Plant-Based Fibrous Product For Thermoforming
A fibrous product for use in a variety of applications. The fibrous product particularly well suited for use in thermoforming 3-D articles such as food packaging, automotive parts, and electronic packaging. The fibrous product can be biodegradable, recyclable, and compostable. The fibrous product can contain a first plant fiber that is a non-wood fiber.
1 . A fibrous product for forming thermoformed articles comprising:
a plant-based fibrous composition comprising a first plant fiber,
wherein the first plant fiber is a non-wood fiber, wherein the first plant fiber has an average fiber length less than about 0.75 mm; and
the plant-based fibrous composition further comprising a binder, wherein the binder is a natural polymer; wherein the binder is present in the plant-based fibrous composition in an amount less than that about 3% by weight.
2 . The fibrous product of claim 1 , wherein the first plant fiber comprises secondary plant fibers.
3 . The fibrous product of claim 1 , wherein the first plant fiber comprises canola fibers.
4 . The fibrous product of claim 1 , wherein the first plant fiber is derived from chemically refined stalk.
5 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a basis weight from about 50 gsm to about 1000 gsm.
6 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a tear index from about 3 mN m 2 /g to about 6 mN m 2 /g.
7 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a freeness from about 250 mICSF to about 750 mICSF.
8 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a tensile index from about 10 N m/g to about 60 N m/g.
9 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a burst index from about 0.3 kPa m 2 /g to about 3.3 kPa m 2 /g.
10 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a tensile energy absorption from about 2 J/m 2 to about 60 J/m 2.
11 . The fibrous product of claim 1 , wherein the plant-based fibrous composition has a bulk from about 1.5 cm 3 /g to about 3.5 cm 3 /g.
12 . The fibrous product of claim 1 , wherein the first plant fiber has a diameter from about 5 μm to about 50 μm.
13 . The fibrous product of claim 1 , wherein the plant-based fibrous composition further comprises a second plant fiber.
14 . The fibrous product of claim 13 , wherein the second plant fiber comprises flax fiber, hemp fiber, kenaf fiber, ramie fiber, jute fiber, or a combination thereof.
15 . The fibrous product of claim 13 , wherein the first plant fiber has an average fiber length that is shorter than the average fiber length of the second plant fiber.
16 . The fibrous product of claim 1 , wherein the natural polymer comprises any one of a starch, a starch derivative, a cellulose derivative, alginate, guar gum, a polysaccharide, lignin, natural rubber, polylactic acid, or mixtures thereof.
17 . The fibrous product of claim 1 , wherein the fibrous product is 3-dimensional.
18 . A process for producing a fibrous product comprising:
introducing a first plant fiber in a tank containing a liquid medium, wherein the liquid medium comprises sodium hydroxide;
cooking the first plant fiber, wherein the cooking occurs under atmospheric conditions;
a first washing of the first plant fiber, wherein the first washing increases the solids content of the first plant fiber to a range from about 15% to about 45%;
a first refining the first plant fiber;
screening the first plant fiber; and
a second washing of the first plant fiber.
19 . The process of claim 18 , wherein the first plant fiber is a non-wood fiber.
20 . The process of claim 19 , wherein the non-wood fiber is canola fiber.
21 . The process of claim 18 , wherein the second washing of the first plant fiber can increase the freeness of the first plant fiber by about 150% to about 400% when compared to the freeness of the first plant fiber after the screening of the first plant fiber.