A repulpable insulated container assembly having a container formed of paper such as corrugated cardboard or varying paper materials and defining an interior; and a repulpable insert placed within the interior of the container and formed of a first paper layer; and a paper fiber pad coupled to the first paper layer.

A method of forming a shipping container includes mixing paper fibers with a binder fiber to form a mixture; disposing the mixture onto a surface to form a layer of the mixture; applying heat to form a paper fiber batt from the mixture having a fixed width and fixed length; and inserting the paper fiber batt within an interior of a corrugated box.

A method of producing inorganic-particle-combined fiber includes: a beating step including beating chemical fiber in a wet manner or a dry manner; and a composite fiber forming step including forming inorganic-particle-combined fiber which is composite fiber composed of the chemical fiber and inorganic particles, the composite fiber forming step including synthesizing the inorganic particles in a slurry that contains the chemical fiber after the beating step.

A method of producing inorganic-particle-combined fiber includes: a beating step including beating chemical fiber in a wet manner or a dry manner; and a composite fiber forming step including forming inorganic-particle-combined fiber which is composite fiber composed of the chemical fiber and inorganic particles, the composite fiber forming step including synthesizing the inorganic particles in a slurry that contains the chemical fiber after the beating step.

Described herein is a filter paper for the production of an aqueous extract, comprising softwood pulp, which has the following properties: a basis weight of more than 9.0 g/m.sup.2 and less than 13.5 g/m.sup.2, a density of more than 280 kg/m.sup.3 and less than 350 kg/m.sup.3, a roughness of more than 700 ml/min and less than 1300 ml/min, a bending resistance in the machine direction of more than 50 mN and less than 75 mN, and an air permeability of more than 17000 cm/(min.Math.kPa) and less than 26000 cm/(min.Math.kPa), wherein the filter paper is either free from abacá fibers and sisal fibers or, if abacá fibers and/or sisal fibers are present, taken together they make up less than 20% of the paper mass.

A method and system for producing an insulated mailer and an insulated box having an insulative paper fiber pad substructure with a density of less than about 10 pounds per cubic foot. The insulative paper fiber pad has entangled reinforcement fibers. A method of forming an insulative paper fiber pad using recycling-compatible or water soluble adhesive and paper layers is provided.

An aqueous coating material for synthetic papers includes 26 wt % to 75 wt % of an acrylic emulsion, 2 wt % to 10 wt % of hollow latex microspheres and 26 wt % to 70 wt % of an inorganic ink-absorbing material. Each of the hollow latex microspheres has a particle size between 500 nm and 1100 nm, and includes a hollow core, a buffering layer covering the hollow core, and a shell covering the buffering layer. The aqueous coating material can be applied onto a surface of a synthetic paper substrate and formed into a surface coating layer.

Methods for forming multi-layer substrates including top and bottom surface layers and a melt softened thermoplastic material layer between the exterior surface layers, where the thermoplastic material includes polyethylene or has a tan delta value of 0.2 to 0.4 within the temperature range of 100 F.-350 F. The 3 (or more) layers are assembled, and heated, melt softening the thermoplastic material, causing bonding of the thermoplastic layer to the exterior surface layers. A cleaning composition may be loaded onto the multi-layer substrate, where a fluid pathway through the melted thermoplastic material allows the cleaning composition to travel between the surface layers. Adhesion between the surface layers and the thermoplastic layer is provided by the thermoplastic material itself, which bonds to groups of fibers in the surface layers. The process does not require chemical adhesives, any processing water, drying, or the like, so as to be possible with low capital investment.

Methods for forming multi-layer substrates including top and bottom surface layers and a melt softened thermoplastic material layer between the exterior surface layers, where the thermoplastic material includes polyethylene or has a tan delta value of 0.2 to 0.4 within the temperature range of 100 F.-350 F. The 3 (or more) layers are assembled, and heated, melt softening the thermoplastic material, causing bonding of the thermoplastic layer to the exterior surface layers. A cleaning composition may be loaded onto the multi-layer substrate, where a fluid pathway through the melted thermoplastic material allows the cleaning composition to travel between the surface layers. Adhesion between the surface layers and the thermoplastic layer is provided by the thermoplastic material itself, which bonds to groups of fibers in the surface layers. The process does not require chemical adhesives, any processing water, drying, or the like, so as to be possible with low capital investment.

An enhanced, co-formed fibrous web structure is disclosed. The web structure may have a co-formed core layer sandwiched between two scrim layers. The core layer may be formed of a blend of cellulose pulp fibers and melt spun filaments. The scrim layers may be formed of melt spun filaments. Filaments of one or both of the scrim layers, and optionally the core layer, may also be meltblown filaments. The core layer may include consolidated masses of cellulose pulp fibers to, for example, enhance texture and cleaning efficacy of a wet wipe made from the structure. The material forming the consolidated masses may be selected and/or processed so as to cause the masses to have reduced visual discernibility relative the surrounding areas of the structure, when the fibrous web structure is wetted. A method for forming the structure, including formation and inclusion of the consolidated masses, is also disclosed.