A tissue paper product is provided having at least one ultra-low density ply having a highly porous, open-celled structure and that comprises cellulosic fibers, a water insoluble binder and a foaming surfactant. The cellulosic fiber comprises greater than 50% by weight of the ply and are bonded to one another by hydrogen bonding. Further, the ply has a density less than about 0.04 g/cc and yet still provides low lint and high strength properties with the use of minimal binder. The ultra-low density ply may comprise or be included in sheets forming a stack of dispensable wipers or may be employed as or part of an absorbent core or liquid distribution layer of a personal care absorbent personal care product such as a diaper or feminine pad.

A tissue paper product is provided having at least one ultra-low density ply having a highly porous, open-celled structure and that comprises cellulosic fibers, a water insoluble binder and a foaming surfactant. The cellulosic fiber comprises greater than 50% by weight of the ply and are bonded to one another by hydrogen bonding. Further, the ply has a density less than about 0.04 g/cc and yet still provides low lint and high strength properties with the use of minimal binder. The ultra-low density ply may comprise or be included in sheets forming a stack of dispensable wipers or may be employed as or part of an absorbent core or liquid distribution layer of a personal care absorbent personal care product such as a diaper or feminine pad.

The disclosure is directed to methods of manufacturing protective packaging materials, as well as the protective packaging materials produced using the disclosed methods. These packaging materials can be biodegradable, compostable, and/or recyclable.

Multi-ply paper products and methods for manufacturing such products are provided. A method includes producing a foam of water, air, a foaming agent, uncooked starch, and a dry strength agent; applying the foam to a first surface of a base embryonic ply web; providing an applied embryonic ply web having a first surface and contacting the first surface of the base web with the first surface of the applied web at an interface to form a combined ply web; and selectively applying vacuum pressure to a second surface of the base web to retain particles of the uncooked starch on or near the first surface, to draw molecules of the dry strength agent into the base web and/or to the first surface of the applied web to retain particles of the uncooked starch in the interface and to draw molecules of the dry strength agent into the applied web.

By constructing packaging or cushioning components with a cellulose-fiber foam and uniquely blending relatively longer fibers serving as mechanical structure with refined chemical fibers serving as a bonding mechanism for the relatively longer fibers together, a lower density, energy absorbing, and resilient cellulose-fiber foam is disclosed. Some cellulose-fiber foam components additional do not require stand-alone foaming agent or surfactant.

A system comprising a pulper configured to (i) accept surfactant, a liquid and fiber stock and (ii) generate a foam that suspends the fiber stock, wherein the foam has a half-life; a headbox configured to receive the foam-suspended fiber stock from the pulper and displace the foam-suspended fiber stock onto a forming wire, wherein a time it takes the foam-suspended fiber stock to move from the pulper to the headbox is less than the half-life; and a foam return device that removes at least some of the foam from the forming wire and returns the at least some of the foam to the pulper.

The present invention relates to a method for manufacturing a multilayer film comprising highly refined cellulose fibers, the method comprising the steps of: a) forming a first wet web by applying a first pulp suspension comprising highly refined cellulose fibers on a first wire; b) partially dewatering the first wet web to obtain a first partially dewatered web; c) forming a second wet web y applying a foamed second pulp suspension comprising highly refined cellulose fibers and a foaming agent on a second wire; d) partially dewatering the foamed second wet web to obtain a second partially dewatered web; e) joining the first and second partially dewatered web to obtain a multilayer web; and f) further dewatering, and optionally drying, the multilayer web to obtain a multilayer film comprising highly refined cellulose fibers.

A composite sheet and a method for producing a decorative sheet using the composite sheet are provided. The composite sheet has a base layer and a foamable layer bonded to the base layer. The foamable layer includes 100 parts by weight of a polyolefin material having an elastic modulus of <0.1 GPa, 0.1 - 10 parts by weight of a foaming agent, and 0 - 200 parts by weight of additives. The foamable layer has a thickness of 0.05 to 0.3 mm.

A composite sheet and a method for producing a decorative sheet using the composite sheet are provided. The composite sheet has a base layer and a foamable layer bonded to the base layer. The foamable layer includes 100 parts by weight of a polyolefin material having an elastic modulus of <0.1 GPa, 0.1 - 10 parts by weight of a foaming agent, and 0 - 200 parts by weight of additives. The foamable layer has a thickness of 0.05 to 0.3 mm.

The invention relates to a method of manufacturing a new low density foam-formed cellulose material comprising dialcohol-modified celllulose, and to bulk sheets, layers, laminates or moulded articles comprising such material. Furthermore, the invention relates to a laminated packaging material comprising a layer or sheet comprising the low density cellulose material as well as to packaging containers comprising the laminated packaging material. In particular, the invention relates to packaging containers intended for liquid or semi-liquid food packaging, comprising the laminated packaging material.