition II contains about 10 to about 60 wt% of the cyanobacteria, microalgae, or a combination thereof.

[0029] According to the disclosure, composition II contains about 1 to about 10 wt% of the foaming agent. Examples of suitable foaming agents are described herein. In some embodiments, composition II contains about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, or about 10 wt% of the foaming agent. In other embodiments, composition II contains about 1 to about 9, about 1 to about 8, about 1 to about 7, about 1 to about 6, about 1 to about 5, about 1 to about 4, about 1 to about 3, about 2 to about 10, about 2 to about 9, about 2 to about 8, about 2 to about 7, about 2 to about 6, about 2 to about 5, about 2 to about 4, about 4 to about 10, about 4 to about 9, about 4 to about 8, about 4 to about 7, about 4 to about 6, about 6 to about 10, or about 6 to about 8, or about 8 to about 10 wt% of the foaming agent. In further embodiments, composition II contains about 2 to about 7 wt% of the foaming agent.

[0030] According to the disclosure, composition II optionally contains a binder. Examples of suitable binders are described herein. In some embodiments, composition II contains about 0.1 to about 75 wt% of the binder. In other embodiments, composition II contains about 0.1, about 1, about 5, about 10, about 20, about 30, about 40, about 50, about 60, about 70, or about 75 wt% of the binder. In other embodiments, composition II contains about 0.1 to about 75, about 0.1 to about 70, about 0.1 to about 60, about 0.1 to about 50, about 0.1 to about 40, about 0.1 to about 30, about 0.1 to about 20, about 0.1 to about 10, about 0.1 to about 1, about 1 to about 75, about 1 to about 70, about 1 to about 60, about 1 to about 50, about 1 to about 40, about 1 to about 30, about 1 to about 20, about 1 to about 10, about 1 to about 5, about 5 to about 75, about 5 to about 70, about 5 to about 60, about 5 to about 60, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 75, about 10 to about 70, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 75, about 15 to about 70, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 75, about 20 to about 70, about 20 to about 60, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 75, aboutAttorney Docket No.: 2024PF00301WO_st30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 75, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 75, about 50 to about 70, about 50 to about 60, about 60 to about 75, about 60 to about 70, or about 70 to about 75 wt% of the binder. In further embodiments, composition II contains about 20 to about 60 wt% of the binder.

[0031] According to the disclosure, composition II optionally contains one or more additives. Examples of suitable additives are described herein. In some embodiments, composition II contains about 0.1 to about 30 wt% of the additives. In other embodiments, composition II contains about 0.1, about 0.5, about 1, about 5, about 10, about 15, about 20, about 25, or about 30 wt% of the one or more additives. In further embodiments, composition II contains about 0.1 to about 25, about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 0.5, about 0.5 to about 30, about 0.5 to about 25, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 1, about 1 to about 30, about 1 to about 25, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 5 to about 30, about 5 to about 25, about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 30, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 30, about 15 to about 25, about 15 to about 20, about 20 to about 30, about 20 to about 25, or about 25 to about 30 wt% of the one or more additives. In further, embodiments, composition II contains about 0.1 to about 10 wt% of the one or more additives.C. Composition III

[0032] According to the disclosure, composition III is provided and comprises cellulose fibers, a foaming agent, and cyanobacteria, microalgae, or a combination thereof. Typically, composition III is a “wet” composition, / .< ., a composition having greater than or equal to 20 wt% of water, including a wet foam wherein air is introduced into the composition such that it contains a certain vol% of air, typically greater than about 30 vol% of air.

[0033] The water may be any water typically used in the manufacture of paper products and can include fresh water, spring water, purified water, distilled water, reverse osmosis water, and the like. Those of ordinary skill in the art will understand that the water can include trace amounts of minerals, inorganic compounds, and organic compounds. In some embodiments, composition III contains greater than or equal to 20 wt% of water. In other embodiments, composition III contains 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, about 60, about 65, about 70, about 75, about 80, about 85, orAttorney Docket No.: 2024PF00301WO_st about 90 wt% of water. In further embodiments, composition III contains 20 to about 90, 20 to about 80, 20 to about 70, 20 to about 60, 20 to about 50, 20 to about 40, 20 to about 30, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 90, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 90, about 50 to about 80, about 50 to about 70, about 50 to about 60, about 60 to about 90, about 60 to about 80, about 60 to about 70, about 70 to about 90, about 70 to about 80, about 80 to about 90, or about 50 to about 75 wt% of water. In yet other embodiments, composition III contains about 30 to about 90 wt% of water. In still further embodiments, composition III contains about 50 to about 75 wt% of water.

[0034] According to the disclosure, composition III contains about 0.1 to about 5 wt% of the foaming agent. Examples of suitable foaming agents are described herein. In some embodiments, composition III contains about 0.1, about 0.5, about 1, about 1.5, about 2, about 2.5, about 3, about 3.5, about 4, about 4.5 or about 5 wt% of the foaming agent. In other embodiments, composition III contains about 0.1 to about 4.5, about 0.1 to about 4, about 0.1 to about 3.5, about 0.1 to about 3, about 0.1 to about 2.5, about 0.1 to about 2, about 0.1 to about 1.5, about 0.1 to about 1, about 0.1 to about 0.5, about 0.5 to about 5, about 0.5 to about 4.5, about 0.5 to about 4, about 0.5 to about 3.5, about 0.5 to about 3, about 0.5 to about 2.5, about 0.5 to about 2, about 0.5 to about 1.5, about 0.5 to about 1, about 1 to about 5, about 1 to about 4.5, about 1 to about 4, about 1 to about 3.5, about 1 to about 3, about 1 to about 2.5, about 1 to about 2, about 1 to about 1.5, about 1.5 to about 5, about 1.5 to about 4.5, about 1.5 to about 4, about 1.5 to about 3.5, about 1.5 to about 3, about 1.5 to about 2.5, about 1.5 to about 2, about 2 to about 5, about 2 to about 4.5, about 2 to about 4, about 2 to about 3.5, about 2 to about 3, about 3 to about 5, about 3 to about 4.5, about 3 to about 4, about 3 to about 3.5, about 3.5 to about 5, about 3.5 to about 3.5, about 3.5 to about 4, about 4 to about 5, or about 4.5 to about 5 wt% of the foaming agent. In other embodiments, composition III contains about 0.75 to about 2 wt% of the foaming agent.

[0035] According to the disclosure, composition III contains about 5 to about 25 wt% of cellulose fibers. Examples of cellulose fibers are described herein. In some embodiments, composition III contains about 5, about 6, about 7, about 8, about 9, about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 17, about 18, about 19, about 20, about 21, about 22, about 23, about 24, or about 25 wt% of cellulose fibers. In other embodiments, composition III contains about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 toAttorney Docket No.: 2024PF00301WO_st about 25, about 15 to about 20, or about 20 to about 25 wt% of cellulose fibers. In further embodiments, composition III contains about 10 to about 20 wt% of cellulose fibers.

[0036] According to the disclosure, composition III contains about 0.1 to about 25 wt% of the cyanobacteria, microalgae, or a combination thereof. In some embodiments, composition III contains about 0.1, about 0.5, about 1, about 5, about 10, about 15, about 20, or about 25 wt% of the cyanobacteria, microalgae, or a combination thereof. In further embodiments, composition III contains about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 0.5, about 0.5 to about 25, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 1, about 1 to about 25, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 5 to about 25, about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 25, about 15 to about 20, or about 20 to about 25 wt% of cyanobacteria, microalgae, or a combination thereof. In other embodiments, composition III contains about 1 to about 15 wt% of the cyanobacteria, microalgae, or a combination thereof.

[0037] According to the disclosure, composition III optionally contains a binder. Examples of suitable binders are described herein. In some embodiments, composition III contains about 0.1 to about 35 wt % of the binder. In further embodiments, composition III contains about 0.1, about 0.5, about 1, about 1.5, about 2, about 2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5, about 6, about 6.5, about 7, about 7.5, about 8, about 8.5, about 9, about 9.5, about 10, about 10.5, about 11, about 11.5, about 12, about 12.5, about 13, about 13.5, about 14, about 14.5, about 15, about 15.5, about 16, about 16.5, about 17, about17.5, about 18, about 18.5, about 19, about 19.5, about 20, about 20.5, about 21, about 21.5, about 22, about 22.5, about 23, about 23.5, about 24, about 24.5, about 25, about 25.5, about 26, about 26.5, about 27, about 27.5, about 28, about 28.5, about 29, about 29.5, about 30, about 30.5, about 31, about 31.5, about 32, about 32.5, about 33, about 33.5, about 34, about34.5, or about 35 wt % of the binder. In other embodiments, composition III contains about 0.1 to about 30, about 0.1 to about 25, about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 1, about 0.5 to about 35, about 0.5 to about 30, about 0.5 to about 25, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 1, about 1 to about 35, about 1 to about 30, about 1 to about 25, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 5 to about 35, about 5 to about 30, about 5 to about 25, about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 35, about 10 to about 30, about 10Attorney Docket No.: 2024PF00301WO_st to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 35, about 15 to about 30, about 15 to about 25, about 15 to about 20, about 20 to about 35, about 20 to about 30, about 20 to about 25, about 25 to about 35, about 25 to about 30, or about 30 to about 35 wt% of the binder. In further embodiments, composition III contains about 0.1 to about 15 wt% of the binder. In yet other embodiments, composition III contains about 5 to about 15 wt% of the binder.

[0038] According to the disclosure, composition III optionally contains one more additives. Examples of suitable additives are described herein. In some embodiments, composition III contains a non-zero wt% of the additive up to about 20 wt% of the additive. The additive can include a single additive, or the additive can comprise more than one additive. If composition III contains more than one additive, the total, combined amount of the additives will be from a non-zero wt% up to about 20 wt%. In some embodiments, composition III contains up to about 20 wt% of additives. In some embodiments, composition III contains up to about 15 wt% of additives. In other embodiments, composition III contains up to about 10 wt% of additives. In further embodiments, composition III contains up to about 5 wt% of additives. In yet other embodiments, composition III contains up to about 2 wt% of additives. In still further embodiments, composition III contains a non-zero wt% that is less than about 0.1 wt%, about 0.1, about 0.2, about 0.3, about 0.4, about 0.5, about 0.6, about 0.7, about 0.8. about 0.9, about 1, about 1.5, about 2, about 2.5, about 3, about 3.5, about 4, about 4.5, about 5, about 5.5, about 6, about 6.5, about 7, about 7.5, about 8, about 8.5, about 9, about 9.5, about 10, about 10.5, about 11, about 11.5, about 12, about 12.5, about 13, about 13.5, about 14, about 14.5, about 15, about 15.5, about 16, about 16.5, about 17, about 17.5, about 18, about 18.5, about 19, about 19.5 or about 20 wt% of additive. In other embodiments, composition III contains about 0.1 to about 20 wt% of the additive. In further embodiments, composition III contains about 0.1 to about 5, about 0.1 to about 10, about 0.1 to about 15, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 5 to about 20, about 5 to about 15, about 5 to about 15, about 10 to about 20, about 10 to about 15, or about 15 to about 20 wt% of additive. In yet other embodiments, composition III contains about 0.1 to about 5 wt% of the additives.

[0039] According to the disclosure, composition III optionally contains a certain vol% of air. The term “air” as used herein incudes ambient air. In some embodiments, composition III contains at least about 30 vol% of air. In other embodiments, composition III contains about 30, about 40, about 50, about 60, about 70, about 80, about 90, about 95, orAttorney Docket No.: 2024PF00301WO_st about 100 vol% of air. In other embodiments, composition III contains about 30 to about 100, about 30 to about 90, about 30 to about 80, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 100, about 40 to about 90, about 40 to about 80, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 100, about 50 to about 90, about 50 to about 80, about 50 to about 70, about bout 50 to about 60, about 60 to about 100, about 60 to about 90, about 60 to about 80, about 60 to about 70, about 70 to about 100, about 70 to about 90, about 70 to about 80, about 80 to about 100, about 80 to about 90, or about 90 to about 100 wt% of air. In further embodiments, composition III contains about 30 to about 100 vol% of air. In yet other embodiments, composition III contains about 65 to about 95 vol% of air.

[0040] In certain embodiments, composition III comprises: about 5 to about 25 wt% of cellulose fibers; about 0.1 to about 20 wt% of cyanobacteria, microalgae, or a combination thereof; about 0.1 to about 5 wt% of foaming agent; about 30 to about 90 wt% of water; about 0 to about 35 wt% of binder; and about 0 to about 20 wt% of additives.

[0041] In other embodiments, composition III comprises: about 5 to about 25 wt% of cellulose fibers; about 0.1 to about 20 wt% of cyanobacteria, microalgae, or a combination thereof; about 0.1 to about 5 wt% of foaming agent; about 30 to about 90 wt% of water; about 0 to about 35 wt% of binder; about 0 to about 20 wt% of additives; and about 60 to about 90 vol% of air.D. Composition IV

[0042] Moreover, as described herein, composition III may be dried and result in a composition IV. Composition IV comprises cellulose fibers, a foaming agent, and cyanobacteria, microalgae, or a combination thereof. Composition IV is dry, i.e., a composition comprising less than 20 wt% water. In some aspects, composition IV is a foam.

[0043] According to the disclosure, composition IV contains about 25 to about 70 wt% of the cellulose fibers. Examples of suitable cellulose fibers are described herein. In some embodiments, composition IV contains about 25, about 30, about 40, about 50, about 60, about 70, or about 75 wt% of the cellulose fibers. In other embodiments, composition IVAttorney Docket No.: 2024PF00301WO_st contains about 25 to about 75, about 25 to about 70, about 25 to about 60, about 25 to about 50, about 25 to about 40, about 25 to about 30, about 30 to about 75, about 30 to about 70, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 75, about 40 to about 70, about 40 to about 60, about 40 to about 50, about 50 to about 75, about 50 to about 70, about 50 to about 60, about 60 to about 75, about 60 to about 70, or about 70 to about 75 wt% of the cellulose fibers.

[0044] According to the disclosure, composition IV contains about 2 to about 50 wt% of the cyanobacteria, microalgae, or a combination thereof. Examples of suitable cyanobacteria and microalgae are described herein. In some embodiments, composition IV contains about 4, about 5, about 10, about 20, about 30, about 40, or about 50 wt% of the cyanobacteria, microalgae, or a combination thereof. In other embodiments, composition IV contains about 2 to about 40, about 2 to about 30, about 2 to about 20, about 2 to about 10, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 50, about 30 to about 40, or about 40 to about 50 wt% of the cyanobacteria, microalgae, or a combination thereof.

[0045] According to the disclosure, composition IV contains about 1 to about 10 wt% of the foaming agent. Examples of suitable foaming agents are described herein. In some embodiments, composition IV contains about 1, about 2, about 3, about 4, about 5, about 6, about 7, about 8, about 9, or about 10 wt% of the foaming agent. In other embodiments, composition IV contains about 1 to about 9, about 1 to about 8, about 1 to about 7, about 1 to about 6, about 1 to about 5, about 1 to about 4, about 1 to about 3, about 2 to about 10, about 2 to about 9, about 2 to about 8, about 2 to about 7, about 2 to about 6, about 2 to about 5, about 2 to about 4, about 4 to about 10, about 4 to about 9, about 4 to about 8, about 4 to about 7, about 4 to about 6, about 6 to about 10, or about 6 to about 8, or about 8 to about 10 wt% of the foaming agent. In further embodiments, composition IV contains about 2 to about 7 wt% of the foaming agent.

[0046] According to the disclosure, composition IV comprises less than 20 wt% of water. In some embodiments, composition IV contains less than about 15, about 10, about 5, about 4, about 3, about 2, about 1, about 0.5, about 0.1, about 0.01, or about 0.001 wt% of water. In other embodiments, composition IV contains 0 wt% water. In further embodiments, composition IV contains less than about 1 wt% water. In yet other embodiments, composition IV contains less than about 5 wt% water. In still furtherAttorney Docket No.: 2024PF00301WO_st embodiments, composition I contains less than about 10 wt% water. In other embodiments, composition IV contains less than about 15 wt% water. In yet other embodiments, composition IV contains about 0.001 to about 20, 0.001 to about 15, about 0.001 to about 10, about 0.001 to about 5, about 0.001 to about 4, about 0.001 to about 3, about 0.001 to about2, about 0.001 to about 1, about 0.001 to about 0.5, about 0.001 to about 0.1, about 0.001 to about 0.01, about 0.01 to about 20, about 0.01 to about 15, about 0.01 to about 10, about 0.01 to about 5, about 0.01 to about 4, about 0.01 to about 3, about 0.01 to about 2, about 0.01 to about 1, about 0.01 to about 0.5, about 0.01 to about 0.1, about 0.1 to about 20, about 0.1 to about 15, about 0.1 to about 10, about 0.1 to about 5, about 0.1 to about 4, about 0.1 to about3, about 0.1 to about 2, about 0.1 to about 1, about 0.1 to about 0.5, about 0.5 to about 20, about 0.5 to about 15, about 0.5 to about 10, about 0.5 to about 5, about 0.5 to about 4, about 0.5 to about 3, about 0.5 to about 2, about 0.5 to about 1, about 1 to about 20, about 1 to about 15, about 1 to about 10, about 1 to about 5, about 1 to about 4, about 1 to about 3, or about 1 to about 2 wt% water. In still further embodiments, composition IV contains about 5 to about 10 wt% water.

[0047] According to the disclosure, composition IV optionally contains a binder. Examples of suitable binders are described herein. In some embodiments, composition IV contains about 0.1 to about 60 wt% of the binder. In other embodiments, composition IV contains about 0.1, about 1, about 5, about 10, about 20, about 30, about 40, about 50, about 60 wt% of the binder. In other embodiments, composition IV contains about 0.1 to about 60, about 0.1 to about 50, about 0.1 to about 40, about 0.1 to about 30, about 0.1 to about 20, about 0.1 to about 10, about 0.1 to about 1, about 1 to about 60, about 1 to about 50, about 1 to about 40, about 1 to about 30, about 1 to about 20, about 1 to about 10, about 1 to about 5, about 5 to about 60, about 5 to about 60, about 5 to about 50, about 5 to about 40, about 5 to about 30, about 5 to about 20, about 5 to about 10, about 10 to about 60, about 10 to about 50, about 10 to about 40, about 10 to about 30, about 10 to about 20, about 15 to about 60, about 15 to about 50, about 15 to about 40, about 15 to about 30, about 20 to about 60, about 20 to about 50, about 20 to about 40, about 20 to about 30, about 30 to about 60, about 30 to about 50, about 30 to about 40, about 40 to about 60, about 40 to about 50, or about 50 to about 60 wt% of the binder.

[0048] According to the disclosure, composition IV optionally contains one or more additives. Examples of suitable additives are described herein. In some embodiments, composition IV contains about 0.1 to about 10 wt% of the additives. In other embodiments, composition IV contains about 0.1, about 0.5, about 1, about 2.5, about 5, about 7.5, or aboutAttorney Docket No.: 2024PF00301WO_st10 wt% of the one or more additives. In further embodiments, composition IV contains about 0.1 to about 7.5, 0.1 to about 5, about 0.1 to about 2.5, about 0.1 to about 1, about 0.1 to about 0.5, about 0.5 to about 10, about 0.5 to about 7.5, about 0.5 to about 5, about 0.5 to about 1, about 1 to about 10, about 1 to about 7.5, about 1 to about 5, about 1 to about 2.5, about 2.5 to about 10, about 2.5 to about 7.5, about 2.5 to about 5, about 5 to about 7.5, about 5 to about 10, or about 7.5 to about 10 wt% of the one or more additives.

[0049] In certain embodiments, composition IV comprises: about 25 to about 70 wt% of cellulose fibers; about 2 to about 50 wt% of cyanobacteria, microalgae, or a combination thereof; about 1 to about 10 wt% of foaming agent; less than 20 wt% of water; about 0 to about 60 wt% of binder; and about 0 to about 10 wt% of additives.

[0050] In other embodiments, composition IV comprises: about 25 to about 70 wt% of cellulose fibers; about 2 to about 50 wt% of cyanobacteria, microalgae, or a combination thereof; about 1 to about 10 wt% of foaming agent; less than 20 wt% of water; about 0 to about 60 wt% of binder; and about 0 to about 10 wt% of additives; wherein the density of composition IV is about 30 to about 300 kg / m3.

[0051] In further embodiments, composition IV comprises: about 25 to about 70 wt% of cellulose fibers; about 2 to about 50 wt% of cyanobacteria, microalgae, or a combination thereof; about 1 to about 10 wt% of foaming agent; less than 20 wt% of water; about 0 to about 60 wt% of binder; and about 0 to about 10 wt% of additives; wherein the density of composition IV is about 50 to about 150 kg / m3.E. Composition Components(i) Foaming Agent

[0052] According to the disclosure, the compositions contain a foaming agent. In some embodiments, the foaming agent is a surfactant. The surfactants suitable for use in any of the compositions can be an anionic surfactant, a cationic surfactant, an amphotericAttorney Docket No.: 2024PF00301WO_st surfactant, or any combination thereof. In some embodiments, the surfactant is an anionic surfactant. In other embodiments, the surfactant is a cationic surfactant. In further embodiments, the surfactant is an amphoteric surfactant.

[0053] Surfactants suitable for use in any of the compositions and / or methods described herein include sodium dodecyl sulfate, dodecyldimethylamine oxide (DDAO), stearyl alcohol, glyceryl laurate, polysorbate, cetostearyl alcohol, starch, sucrose, hexadecyl palmitate, lauryl dimethylamine oxide (LDAO), coamidopropyl betaine (CAPB), ethanolamine, sorbitol, a disodium dihydrogen ethylene diaminetetraacetate, sulfosuccinate, or a combination thereof. In some embodiments, the surfactant is sodium dodecyl sulfate. In other embodiments, the surfactant is DDAO. In further embodiments, the surfactant is stearyl alcohol. In yet other embodiments, the surfactant is glyceryl laurate. In still further embodiments, the surfactant is polysorbate. In other embodiments, the surfactant is cetostearyl alcohol. In further embodiments, the surfactant is starch. In yet other embodiments, the surfactant is sucrose. In still other embodiments, the surfactant is hexadecyl palmitate. In still further embodiments, the surfactant is LDAO. In other embodiments, the surfactant is CAPB. In further embodiments, the surfactant is ethanolamine. In yet other embodiments, the surfactant is sorbitol. In still further embodiments, the surfactant is a disodium dihydrogen ethylene diaminetetraacetate, sulfosuccinate such as sodium dioctyl sulfosuccinate.(ii) Cellulose Fibers

[0054] According to the disclosure, certain compositions may contain cellulose fibers. The cellulose fibers used herein may be wood fibers. The wood fibers can be virgin or recycled fibers, or a combination thereof. The virgin or recycled fibers can be hardwood fibers, e.g., fibers produced from a deciduous tree, z.e., hardwood virgin fibers or recycled hardwood fibers. The wood fibers can be softwood fibers, e.g., fibers produced from a coniferous tree, / .< ., softwood virgin fibers or recycled softwood fibers.

[0055] The wood fibers used in in any of the embodiments described herein can be a combination of hardwood fibers and softwood fibers. The wood fibers can be softwood virgin wood fibers, such as, softwood virgin kraft pulp. The wood fibers can be kraft pulp fibers, fluff pulp fibers, Northern bleached softwood kraft (NBSK) pulp fibers, Southern bleached softwood kraft (SBSK) pulp fibers, virgin pulp fibers, bleached virgin pulp fibers, bleach virgin softwood, newsprint, recycled newsprint, recycled pulp fibers, deinked pulp fibers, bleached pulp fibers, or any combination thereof.Attorney Docket No.: 2024PF00301WO_st

[0056] In some embodiments, the wood fibers comprise kraft pulp fibers. In other embodiments, the wood fibers comprise fluff pulp fibers. In further embodiments, the wood fibers comprise NBSK fibers. In yet other embodiments, the wood fibers comprise SBSK fibers. In still further embodiments, the wood fibers comprise recycled fibers. In other embodiments, the wood fibers comprise deinked fibers. In further embodiments, the wood fibers comprise bleached fibers.

[0057] The wood fibers used herein can include wood fibers of any species typically used for manufacturing paper products. The wood fibers suitable for use in in any of the embodiments described herein include, e.g., spruce fibers, pine fibers, fir fibers, western Hemlock fibers, balsam fibers, cedar fibers, or a combination thereof. In some embodiments, the wood fibers comprise spruce fibers. In other embodiments, the wood fibers comprise pine fibers. In further embodiments, the wood fibers comprise fir fibers. In yet other embodiments, the wood fibers comprise western Hemlock fibers. In still further embodiments, the wood fibers comprise balsam fibers. In other embodiments, the wood fibers comprise cedar fibers. In further embodiments, synthetic fibers can be added, in addition, to the wood fibers to form a composition. Synthetic fibers can be made from polymeric materials, including, but not limited to, polyester fibers and / or acrylonitrile fibers.

[0058] In certain embodiments, the wood fibers have a fiber length of about 0.5 mm to about 5 mm. Softwood fibers can measure from about 2 to about 4 mm (about 0.08 to about 0.16 inch) in length. Hardwood fibers can measure from about 0.5 to about 1.5 mm (about 0.02 to about 0.06 inch). Recycled fibers can have a reduced length of about 0.01 to about 5 mm. In some embodiments, the wood fibers have a fiber length of about 0.5 mm to about 4 mm. In other embodiments, the wood fibers have a fiber length of about 0.5 mm to about 3 mm. In further embodiments, the wood fibers have a fiber length of about 0.5 mm to about 2 mm. In yet other embodiments, the wood fibers have a fiber length of about 0.5 mm to about 1 mm. In still further embodiments, the wood fibers have a fiber length of about 1 mm to about 4 mm. In other embodiments, the wood fibers used have a fiber length of about 2 mm to about 4 mm. In further embodiments, the wood fibers have a fiber length of about 3 mm to about 4 mm. For example, the wood fibers have a fiber length of about 0.5, about 0.6, about 0.7, about 0.8, about 0.9, about 1, about 1.1, about 1.2, about 1.3, about 1.4, about 1.5, about 1.6, about 1.7, about 1.8, about 1.9, about 2, about 2.1, about 2.2, about 2.3, about 2.4, about 2.5, about 2.6, about 2.7, about 2.8, about 2.9, about 3, about 3.1, about 3.2, about 3.3, about 3.4, about 3.5, about 3.6, about 3.7, about 3.8, about 3.9, or about 4 mm.Attorney Docket No.: 2024PF00301WO_st

[0059] In certain embodiments, the wood fibers have a fiber width of about 20 m to about 35 pm, for example about 20 pm to about 25 pm. In some embodiments, the wood fibers have a fiber width of about 20 pm to about 30 pm. In other embodiments, the wood fibers have a fiber width of about 25 pm to about 30 pm. In further embodiments, the wood fibers have a fiber width of 30 pm to 35 pm. For example, the wood fibers about have a fiber length of about 20, about 21, about 22, about 23, about 24, about 25, about 26, about 27, about 28, about 29, about 30, about 31, about 32, about 33, about 34, or about 35 pm.

[0060] In certain embodiments, the wood fibers have a weight of about 5 million fibers per gram to about 30 million fibers per gram. In some embodiments, the wood fibers have a weight of about 5 million to about 10 million fibers per gram. In other embodiments, the wood fibers have a weight of about 10 million to about 15 million fibers per gram. In further embodiments, the wood fibers have a weight of 15 million to 20 million fibers per gram. In yet other embodiments, the wood fibers have a weight of 20 million to 25 million fibers per gram. In still further embodiments, the wood fibers have a weight of 25 million to 30 million fibers per gram. For example, the wood fibers have a weight of about 5, about 6, about 7, about 8, about 9, about 10, about 11, about 12, about 13, about 14, about 15, about 16, about 17, about 18, about 19, about 20, about 21, about 22, about 23, about 24, about 25, about 26, about 27, about 28, about 29 or about 30 million fibers per gram.

[0061] In certain embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.5 mg / m. In some embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.1 mg / m. In other embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.15 mg / m. In further embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.2 mg / m. In yet other embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.25 mg / m. In still further embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.3 mg / m. In other embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.35 mg / m. In further embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.4 mg / m. In yet other embodiments, the wood fibers have a fiber coarseness of about 0.05 mg / m to about 0.45 mg / m. In still further embodiments, the wood fibers have a fiber coarseness of about 0.1 mg / m to about 0.2 mg / m. In other embodiments, the wood fibers have a fiber coarseness of about 0.2 mg / m to about 0.3 mg / m. In further embodiments, the wood fibers have a fiber coarseness of about 0.3 mg / m to about 0.4 mg / m. In yet other embodiments, the wood fibers have a fiber coarseness of about 0.4 mg / m to about 0.5 mg / m. For example, the wood fibers used in the disclosed methods and compositions have a fiberAttorney Docket No.: 2024PF00301WO_st coarseness of about 0.05, about 0.1, about 0.15, about 0.2, about 0.25, about 0.3, about 0.35, about 0.4, about 0.45 about or 0.5 mg / m.

[0062] Wood fibers suitable for use in any of the processes and compositions described herein may be, for example, softwood kraft pulp (Mercer Peace River Pulp Ltd.) comprising White Spruce (Picea glauca) (>90%) and Lodgepole Pine (Pinus contortd) (<10%), e.g., having fiber length of 2.39 mm, fiber width of 27.4 pm, weight of 8.7 million fibers per gram, fiber coarseness of 0.14 mg / m.(iii) Binder

[0063] According to the disclosure, certain composition contain one or more binders. In some embodiments, the binder is starch, polyvinyl alcohol (PVOH), polyvinyl acetate, polylactic acid, an ethylene-vinyl alcohol copolymer (EVOH), a polyvinyl acetate, an ethylene vinyl acetate acrylic, a dextrin, or a combination thereof. In some embodiments, the binder is starch, e.g., cooked or raw. In other embodiments, the binder is PVOH. In further embodiments, the binder is polyvinyl acetate. In yet other embodiments, the binder is polylactic acid. In still further embodiments, the binder is EVOH. In other embodiments, the binder is a polyvinyl acetate. In further embodiments, the binder is an ethylene vinyl acetate acrylic. In yet other embodiments, the binder is a dextrin.

[0064] The starch used herein can be sourced from potato, wheat, tapioca, com, rice, or any combination thereof. The starch can be unmodified or, in part, modified. In some embodiments, the starch is a non-gelatinized starch. Examples of non-gelatinized starches include, without limitation, non-gelatinized potato starch, non-gelatinized wheat starch, nongelatinized com starch, non-gelatinized tapioca starch, non-gelatinized rice starch, or a combination thereof.(iv) Additives

[0065] The compositions described herein may optionally include one or more additives. Suitable additives include, but are not limited to, adhesion promoters, anti-fungal agents, biocides, calcium carbonate, clay, crosslinkers, defoamers, dyes, humectants, microencapsulated chemicals, microspheres, nanocellulose, nanocrystalline cellulose, phasechange materials, pigments, plasticizers, polyether compounds, preservatives, rheology modifiers, salts, starches, tackifiers, thickeners, waxes, or any combination thereof. In some embodiments, the additive is an adhesion promoter such as EGDA or PEI. In other embodiments, the additive is an anti-fungal agent. In further embodiments, the additive is a biocide. In yet other embodiments, the additive is calcium carbonate. In still further embodiments, the additive is clay. In other embodiments, the additive is a crosslinker. InAttorney Docket No.: 2024PF00301WO_st further embodiments, the additive is a defoamer. In yet other embodiments, the additive is a dye such as a UV dye. In still further embodiments, the additive is a humectant. In other embodiments, the additive is a microencapsulated chemicals. In still other embodiments, the additive is nanocellulose. In yet further embodiments, the additive is nanocrystalline cellulose. In other embodiments, the additive is a phase-change material. In further embodiments, the additive is a pigment. In yet other embodiments, the additive is a plasticizer. In further embodiments, the additive is a polyether compound. In still other embodiments, the additive is a preservative. In yet further embodiments, the additive is a rheology modifier (such as, for example, xanthan gum, carboxymethyl cellulose, carrageenan, guar gum, alginate, polyethylene glycol derivate, acrylic polymer, clay, paraffin wax, gelatin, and silicas).

[0066] In other embodiments, the additive is a salt. In further embodiments, the additive is a starch. In yet other embodiments, the additive is a tackifier. In still further embodiments, the additive is a thickener. In other embodiments, the additive is a wax.

[0067] In further embodiments, the additive are microspheres such as unexpanded microspheres or expanded microspheres. Microspheres suitable for use in the compositions described herein are described in, for example, U.S. Patent Publication Nos. 2021 / 0214581, 2019 / 0284438 and 2019 / 0062028 and U.S. Patent No. 10,100,204, the entire contends of each of which is incorporated herein by reference.

[0068] The expandable microspheres can expand in size in the presence of heat. The microspheres useful herein include, e.g., heat expandable polymeric microspheres, including those having a hydrocarbon core and a polyacrylonitrile shell (such as those sold under the trade name DU ALITE®) and other similar microspheres (such as those sold under the trade name EXPANCEL®). The expandable microspheres may have any unexpanded size, including from about 5 microns to about 30 microns in diameter. In the presence of, the expandable microspheres can increase in diameter by about 3 times to about 10 times the original size. Upon expansion of the microspheres in the composition, the composition becomes a foam-like material, which has improved insulation properties. The microspheres are typically made of plastic or polymeric shells and a blowing agent is inside the shell, designed to activate upon reaching specific temperatures.

[0069] In some embodiments, the compositions described herein do not include an additive that is an inorganic ionic salt, that is, the compositions described herein include about 0 wt% of an inorganic ionic salt.Attorney Docket No.: 2024PF00301WO_st

[0070] In some embodiments, the compositions described herein include an additive that is an inorganic ionic salt. In some embodiments, the inorganic ionic salt may be present in the composition in an amount up to about 10 wt%. Suitable inorganic ionic salts for use in the compositions described herein include, but are not limited to, sodium chloride, calcium chloride, magnesium chloride, aluminum nitrate, ammonium zirconium, or any combination thereof. Sodium chloride is a particularly preferred inorganic ionic salt.Processes

[0071] The compositions described herein, e.g., Compositions I, II, and III, may be prepared using techniques known in the art including, without limitation, mechanical mixing. The components of the compositions may be added in any order.

[0072] Compositions containing water, / .< ., wet compositions, may be prepared by combining water with the solid components. In some embodiments, water is added to the solid components. In other embodiments, the solid components are added to water.

[0073] The wet compositions, e.g., Composition III, may be foamed to incorporate air to form “wet foams.” The wet foams of the disclosure can be produced by combining air with a composition containing water using one or more methods known in the art. Suitable methods of combining air include, e.g., mixing, shearing, paddle mixing, cowles mixing, turbine mixing, injection, gate mixing, auger mixing, or a combination thereof. As described in the Examples, air content can be measured by quantifying the change in volume in the mixture from right before mixing to the end of mixing and dividing by the final volume.

[0074] In some embodiments, the mixing and foaming steps are performed concurrently such as in a singular mixing process step. By way of example, the components of the composition (e.g., raw materials) are added to a mixing tank. The tank is configured with high shear turbine blades. In some embodiments, the high shear turbine blades disintegrate the cellulose fibers and homogenize the mixture into a foam by incorporating air. In some embodiments, the combined mixing and foaming is performed for less than about 25 minutes. In other embodiments, the combined mixing and foaming is performed for less than about 20, about 15, about 10, or about 5 minutes. In further embodiments, the combined mixing and foaming is performed for about 5 to about 20, about 5 to about 15, about 5 to about 10, about 10 to about 25, about 10 to about 20, about 10 to about 15, about 15 to about 25, about 15 to about 20, or about 20 to about 25 minutes. The time selected depends on the desired air content.

[0075] Mixing and foaming is performed at temperatures to ensure that the cellulose fibers remains non-gelatinized. In some embodiments, the mixing / foaming is performed at aAttorney Docket No.: 2024PF00301WO_st temperature of about 20 to about 60°C. In other embodiments, the mixing / foaming is performed at a temperature of about 20, about 25, about 30, about 35, about 40, about 45, about 50, about 55, or about 60°C. In further embodiments, the mixing / foaming is performed at a temperature of about 20 to about 55, about 20 to about 50, about 20 to about 45, about 20 to about 40, about 20 to about 35, about 20 to about 30, about 20 to about 25, about 25 to about 60, about 25 to about 55, about 25 to about 50, about 25 to about 45, about 25 to about 40, about 25 to about 35, about 25 to about 30, about 30 to about 60, about 30 about 55, about 30 to about 50, about 30 to about 45, about 30 to about 40, about 30 to about 35, about 35 to about 60, about 35 to about 55, about 35 to about 50, about 35 to about 45, about 35 to about 40, about 40 to about 60, about 40 to about 55, about 40 to about 50, about 40 to about 45, about 45 to about 60, about 45 to about 55, about 45 to about 50, about 50 to about 60, about 50 to about 55, or about 55 to about 60°C.

[0076] The foam may then be pumped away from the mixer using pumps and methods known in the art. Desirably, the temperature of the foam remains at a temperature below about 60° C during pumping. In some embodiments, pumping is performed to ensure that the temperature of the foam remains at a temperature of below about 50° C, below about 45° C, below about 40° C, below about 35° C, below about 30° C or below about 25° C. Increasing the temperature beyond, e.g., about 60° C may lead to a significant increase in foam viscosity due to the starch swelling and beginning to gelatinize. This can lead to pump or application site blockages.

[0077] The resulting wet foams can be applied into a mold or to one or more substrates as described herein using techniques known to those skilled in the art. The substrates described herein can be any material, such as web material, suitable for the manufacture of packaging materials. For example, the substrate (e.g., a bottom and / or or a top (laminate) substrate) can independently be paper, corrugate, compostable polymer film, biodegradable polymer film, biobased films, cellophane, polymer film (e.g., polyester film, polypropylene film, polyethylene film), metalized film, recyclable paper, recycled paper, recyclable coated paper, recyclable metal vapor deposited paper, or any combination thereof. In certain embodiments, the substrate(s) are paper or fiber-based in nature (corrugate, recycled paper, coated paper). In other embodiments, the substrates are cellulosic, metal, plastic, or a combination thereof. In further embodiments, the one or more substrates is paper. In yet other embodiments, the substrates are recyclable or recycled. In still further embodiments, the substrates are compostable and / or biodegradable polymer film.Attorney Docket No.: 2024PF00301WO_st

[0078] Water may then be removed from the wet foam using techniques known in the art to form a dry foam, / .< ., the foam is dried to remove moisture at a levels less than 20 wt% , 19 wt%, 18 wt%, 17 wt%, 16 wt%, 15 wt%, 14 wt%, 13 wt%, 12 wt%, 11 wt%, 10 wt%, 9 wt%, 8 wt%, 7 wt%, 6 wt%, 5 wt%, 4 wt%, 3 wt%, 2 wt%, 1 wt%, 0.5 wt%, 0. lwt% or essentially free of any moisture, based ono the total weight of the composition. In some embodiments, water is removed from the wet foam by drying. Importantly, even with the water removal, the foam construed on / shape is maintained to provide structure of the composition. Drying techniques for foams are known in the art. Suitable methods for heating and drying include, e.g., dielectric heating (such as radio frequency or microwave heating), convection heating, infrared heating, conventional heating, air impingement heating, or a combination thereof.

[0079] In some embodiments, dielectric heating is used at least in part for removing water and gelatinizing starch. Dielectric heating may be used to remove water from thick products (about 3 to about 100 mm) and allows for different substrates, including different web substrates, to be utilized. Convectional heating is often be used with very thin foam layers.

[0080] Dielectric heating, electronic heating, radio frequency (RF) heating, and high-frequency heating, all interchangeably used herein, is the process in which high- frequency alternating electric field or radio wave heats a dielectric material. RF heating is distinguishable from microwave heating. Industrial radio frequencies operate between approximately 2 MHz and 300 MHz with typical wavelengths of about 141 to about 24 feet (43 to 7.3 meters). Industrial microwave systems use frequencies over 300 MHz with typical wavelengths of about 13 to about 5 inches (33 and 12 cm).

[0081] In certain embodiments, dielectric RF heating is used for the drying step. RF creates an alternating electric field between a dielectric material, namely, polar water molecules. The article is conveyed between the electrodes causing the water molecules in the composition to continuously reorient to face opposite electrodes. Friction from this molecular movement causes the rapid heating. RF operates at much lower frequency than microwave heating and is associated with lower health risks than microwaves. RF is also suitable for heating bulkier and odd-shaped containers due to its higher depth of penetration. RF heating also allows for fast throughput of making articles. The composition must be designed to accommodate this fast throughput method to maximize solid contents in the composition. It is preferable that the water molecules to be efficiently driven off without leaving unsightly wrinkles or unevenness on the substrates. RF heating provides a uniform and faster egress ofAttorney Docket No.: 2024PF00301WO_st water from the composition, at a faster throughput. The uniform and evenness of the coalesced coating provides uniform thermal insulation to the article and minimizes unsightly wrinkles on the substrates, while increasing the production.

[0082] In certain embodiments, partial drying is performed using dielectric heating, while the removal of additional excess moisture may subsequently be achieved using convectional and / or dielectric heating.

[0083] By doing so, the dried foam prepared as described herein has increased compressive strength compared to a dried foam that is prepared without the cyanobacteria and / or microalgae. The dried foam prepared according to this disclosure has a density of about 20 to about 300 kg / m3. As explained in the Examples, dried foam density can be calculated by dividing the sample’s weight by volume. The weight is measured and recorded using a balance. The volume is calculated by multiplying the length, measured by ruler, width, measured by ruler, and thickness, measured using caliper. See also the density measurement in accordance with ASTM D3575, such as ASTM D3575 Suffix W.

[0084] In some embodiments, the density of the dried foam is about 30, about 50, about 75, about 100, about 125, about 150, about 175, about 200, about 225, about 250, about 275, or about 300 kg / m3. In other embodiments, the density of the dried foam is about 30 to about 275, about 30 to about 250, about 30 to about 225, about 30 to about 225, about 30 to about 200, about 30 to about 175, about 30 to about 150, about 30 to about 125, about 30 to about 100, about 30 to about 75, about 30 to about 50, about 50 to about 300, about 50 to about 275, about 50 to about 250, about 50 to about 225, about 50 to about 200, about 50 to about 175, about 50 to about 150, about 50 to about 125, about 50 to about 100, about 50 to about 75, about 75 to about 300, about 75 to about 275, about 75 to about 250, about 75 to about 225, about 75 to about 200, about 75 to about 175, about 75 to about 150, about 75 to about 100, about 100 to about 300, about 100 to about 275, about 100 to about 250, about 100 to about 225, about 100 to 200, about 100 to about 175, about 100 to about 150, about 100 to about 125, about 125 to about 300, about 125 to about 275, about 125 to about 250, about 125 to about 225, about 125 to about 200, about 125 to about 175, about 125 to about 150, about 150 to about 300, about 150 to about 275, about 150 to about 250, about 150 to about 225, about 150 to about 200, about 150 to about 175, about 175 to about 300, about 175 to about 275, about 175 to about 250, about 175 to about 225, about 175 to about 200, about 200 to about 300, about 200 to about 275, about 200 to about 250, about 200 to about 225, about 225 to about 300, about 225 to about 275, about 225 to about 250, about 250 to about 300, aboutAttorney Docket No.: 2024PF00301WO_st250 to about 275, or about 275 to about 300 kg / m3. In further embodiments, the density of the dried foam is about 40 to about 150 kg / m3.

[0085] The solid, dried compositions described herein have a compressive strength as measured in accordance with ASTM D3575, such as ASTM D3575 Suffix D, that is at least 100% higher than a reference composition lacking the cyanobacteria, microalgae, or a combination thereof, wherein the density of the composition is the same or substantially the same as the density of the reference composition (e.g. a reference composition can be otherwise consistent to the composition but for lacking the cyanobacteria, microalgae, or a combination thereof). The term “substantially the same” as used herein refers to a density of the composition that is within about 5 kg / m3(±) of a reference composition lacking the cyanobacteria, microalgae, or a combination thereof. In some embodiments, “substantially the same” as used herein refers to a density of the composition that is within about 1, about 2, about 3, about 4, or about 5 kg / m3of a reference composition lacking the cyanobacteria, microalgae, or a combination thereof. In other embodiments, “substantially the same” as used herein refers to a density of the composition that is within about 1 to about 5, about 1 to about 4, about 1 to about 3, about 1 to about 2, about 2 to about 5, about 2 to about 4, about 2 to about 3, about 3 to about 5, about 3 to about 4, or about 4 to about 5 kg / m3of a reference composition lacking the cyanobacteria, microalgae, or a combination thereof. In some embodiments, solid, dried compositions described herein have a compressive strength as measured in accordance with ASTM D3575, such as ASTM D3575 Suffix D, that is up to about 950% higher than a reference composition lacking the cyanobacteria, microalgae, or a combination thereof, wherein the density of the composition is the same or substantially the same as the density of the reference composition. In other embodiments, the solid, dried compositions described herein have a compressive strength as measured in accordance with ASTM D3575, such as ASTM D3575 Suffix D, that is about 100, about 200, about 300, about 400, about 500, about 600, about 700, about 800, about 900, or about 950% higher than a reference composition lacking the cyanobacteria, microalgae, or a combination thereof, wherein the density of the composition is the same or substantially the same as the density of the reference composition. In other embodiments, the solid, dried compositions described herein have a compressive strength as measured in accordance with ASTM D3575, such as ASTM D3575 Suffix D, that is about 100 to about 950, about 100 to about 900, about 100 to about 800, about 100 to about 700, about 100 to about 600, about 100 to about 500, aboutlOO to about 400, about 100 to about 300, about 100 to about 200, about 200 to about 950, about 200 to about 900, about 200 to about 800, about 200 to about 700, about 200 to about 600,Attorney Docket No.: 2024PF00301WO_st about 200 to about 500, about 200 to about 400, about 200 to about 300, about 300 to about 950, about 300 to about 900, about 300 to about 800, about 300 to about 700, about 300 to about 600, about 300 to about 500, about 300 to about 400, about 400 to about 950, about 400 to about 900, about 400 to about 800, about 400 to about 700, about 400 to about 600, about 400 to about 500, about 500 to about 950, about 500 to about 900, about 500 to about 800, about 500 to about 700, about 500 to about 600, about 600 to about 950, about 600 to about 900, about 600 to about 800, about 600 to about 700, about 700 to about 950, about 700 to about 900, about 700 to about 800, about 800 to about 950, about 800 to about 900, or about 900 to about 950 % higher than a reference composition lacking the cyanobacteria, microalgae, or a combination thereof, wherein the density of the composition is the same or substantially the same as the density of the reference composition

[0086] Additional steps may be performed before, during, or after preparing the dried foam. In some embodiments, the processes include a laminating step, thus resulting in a laminated product. According to the disclosure, “laminated” products refer to those products having a foam of the disclosure (e.g., a wet foam) sandwiched between the surfaces of one or more substrates, such as one or more web substrates.

[0087] In other embodiments, the processes include a molding step. A molding step as described herein refers to molding the product with any suitable tools, forms or equipment into a desired shape. For example, the substrate may be a molding belt to form the molded product. The molded product is subsequently removed to form the stand-alone finished molded product.

[0088] In further embodiments, the processes include a folding step. Folding can be performed using techniques and equipment known in the art. Folding is typically performed on substrates having partially dried or dried foam thereon, and can be aided by the use of scored markings.

[0089] In some aspects, the disclosure provides processes of preparing a dried foam by: preparing a wet foam composition described herein, applying the wet foam onto a substrate, optionally laminating; removing water from the wet foam by heating / drying to form a dried foam product; and optionally molding the product with any suitable tools, forms or equipment.Attorney Docket No.: 2024PF00301WO_st

[0090] In other aspects, the disclosure provides processes of preparing a dried foam by: preparing a wet foam composition described herein; applying the wet foam onto a substrate; partially removing water by heating / drying forming a partially dried foam; folding or molding partially dried product; and finish heating / drying to form a dried foam product.

[0091] In further aspects,, the disclosure provides processes of preparing dried foams by: preparing a wet foam composition described herein; applying the wet foam to a mold; removing water by heating / drying to form a dried foam product.Foamed Products

[0092] According to the disclosure, foamed compositions are provided. These foamed compositions are prepared according to the processes described herein.

[0093] In certain aspects, the foamed compositions is an article. In some embodiments, the article is paper packaging product. Examples of packaging products include, without limitation folded forms (e.g., envelope), pouch, bag, box, carton, case, lid, wrap, clamshell, cup, flat sheet (e.g., flat thermally insulating sheet, flat sheet with scored markings for later folding, an embossed sheet with patterns or a sheet of an initial thickness when applied wet but with various thickness levels after forming with pressure), molded three-dimensional package element (e.g., a comer brace), folded package element, or food container with adhesive. In other embodiments, the article is in the form of a support element, such as support element that protects a fragile object such as an electronic component or food. In further embodiments, the article is compostable, recyclable, and / or renewable.ExamplesExample 1

[0094] In this example, cellulose fibers are blended with Spirulina cyanobacteria, water and other additives in a mechanical mixing process. See, Table 1 for the components of the composition.Attorney Docket No.: 2024PF00301WO_st

[0095] The mixture is blended for 4 minutes at approximately 700 RPM. During this process, air is incorporated into the foam. The air content is measured by quantifying the change in volume in the mixture from right before mixing to the end of mixing and dividing by the final volume and was found to be 85 vol%.

[0096] The foam is then dried in a 1000 Watt SHARP microwave until the water has been removed. The final dried foam density is 65 kg / m3. The dried foam density is calculated by dividing the sample’s weight by volume. The weight is measured and recorded using a balance. The volume is calculated by multiplying the length, measured by ruler, width, measured by ruler, and thickness, measured using caliper.

[0097] The foam sample was then tested according to ASTM D3575 Suffix D using an Instron 5582 UTM. In this method, a 2” x 2” x 1” sample of foam is compressed between two parallel platens. The forces are measured to deform the sample to 10% and 25% of the sample’s initial height. In this example, the sample had the following average compressive strength at these values: 5.7 psi and 12.1 psi, respectively.Example 2

[0098] The compositions in Table 2 represent the wet foam makeup.

[0099] In addition to the components in Table 2, samples 1-4 contain 1 wt% surfactant, 1 wt% additives (e.g., salt and / or rheology modifier), and water as the balance. By way of example, sample #1 (15% cellulose only foam) contains 15 wt% cellulose fibers, 1 wt% surfactant, 1 wt% additives, and 83 wt% water.Attorney Docket No.: 2024PF00301WO_st

[0100] At approximately 100 kg / m3, cellulose foam with Spirulina cyanobacteria alone results in a compressive strength at 25% deformation, according to ASTM D3575, more than 6x the compressive strength of cellulose only foam and more than double the compressive strength of cellulose foam with a binder. Likewise, the cellulose foams containing Spirulina cyanobacteria offer solutions with compressive strength at a similar level as Type I expanded polystyrene foam (EPS; sample 5).

[0101] From this result, the combination of a binder with Spirulina cyanobacteria shows the highest compressive strength of the cellulose foam types at 100 kg / m3dried foam density.Example 3

[0102] In this example, cellulose fibers are blended with Chlorella microalgae, water and other additives in a mechanical mixing process. See, Table 3 for the components of the composition.

[0103] The mixture is blended for 9 minutes at approximately 700 RPM. During this process, air is incorporated into the foam. The air content is measured by quantifying the change in volume in the mixture from right before mixing to the end of mixing and then dividing by the final volume and was found to be 75 vol%. The foam is then dried in a 1000 W SHARP microwave until the water has been removed. The final dried foam density is 90 kg / m3. The dried foam density is calculated by dividing the sample’s weight by volume. The weight is measured and recorded using a balance. The volume is calculated by multiplying the length, measured by ruler, width, measured by ruler, and thickness, measured using caliper.

[0104] The foam sample was then tested according to ASTM D3575 Suffix D using an Instron 5582 UTM. In this method, a 2” x 2” x 1” sample of foam is compressed between two parallel platens. The forces are measured to deform the sample to 10% and 25% of the sample’s initial height. In this example, the sample had the following average compressive strength at these values: 5.5 psi, 11.9 psi, respectively.Attorney Docket No.: 2024PF00301WO_stExample 4

[0105] The compositions described in Table 4 were prepared and represent a wet foam makeup.

[0106] Each sample in Table 4 contains 1 wt% surfactant, 1 wt% additives (e.g., salt and / or rheology modifier), and water as the balance. By way of example, sample 3 (15% cellulose + 5% Chlorella microalgae foam) contains 15 wt% cellulose fibers, 5 wt% Chlorella microalgae, 1 wt% surfactant, 1 wt% additives, and 78 wt% water.

[0107] At approximately 100 kg / m3, cellulose foam with Chlorella microalgae alone results in a compressive strength at 25% deformation, according to ASTM D3575, more than 6x the compressive strength of cellulose only foam and more than double the compressive strength of cellulose foam with a binder. Likewise, the cellulose foams containing Chlorella microalgae offer solutions with compressive strength greater than that of Type I expanded polystyrene foam (EPS).

[0108] From this result, the combination of a binder with Chlorella microalgae shows the highest compressive strength of the cellulose foam types at 100 kg / m3dried foam density.Example 5

[0109] This example demonstrates the weight percent range of microalgae and / or cyanobacteria that can be added to a wet cellulose-based mixture to still result in a foam. A foam in this context refers to a mixture with greater than thirty percent (>30%) air by volume. Any mixture with less than this air content, may result in a high-density paste-like substance, which may not be cost effective or economically viable in the packaging industry. The air content results are reported in the chart above. The air content in this example is calculated by dividing the difference in volume from prior to mixing to after mixing by the final volume.Attorney Docket No.: 2024PF00301WO_st

[0110] All compositions (Table 5) were made with 5 wt% softwood fibers, 5 wt% hardwood fibers, 0 wt% binder, 1 wt% surfactant, 1 wt% additives (e.g., salt and / or rheology modifier) and the described amount of Spirulina cyanobacteria / Chlorella microalgae as shown in Table 5. The remainder of the balance is water to result in a total of 100% by weight basis. For instance, the column labelled “10%” represents a wet foam composition containing 5 wt% softwood fibers, 5 wt% hardwood fibers, 10 wt% Spirulina cyanobacteria / Chlorella microalgae, 1 wt% surfactant, 1 wt% additives, and 78 wt% water.

[0111] The Spirulina cyanobacteria containing cellulose foams were able to accept up to 20% Spirulina cyanobacteria by weight but at 20%, air could no longer be incorporated readily resulting in a composition with less than 30% air by volume.

[0112] The Chlorella microalgae containing cellulose foams were able to be added up to 15% by weight but at 15%, air could no longer be incorporated readily resulting in a composition with less than 30% air by volume.

[0113] This example demonstrates the broader range of microalgae or cyanobacteria to be from 0 to 25 wt% and 0 to 15 wt% on a narrow basis.Example 6

[0114] This example demonstrates how different addition amounts and dried foam densities can produce a result that matches or exceeds the compressive strength of typical polymeric foams in the packaging industry. Each cellulose foam example in Table 6 is described by the wet foam composition on a weight percent basis.Attorney Docket No.: 2024PF00301WO_st

[0115] For example, the samples labelled “15% Cellulose + 7.5% Spirulina cyanobacteria foam” contain 15 wt% cellulose fibers, 7.5 wt% Spirulina cyanobacteria, 1% surfactant, 1 wt% additives (e.g., salt, and / or rheology modifier) and 75.5 wt% water. The samples labelled “15% cellulose + 5% binder + 5% Spirulina cyanobacteria” contain 15 wt% cellulose fibers, 5 wt% binder, 5 wt% Spirulina cyanobacteria, 1 wt% surfactant, 1 wt% additives and 73 wt% water.

[0116] To match the performance of expanded polyethylene foam (EPE) at 35 kg / m3, a cellulose foam with 7.5% Spirulina cyanobacteria at 55 kg / m3or a cellulose foam with 5% binder and 5% Spirulina cyanobacteria at 80 kg / m3can be used.

[0117] To match or exceed the performance of expanded polypropylene foam (EPP) at 21 kg / m3, a cellulose foam with 7.5% Spirulina cyanobacteria at 75 kg / m3or a cellulose foam with 5% binder + 5% Spirulina cyanobacteria at 100 kg / m3can be used.

[0118] To match or exceed the performance of expanded polystyrene foam (EPS) at 16 kg / m3, a cellulose foam with 7.5% Spirulina cyanobacteria at 85 kg / m3or a cellulose foam with 5% binder + 5% Spirulina cyanobacteria at 107 kg / m3can be used.

[0119] Figure 1 is a photograph of dried foam laminates as described in Example 2, Sample 4. The foam was applied between two sheets of Kraft paper, #40, having an 8”, 6”, and 4” squares.

[0120] Figure 2 is a side-view photograph of Example 2, Sample 4.

[0121] Figure 3 is a molded corner brace / protector of Example 2, Sample 4.

[0122] All patents and publications cited herein are incorporated by reference in their entirety. ASTM references are to those versions available at the time of the filing of the application.

Claims

Attorney Docket No.: 2024PF00301WO_stWhat is claimed is:

1. A composition comprising:(a) a foaming agent; and(b) cyanobacteria, microalgae, or a combination thereof.

2. The composition of claim 1, that is dry, such as a powder.

3. The composition of claim 1 or 2, comprising about 4 to about 98 wt% of the cyanobacteria, microalgae, or a combination thereof, or such as about 4 to about 95 wt%, or such as about 15 to about 65 wt%.

4. The composition of any one of the preceding claims, comprising about 1 to about 25 wt% of the foaming agent, or such as about 1 to about 7 wt%.

5. The composition of any one of the preceding claims, further comprising a binder.

6. The composition of claim 5, comprising about 0.1 to about 90 wt% of the binder, or such as about 20 to about 90 wt%.

7. The composition of any one of the preceding claims, further comprising one or more additives.

8. The composition of claim 7, comprising about 0.1 to about 35 wt% of the additive, or such as about 0.1 to about 5 wt%.

9. A composition, comprising:(a) cellulose fibers;(b) a foaming agent; and(c) cyanobacteria, microalgae, or a combination thereof.

10. The composition of claim 9, that is dry.

11. The composition of claim 10, comprising about 10 to about 95 wt% of the cellulose fibers, or such as about 20 to about 90 wt%.

12. The composition of claim 10 or 11, comprising about 2 to about 80 wt% of the cyanobacteria, microalgae, or a combination thereof, or such as about 2 to about 80 wt%, or such as about 10 to about 60 wt%.Attorney Docket No.: 2024PF00301WO_st13. The composition of any one of claims 10-12, comprising about 1 to about 10 wt% of the foaming agent, or such as about 2 to about 7 wt%.

14. The composition of any one of claims 10-13, further comprising a binder.

15. The composition of claim 14, comprising about 0.1 to about 75 wt% of the binder, or such as about 0.1 to about 60 wt%.

16. The composition of any one of claims 10-15, further comprising one or more additives.

17. The composition of claim 16, comprising about 0.1 to about 30 wt% of the additive, or such as about 0.1 to about 10 wt%.

18. The composition of any one of claims 9-17, comprising less than 20 wt% of water, such as less than about 10 wt% of water, or such as about less than 5 wt% of water, or such as about less than about 1 wt% of water, or about 0 wt% of water.

19. The composition of one of claims 18, having a density of about 30 to about 300 kg / m3, or such as about 50 to 150 kg / m3.

20. The composition of claim 19, comprising a compressive strength as measured in accordance with ASTM D3575 that is at least 100% higher than a reference composition lacking the cyanobacteria, microalgae, or a combination thereof, wherein the density of the composition is the same or substantially the same as the density of the reference composition.

21. The composition of claim 19 or 20, comprising: about 25 to about 70 wt% of cellulose fibers; about 2 to about 50 wt% of cyanobacteria, microalgae, or a combination thereof; about 1 to about 10 wt% of foaming agent; less than 20 wt% of water; about 0 to about 60 wt% of binder; and about 0 to about 10 wt% of additives.

22. A composition, comprising:(a) cellulose fibers;Attorney Docket No.: 2024PF00301WO_st(b) a foaming agent;(c) water; and(e) cyanobacteria, microalgae, or a combination thereof.

23. The composition of claim 22, comprising about 0.1 to about 25 wt% of the cyanobacteria, microalgae, or a combination thereof, or such as about 1 to about 15 wt% of the cyanobacteria, microalgae, or a combination thereof.

24. The composition of claim 22 or 23, comprising about 5 to about 25 wt% of cellulose fibers, or such as about 10 to about 20 wt% of cellulose fibers.

25. The composition of any one of claims 22-24, comprising about 0.1 to about 5 wt% of the foaming agent, or such as about 0.75 to about 2 wt% of the foaming agent.

26. The composition of any one of claims 22-25, further comprising a binder.

27. The composition of claim 26, comprising about 0.1 to about 35 wt% of the binder, or such as about 0.1 to about 15 wt% of the binder, or about 5 to about 15 wt% of the binder.

28. The composition of any one of claims 22-27, further comprising one or more additives.

29. The composition of claim 28, comprising about 0.1 to about 20 wt% of the additive, or such as about 0.1 to about 5 wt% of the additive.

30. The composition of any one of claims 22-29, comprising greater than or equal to 20 wt% of water, or such as about 30 to about 90 wt% of water, or such as about 50 to about 75 wt% of water.

31. The composition of any one of claims 22-30, comprising: about 5 to about 25 wt% of cellulose fibers; about 0.1 to about 20 wt% of cyanobacteria, microalgae, or a combination thereof; about 0.1 to about 5 wt% of foaming agent; about 30 to about 90 wt% of water; about 0 to about 35 wt% of binder; and about 0 to about 20 wt% of additives.Attorney Docket No.: 2024PF00301WO_st32. The composition of any one of claims 22-31, further comprising air.

33. The composition of claim 32, comprising at least about 30 vol% of air, such as about 30 to about 100 vol%, or such as about 65 to about 95 vol% of air.

34. The composition of any one of the preceding claims, wherein the cyanobacteria and microalgae are photosynthetic.

35. The composition of any one of the preceding claims, comprising cyanobacteria.

36. The composition of any one of the preceding claims, wherein the cyanobacteria is Anabaena. Aphanizomenon flos-aquae, Arthrospira (A. platensis, A. fusiformis, or A. maxima), Chroococcus, Cyanophyceae, Fat choy, Gloeocapsa, Lyngbya, Microcystis, Oscillatoria, Phormidium, Prochlorococcus, Synechococcus, Nostoc, Spirulina, Suizenji nori platensis, Synechocystis sp. PCC 6803, or Trichodesmium, or a combination thereof.

37. The composition of claim 36, wherein the cyanobacteria is Spirulina, such as Spirulina abbreviate, Spirulina agilis, Spirulina agilissima, Spirulina albida, Spirulina ardissoni, Spirulina baltica, Spirulina bayannurensis, Spirulina breviarticulata, Spirulina cabrerae, Spirulina caldaria, Spirulina cavanillesiana, Spirulina condensate, Spirulina corakiana, Spirulina flavovirens, Spirulina funiformis, Spirulina gessneri, Spirulina gomontiana, Spirulina gomontii, Spirulina gordiana, Spirulina gracilis, Spirulina innatans, Spirulina labyrinthiformis, Spirulina laxa, Spirulina laxissima, Spirulina legitima, Spirulina magnifica, Spirulina major, Spirulina margaritae, Spirulina mariae, Spirulina massartii, Spirulina maxima, Spirulina miniate, Spirulina minima, Spirulina mukdensis, Spirulina nodosa, Spirulina nordstedtii, Spirulina okensis, Spirulina oscillarioides, Spirulina platensis, Spirulina princeps, Spirulina pseudotenuissima, Spirulina robusta, Spirulina rosea, Spirulina schroederi, Spirulina sigmoidea, Spirulina socialis, Spirulina spirulinoides, Spirulina subsalsa, Spirulina subtilissima, Spirulina super salsa, Spirulina tenerrima, Spirulina tenuior, Spirulina tenuis, Spirulina tenuissima, Spirulina thermalis, Spirulina turfosa, Spirulina versicolor, Spirulina weissii, or Spirulina spp.

38. The composition of any one of the preceding claims, comprising microalgae.Attorney Docket No.: 2024PF00301WO_st39. The composition of claim 38, wherein the microalgae is Chlorella, Haematococcus, Dunaliella, Pediastrum, Phaeodactylum tricornutum, Nostoc commune, Aphanizomenon flosaquae, Porphyridium sp, Isochrysis, Pavlova spp, Nannochloropsis sp, Chaetoceros sp, Schizotrichium, or Ulkenia spp.

40. The composition of claim 39, wherein the microalgae is Chlorella, such as Chlorella autotrophica, Chlorella colonials, Chlorella lewinii, Chlorella minutissima, Chlorella pituita, Chlorella pulchelloides, Chlorella pyrenoidosa, Chlorella regularis, Chlorella rotunda, Chlorella saccharophila, Chlorella singularis, Chlorella sorokiniana, Chlorella variabilis, Chlorella volutis, or Chlorella vulgaris, or such as Chlorella pyrenoidosa, or such as Chlorella vulgaris.

41. The composition of any one of claims 9-40, wherein the cellulose fibers comprise softwood virgin fibers, hardwood virgin fibers, recycled softwood virgin fibers, recycled hardwood virgin fibers, or any combination thereof, or such as kraft pulp fibers.

42. The composition of any one of the preceding claims, wherein the foaming agent is a surfactant, such as an anionic surfactant, a cationic surfactant, an amphoteric surfactant, or a combination thereof.

43. The composition of claim 42, wherein the surfactant is cetostearyl alcohol, coamidopropyl betaine (CAPB), disodium dihydrogen ethylene diaminetetraacetate, dodecyldimethylamine oxide, ethanolamine, glyceryl laurate, hexadecyl palmitate, lauryl dimethylamine oxide (LDAO), polysorbate, sodium dodecyl sulfate, sorbitol, starch, stearyl alcohol, sucrose, sulfosuccinate e.g., sodium dioctyl sulfosuccinate), or a combination thereof.

44. The composition of any one of claims 5-8, 14-21, or 26-43, wherein the binder is starch (e.g., cooked or raw), polyvinyl alcohol, polyvinyl acetate, polylactic acid, an ethylene-vinyl alcohol copolymer, a polyvinyl acetate, an ethylene vinyl acetate acrylic, a dextrin, or a combination thereof.

45. The composition of claim 44, wherein the starch is a non-gelatinized starch such as non-gelatinized potato starch, non-gelatinized wheat starch, non-gelatinized comAttorney Docket No.: 2024PF00301WO_st starch, non-gelatinized tapioca starch, non-gelatinized rice starch, or a combination thereof.

46. The composition of any one of claims 7-8, 16-21, or 28-45, wherein the additive is an adhesion promoter (e.g. EGDA, PEI), anti-fungal agent, biocide, calcium carbonate, clay, crosslinker, defoamer, dye (e.g., UV dye), expanded microsphere, humectant, pigment, plasticizer, preservative, microencapsulated chemical, nanocellulose, nanocrystalline cellulose, phase-change material, polyether compound, rheology modifier, salt, starch, tackifier, unexpanded microsphere, or wax, or a combination thereof.

47. A process for preparing a foamed composition, comprising incorporating air into the composition of any one of claims 22-46 to provide a wet foam.

48. The process of claim 47, further comprising partially removing water to form a partially dried foam.

49. The process of claim 47, further comprising removing water to form a dry foam.

50. The process of claims 47-48, wherein removing water is performed using heating, such as dielectric heating, convection heating, infrared heating, conventional heating, air impingement heating, microwave heating, or a combination thereof.

51. The process of any one of claims 47-50, further comprising applying the wet foam into a mold or onto one or more substrates before removing water to form the dry foam or partially dried foam.

52. The process of claim 51, wherein the one or more substrates is a cellulosic substrate, a metal substrate, a plastic substrate, or a combination thereof.

53. The process of claim 51, wherein the one or more substrates is, independently, paper (e.g., recyclable, recycled, or recyclable and coated), a corrugate, a polymer film (e.g., compostable, biodegradable, polyester, polypropylene, polyethylene), a biobased film, cellophane, a metalized film, a recyclable metal vapor deposited paper, or a combination thereof.Attorney Docket No.: 2024PF00301WO_st54. The process of any one of claims 51-53, further comprising laminating the foamed composition and / or the one or more substrates.

55. The process of any one of claims 51-54, further comprising molding the foamed composition and / or the one or more substrates.

56. The process of any one of claims 51-55, further comprising folding the foamed composition and / or the one or more substrates.

57. A foamed composition prepared according to the process of any one of claims 47-50.

58. An article comprising a composition of any one of claims 9-46, wherein the article is in the form of a folded form (e.g., envelope), pouch, bag, box, carton, case, lid, wrap, clamshell, cup, flat sheet (e.g., flat thermally insulating sheet, flat sheet with scored markings for later folding, an embossed sheet with patterns or a sheet of an initial thickness when applied wet but with various thickness levels after forming with pressure), molded three-dimensional package element (e.g., a comer brace), folded package element, or food container with adhesive.

59. The article of claim 58, that is in the form of a support element, such as support element that protects a fragile object such as an electronic or food.

60. The article of claim 58 or 59, that is compostable, recyclable, and / or renewable.

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