Container insulation including a batt comprised of large paper particles, at least 90% of which by weight are greater than 10 mm in diameter. Less than 5% by weight binder fibers are used, which have a length of at least 20 mm. Most preferably, no binder fibers are used. Where the batts are faced with paper, the paper is coated with a biodegradable coating. The resulting product is repulpable and recyclable in accordance with Fiber Box Association (FBA) testing protocols.

Contoured articles formed in a mold from a fiber slurry are provided. The articles comprise a blend of cellulose fibers and cellulose ester, such as cellulose ester staple fibers. The articles are suitable in a wide array of end uses, including as cups, lids, boxes or pouches, storage containers, trays, plates, food trays, cutlery, coffee cups, coffee cup lid, packaging, bowls, clam shells, bottle caps, straws, covers, and packaging inserts.

Contoured articles formed in a mold from a fiber slurry are provided. The articles comprise a blend of cellulose fibers and cellulose ester, such as cellulose ester staple fibers. The articles are suitable in a wide array of end uses, including as cups, lids, boxes or pouches, storage containers, trays, plates, food trays, cutlery, coffee cups, coffee cup lid, packaging, bowls, clam shells, bottle caps, straws, covers, and packaging inserts.

A bottle for holding liquids that is biodegradable and that is made from environmentally sustainable materials. The bottle includes a body, a shoulder, a neck portion, and a cap. According to one aspect, the neck portion of the bottle is made of bioplastic, and the shoulder and body of the bottle are made from thermoformed pulp. The bioplastic neck can mate with, and be adhered to, the shoulder, and the shoulder can mate with, and be adhered to, the pulp body.

The invention is directed to a process to prepare a three-dimensional shaped biodegradable pulp product by (b) pressing a 3D product made of biodegradable pulp which product is coated with a water-resistant compound having a melting temperature of above 40 C. in a mould at a temperature above the melting temperature of the water-resistant compound, and (c) releasing the product from the mould and reducing the temperature to below the melting temperature of the water-resistant compound.

The invention is directed to a process to prepare a three-dimensional shaped biodegradable pulp product by (b) pressing a 3D product made of biodegradable pulp which product is coated with a water-resistant compound having a melting temperature of above 40 C. in a mould at a temperature above the melting temperature of the water-resistant compound, and (c) releasing the product from the mould and reducing the temperature to below the melting temperature of the water-resistant compound.

An apparatus for fabricating three-dimensional paper-molded products with zero-draft angles is disclosed herein, which comprises at least one conveying rail and at least three sets of mold assemblies for sequentially applying a pre-compression, a first thermo-compression and a second thermo-compression on each semi-finished product. The at least three sets of mold assemblies are collocated, in ascending order of their transversally cross-sectional concave widths, along the at least one conveying rail. By gradually compressing the semi-finished product in sequence of compression operations of the at least three sets of mold assemblies, a specific transversally cross-sectional width of the semi-finished product are gradually and transversally widened to finalize a formation of a three-dimensional paper-molded product having zero-draft angles, thereby enhancing a structural strength of the entire product, shortening its manufacturing time and saving its manufacturing cost.

An apparatus for fabricating three-dimensional paper-molded products with zero-draft angles is disclosed herein, which comprises at least one conveying rail and at least three sets of mold assemblies for sequentially applying a pre-compression, a first thermo-compression and a second thermo-compression on each semi-finished product. The at least three sets of mold assemblies are collocated, in ascending order of their transversally cross-sectional concave widths, along the at least one conveying rail. By gradually compressing the semi-finished product in sequence of compression operations of the at least three sets of mold assemblies, a specific transversally cross-sectional width of the semi-finished product are gradually and transversally widened to finalize a formation of a three-dimensional paper-molded product having zero-draft angles, thereby enhancing a structural strength of the entire product, shortening its manufacturing time and saving its manufacturing cost.

The present description relates to in-plane isotropic products derived from cellulosic filament based compositions that are substantially free of binders; and comprising inorganic fillers with an average particle size of less than 5 m; and methods for producing these in-plane isotropic products. The method comprising providing a cellulosic filament substantially free of any binder; providing an inorganic filler comprising an average particle size of less than 5 m; mixing the cellulosic filament and the filler to produce a slurry; transferring the slurry in a preforming jig to produce a wet mat in the jig; and hot press compression molding the mat to produce the in-plane isotropic product. The inorganic fillers were uniquely shown substantially useful to accelerate the final dewatering (drying) in the hot press at 150 C./250 psi and to eliminate delamination issue insitu the molded products. Furthermore, the hot press molded products were remarkably improved with respect to the surface quality and the dimensional stability with outstanding increase in its tensile, flexural and impact properties, all with respect to the cellulosic filament inorganic filler-free molded products.

The invention relates to a process for producing a thermoformable and/or embossable particle/polymer composite using a substrate S based on shredded polymer-coated paper and a thermoplastic polymer P, therewith providing a new method of recycling/upcycling paper waste. Furthermore, a process for the manufacturing of a molded article obtained from the paper-based particle/polymer composite and its use as an element in buildings or in furniture are disclosed.