US 20140352903A1

(19) United States

(12) Patent Application Publication (10) Pub. No.: US 2014/0352903A1
Ernegg (43) Pub. Date: Dec. 4, 2014
(54) CELLULOSE FIBRE COMPOSITION (30) Foreign Application Priority Data
(75) Inventor: Martin Charles Ernegg, Mullumbimby Oct. 26, 2010 (AU) ----- --------- -- --- ------ --- ---- 2010904775

(AU) Publication Classification

(51) Int. Cl.

(73) Assignee: ZEO IP PTY LTD, Mullumbimby, New D2 IIH II/4 (2006.01)
South Wales (AU) (52) U.S. C.
CPC ..................................... D2 IH II/14 (2013.01)
(21) Appl. No.: 13/881,408 USPC ........... 162/149; 162/100: 162/162; 162/158:
(22) PCT Filed: Oct. 26, 2011 162/159
(57) ABSTRACT
(86). PCT No.: PCT/AU2O11?0O1360
A cellulosic composition comprising fibres having a length
S371 (c)(1), weighted average fibre length (“LWAFL) of 0.25 to 0.40
(2), (4) Date: Jul. 8, 2014 .
Patent Application Publication Dec. 4, 2014 Sheet 1 of 9 US 2014/0352903A1

Water Retention Value

Centrifuge
cup or shield

Fife'
Sample in
centrifuge tube
TAPPI Useful Method UM 256
Figure 1

(a) (b)

(a) (b)
Patent Application Publication Dec. 4, 2014 Sheet 2 of 9 US 2014/0352903A1

(a) (b)
Patent Application Publication Dec. 4, 2014 Sheet 3 of 9 US 2014/0352903A1

(a) (b)

(a) (b)
Patent Application Publication Dec. 4, 2014 Sheet 4 of 9 US 2014/0352903A1

Distribution of fibre lengths Sample A

8,8 - - - - - -

so
4.3 :

Illin. * * * 8 & 3 x : $ $8
x : : - - -
Patent Application Publication Dec. 4, 2014 Sheet 5 of 9 US 2014/0352903A1

Distribution of fibre lengths Sample B

7.3

s
Q> | - - - - -- - - - - - - - -. . .. .

r
Hill.
a- - - -r:
S$ 3 : S. 3' s s: : s s: , ;
is is..... wasaka.

Length of fibre (mm)

s

3 :

2. 8s 3.8 .38 33 8,
P
Cy
r
A.r &8

Length of fibre (mm)

Figure 9
Patent Application Publication Dec. 4, 2014 Sheet 6 of 9 US 2014/0352903A1

Distribution of fibre lengths Sample C

s>
2t 2.8

2rD 3.
|III ar is is is .......
: s , S: , s 3 - ? 8° S : y : * * :
Length of fibre (mm)

&

3.
- ?
Š
Z.
r
P
Cy
r : :

88:

Length Of fibre (mm)

Figure 10
Patent Application Publication Dec. 4, 2014 Sheet 7 of 9 US 2014/0352903A1

Distribution of fibre lengths sample D

s> W
O
Z.
Cy s
r

--------------rr-r Illiluli.
& *s as $ 3 S $ & $
Length of fibre (mm)

&

s
O
Z.
Cy
2

338 fi 88: 8,33 3.3s 87 & 8: 8,38 8.8

Length of fibre (mm)

Figure 11
Patent Application Publication Dec. 4, 2014 Sheet 8 of 9 US 2014/0352903A1

Distribution O fibre lengths Sample E

s>
Q
Z.
-
t
Cy
r
A.
r s

W v lin.
is 3 & y & 8 s: s 2 & 3 S S & 8 :
Length of fibre (mm)

D
Q
Z.
-
r :

Sr

, 8, 8,88 3,33 s 88. 8.7 8. 3.3S .

Length of fibre (mm)

Figure 12
Patent Application Publication Dec. 4, 2014 Sheet 9 of 9 US 2014/0352903A1

Distribution of fibre lengths Sample F

S k 3 && K.3 S.8.

&3 s :- SY3 sN. S.& &x
:
SY s&: s &
Length of fibre (mm)

s
s
>
tr
Cy ; :
r
A.
r
; :8
8 . -
8.8

Length of fibre (mm)

Figure 13
US 2014/0352903A1
CELLULOSE FIBRE COMPOSITION
TECHNICAL FIELD
0001. The disclosure relates to cellulosic compositions
that are useful as structural building components for objects
including, but not limited to, buildings, furniture, car parts,
coffins, cabinets & cases, electronic housing, structural build
ing pillars, beams, boards, sheets, Veneers, chairs, musical
instruments, and toys.
BACKGROUND
0002 Large amounts of waste generated in the pulp and
paper processing industry are typically disposed to landfill.
Disposal to landfill, however, is becoming increasingly prob
lematic due to the environmental constraints associated with
land availability and land/soil contamination. As such, there
is significant pressure to reduce the amount of waste disposed
to landfill, one means of reduction being recycling.
0003 Recycling of paper and textile materials requires the
breakdown of such materials into fibres or fibre-like material
which may then be reformed into material to provide paper
and paper-like products. As an alternative to reforming into
material to provide paper and paper-like products, a recycling
process has previously been developed for producing moul
ded pieces out of cellulose fibres in which the specific gravity
of the moulded pieces approaches that of pure cellulose, 1.5.
The process involves finely chopping and grinding cellulose
fibres in the presence of water into micro-fibres prior to form
ing a fibre-water mixture in which the cellulose fibre content
is about 1-15% by weight. The process subsequently involves
shaping and drying the mixture of cellulose fibres and water
into the moulded pieces. Details of the process and the moul
ded pieces produced by the process are set out in U.S. Pat. No.
6,379,594.
0004 Efforts have continued in the production of cellulo
sic based compositions derived from pulp and paper process
ing waste and plant fibres which have high load bearing
capacities and the ability for use as structural components.
SUMMARY
0005. The disclosure provides a cellulosic composition
comprising fibres having a length weighted average fibre
length (“LWAFL) of 0.25 to 0.40 mm.
0006 Preferably, 0.28 to 0.38 mm.
0007. The disclosure also provides a cellulosic composi
tion comprising, by weight:
0008 (a) 15% to 25% fibres of a length weighted aver
age fibre length of 0.001 mm to 0.2 mm:
0009 (b) 40% to 60% fibres of a length weighted aver
age fibre length of 0.2 mm to 0.5 mm;
0010 (c) 8% to 35% fibres of a length weighted average
fibre length of 0.5 mm to 1.2 and
0011 (d) less than 3% fibres of a length weighted aver
age fibre length of 1.2 mm to 2.0 mm.
0012. The length weighted average fibre length
(“LWAFL) provides a measure of the average length of the
fibres in a sample of fibres which is weighted by the length of
the individual fibres. The LWAFL gives emphasis to the
longer fibers in the sample and imparts less emphasis to the
shorter fibers and fines. The LWFAFL is sometimes referred
to as just the weighted average fibre length or “WAFL. The
LWAFL can be compared to other measures of the average
length of the fibres in a sample such as the arithmetic or
Dec. 4, 2014
numerical average (AFL) and the weight weighted average
fiber length (WWAFL). These averages are obtained through
the following calculations:
AFL = =
X (if n.)
LWAFL= St.
X(f-n,)
WWAFL– (l. n.)
where
0013 x=bin it
0014 1-bin median length
00.15 n=bin fiber count
0016 N=total number of fibers counted
0017 Preferably, the composition has a Water Retention
Value (WRV) of 600% to 2000%, more preferably, 700% to
1300%.
(0018. The water retention value (WRV) is defined as the
amount of water that participates in the swelling of the fibrous
material and that which is not released under the application
of a centrifugal force. The WRV is also highly correlated to
the bonding ability of kraft fibers. The test to determine the
WRV is carried out by placing a pad of moist fibers in a
centrifuge tube that has a fritted glass filter at its base. The
centrifuge is accelerated at 3000 g for 15 minutes to remove
water from the outside surfaces and lumens of the fiber. The
remaining water is believed to be associated with submicro
scopic pores within the cell wall. The centrifuged fibers are
weighed, dried at 105°C., and then reweighed. The WRV can
then be calculated from the ratio of the water mass to the dry
mass. The apparatus used to measure the WRV is shown
schematically in FIG. 1.
0019. In an embodiment, the composition comprises, by
weight:
0020 (a) 15% to 25% fibres of a length weighted aver
age fibre length of 0.001 mm to 0.2 mm:
0021 (b) 45% to 55% fibres of an a length weighted
average fibre length of 0.2 mm to 0.5 mm;
0022 (c) 20% to about 30% fibres of a length weighted
average fibre length of 0.5 mm to 1.2 mm and
0023 (d) less than 1% fibres of a length weighted aver
age fibre length of 1.2 mm to 2.0 mm.
0024. The cellulosic composition may be in a wet or dry
State.
0025. In an embodiment, the cellulosic composition are
dried in the form of pellets, granules or powders. In the dry
state, the cellulosic composition may be conveniently stored
and transported.
0026. The dry pellets, granules or powders may be mixed
with water to form mouldable, fine pulps that may be dried to
create materials for use as structural components.
0027. The mouldable, fine pulps may be moulded using
any Suitable method including, but not limited to, spray mold
ing, injection molding, extrusion or three stage molding. The
moulded or green articles may be subsequently dried to form
a product
0028. The density of the product produced from a compo
sition according to the disclosure may be from 0.5 g/cm3 to
US 2014/0352903A1
1.5 g/cm3. The tensile modulus of the product may be from
3500 MPa to 10800 MPa and the tensile strength may be from
27 MPa to 115 MPa.
0029 Whilst functional additives (such as dyes and pig
ments for colouring, resins and waxes for waterproofing,
lime, fire retardants including natron silicate, glues, metal
powders and graphites for electrical conductivity, latex for
flex and waterproofing, fillers and very long fibres of 1.5-6.0
mm in length for increased tensile strength) may be added to
the pulp of dry cellulosic powders/granules/pellets mixed
with water, there is no need for the addition of any functional
additives or the application of pressure to dry and harden the
pulp.
0030. In an embodiment, the composition may be pre
pared by any one or combination of processing methods
including, but not limited to, ultra friction grinding, high
pressure homogenizing, cryo grinding, extrusion, Steam
explosion, ultra Sonic treatment, enzyme-fibre separation,
high consistency/medium consistency/low consistency refin
ing, chemical treatment or whitewater fines recovery.
0031 Components of the composition may be prepared
separately and mixed together. In an embodiment, two or
more intermediary compositions with different fibre length
distributions may be prepared and mixed in the required pro
portions to form the compositions defined above.
0032 Various raw materials may be used in the prepara
tion of the compositions as described herein, including, but
not limited to, short/ultra short cellulose fibres/fines recov
ered from waste streams, for example, recovered paper,
recovered fines in whitewater from paper & pulp processing
and recovered cotton fibers. Additional raw materials may
also include any cellulosic fibers used in pulp & paper pro
cessing and various plant fibers having a high cellulosic con
tent, for example, hemp, flax, cotton, abaca, sisal and jute.
0033. The disclosure also provides a product made from a
composition as described herein.
BRIEF DESCRIPTION OF THE FIGURES
0034 Embodiments will now be described, with reference
to the accompanying Figures, in which:
0035 FIG. 1 is a schematic view of an apparatus for mea
suring the Water Retention Value (WRV) of fibre samples:
0036 FIGS. 2-6 depict Norval Wilson stained microscope
images of wet pulp compositions derived from wastepaper a
the scales indicated;
0037 FIG. 7 depicts Norval Wilson stained microscope
images of wet pulp compositions derived from hemp cellu
lose at the scales indicated; and
0038 FIGS. 8-13 are graphs of the fibre length distribu
tions for the wet pulp compositions shown in FIGS. 2-7.
DETAILED DESCRIPTION OF THE
EMBODIMENTS
0039 Embodiments provide cellulosic composition made
up of fibres having different specific lengths, a high degree of
fibrillation and a high water retention capacity. These com
position may be subsequently moulded and dried to produce
finished wood-like or horn-like articles of high strength and
which therefore can be used as load bearing products.
0040. The composition comprise fibres having a length
weighted average fibre length (“LWAFL) of 0.25 to 0.40
mm, preferably 0.28 to 0.38 mm. The fibre lengths in the
Dec. 4, 2014
composition are distributed in a skewed bell curve, with the
composition comprising, by weight:
0041 (a) 15% to 25% fibres of a length weighted aver
age fibre length of 0.001 mm to 0.2 mm:
(0.042 (b) 40% to 60% (preferably 45% to 55%) fibres of
a length weighted average fibre length of 0.2 mm to 0.5
(0.043 (c) 8% to 35% (preferably 20% to 30%) fibres of
a length weighted average fibre length of 0.5 mm to 1.2
and
0044) (d) less than 3% (preferably less than 1%) fibres
of a length weighted average fibre length of 1.2 mm to
2.0 mm.
0045 Thus the composition consists of a significant
amount of fines (fibre length <0.2 mm) mixed with short
length fibres (fibre length of 0.2-1.2 mm).
0046 Additionally, the composition has a high degree of
fibrillation indicated by a high Water Retention Value (WRV)
of 600-2000%, preferably, 700-1300%.
0047. The composition is prepared by any one or combi
nation of processing methods including, but not limited to,
ultra friction grinding, high pressure homogenizing, cryo
grinding, extrusion, steam explosion, ultra Sonic treatment,
enzyme-fibre separation, high consistency/medium consis
tency/low consistency refining, chemical treatment or white
water fines recovery.
0048 Components of the composition may be prepared
separately and mixed together. In some embodiments, two or
more intermediary compositions with different fibre length
distributions are prepared and mixed in the required propor
tions to form the composition.
0049 Various raw materials may be used in the prepara
tion of the composition, including, but not limited to, short/
ultra short cellulose fibres/fines recovered from waste
streams, for example, recovered paper, recovered fines in
whitewater from paper & pulp processing and recovered cot
ton fibers. Additional raw materials may also include any
cellulosic fibers used in pulp & paper processing and various
plant fibers having a high cellulosic content, for example,
hemp, flax, cotton, abaca, sisal and jute.
0050. The composition may be dried for transport and/or
storage in the form of pellets, granules or powders. From
these forms, the compositions may be re-wetted to form
moldable, fine pulps. Alternatively, the compositions may be
prepared as a pulp and used directly in a molding process. The
compositions as a pulp may be moulded by any moulding
operations known to persons skilled in the art, for example,
spray molding, injection molding, extrusion or three stage
molding. The moulded or green articles may be Subsequently
dried to form a product.
0051) Advantageously, the composition can be used to
create a material with appropriate hardness, strength and duc
tility to be used as a structural material yet remains (as a wet
pulp) capable of being readily handled during processing and
manufacture of articles from the composition, including very
large articles. Furthermore, the composition does not require
excessive energy to produce and is therefore economically
viable.
0.052 Accordingly when molded and dried, the composi
tion can be used to create structural and industrial compo
nents such as coffins, electronic housings, structural building
pillars, beams, boards, sheets, Veneers, boxes, chairs, cabi
nets, cases and other furniture, car parts and toys.
US 2014/0352903A1 Dec. 4, 2014

0053. It will be appreciated that due to a variation in the TABLE 1

compositions of the raw materials in terms of for example,
lignin content, ash content, OH bonding capacity and degree Fibre length
of entanglement/fibrillation, as well as the choices of fibre Length Weighted Mass Weighted
processing parameters, the physical properties of the final Arithmetic Average Fibre Average Fibre
product produced from the composition will vary. For Fibre Length Length Length
example, the density may vary from 0.5 to 1.5 g/cm3, the (mm) (mm) (mm)
tensile modulus may vary from 3500 to 10800 MPa and the Sample (AFL) (LWAFL) (WWAFL)
tensile strength may vary from 27 to 115 MPa. A. O.25 0.37 O.47
B 0.27 O4O O.S4
EXAMPLES C O.26 O.39 O.49
D O.30 0.44 0.55
E O.25 O.36 O46
Fibre Furnish and Degree of Fibrillation F O.20 O.29 O41

0054 Five samples (A to E) based on waste paper,

RCW80 de-inked recovered waste paper from Amcor, and 0059. The results in Table 1 show that all samples (Ato F)
one sample (F) based on hemp cellulose, Hempcell B from contain extremely shortened fibres. The arithmetic average of
Celesa in Spain, were Subjected to grinding in a high consis
tency 22" refiner. The fibre (solids) content in the pulp was 16 the measured fibre lengths is skewed somewhat by the pres
wt % and the flow rate of pulp through the refiner was ence of fines (<0.2 mm). This can be mathematically cor
approximately 200 L/min. The specific energy (the amount of rected (reduced), by weighting the lengths and masses, i.e. by
energy transferred from the refiner's motor to the fibre) input referring to the LFAFL or WWAFL.
was for each of the Samples: 0060. In practice the length weighted average fibre length
(LFAFL) is typically used for the comparison offibrous mate
Sample A 1.8 kWh/kg rials with one another. From the values of the LFAFL for all
Sample B 1.8 kWh/kg Samples in Table 1, it can be seen that similar values are
Sample C 1.8 kWh/kg obtained for all Samples based on wastepaper (A to E) with a
Sample D 1.6 kWh/kg slightly shorter value for the Sample based on hemp cellulose
Sample E 2.0 kWh/kg
Sample F 1.9 kWh/kg (F).
0061. The results shown in Table 2 below are an evaluation
0055. The specific edge load (the amount of energy of the distribution of fibre lengths within certain length
applied across one meter of refiner plate's bar edge and trans ranges. The majority offibres of all six Samples (Ato F) after
ferred to the pulp in one second) was between 4-8 WS/m at the processing are 0.2-0.5 mm, which is considered to be the
beginning of the refining process and this load was gradually short fibre or fibre fragment range. This is also shown graphi
reduced to between 1-4 WS/m by the end of the process. cally in FIGS. 8-13. Each of these Figures (for respective
0056. The fibres were processed until the spread of the samples) contains two graphs. The top graph in each of FIGS.
average fibre length matched a known “bell curve'. From 8-13 shows the distribution of fibres having lengths of <0.06
experience and knowing the process inputs, this occurs after mm whilst the lower graph in each of these Figures shows the
a certain time period of processing. However, the fibres may distribution of fibres having lengths of >0.1 mm.
be sampled to confirm that they have this distribution of fibre
lengths. TABLE 2
0057. A light microscope and a Norval Wilson stain was Distribution of fibre lengths (length weighted
used on the prepared slides containing dispersed fibre average length in length ranges) by weight%
samples and images were taken of each sample as depicted in O.OO1-0.2 0.2-0.5 0.5-1.2 1.2-2.O 20-32 3.2-7.6
FIGS. 2 to 7. As can been seen from these Figures, a high l l ill ill ill ill
degree offibrillation is observed for the six samples and most Sample A 22.8% 54.1%. 23.1% 0.1% O.0% O.0%
of the fibres were broken or cut into very small fragments. Sample B 19.3% 51.0%. 29.1% 0.3% O.2% O.1%
Sample C 19.1% 53.1%. 27.8% 0.0% O.0% O.0%
Suspension Properties: Morphological Properties as Well as Sample D 15.2% 48.7%. 35.8% 0.3% O.0% O.0%
Sample E 22.5% SS.6%. 21.8% 0.2% O.0% O.0%
Resistance to Dehydration and Swelling Behaviour Sample F 33.2% 57.29% 9.3% 0.2% O.1% O.0%
0058 0.2 g (dry weight) of each Sample A-F after the
grinding process described above were strongly diluted by The fines content of the ground samples were investigated
pre-suspending in water, stirring, and Subsequently filling
with water to 5000 ml. From this suspension, 25 ml were further by determining the fraction of the fines (fibres <0.2
taken (corresponding to 1.0 mg (dry weight) fibrous material) mm) in each Sample based on the arithmetic average fibre
and photographed. The photographs were Subsequently length (AFL). This fraction for each Sample is compared to
analysed (double determination) using FibreLab 3.0" equip the length weighted fraction offines (as per Table 2) is shown
ment to determine the fibre-morphological properties and in Table 3 below. As can be seen from Table 3, the fines
distribution parameters for the separated and Suspended content of all Samples (A to F) is very high. The hemp
fibres, including the fibre length. The results for fibre length cellulose Sample F, notably contained markedly more fine
are provided in Table 1 below. material than the wastepaper samples (A to E).
US 2014/0352903A1 Dec. 4, 2014

TABLE 3 able, strongly ground celluloses. The higher WRC generally

Fine material contents
equates to a denser material which when moulded and dried
into a final product results in a product which has a lower tear
Fine material (<0.2 mm) Fine material (<0.2 mm) or tensile strength but a higher load bearing capacity and
(arithmetic average) (length weighted average) Young's modulus. A preferred range for Water Retention
Sample % % Capacity is generally between 700 and 1200% as above this
A. 49.4 22.8 range, the low tear strength makes it difficult to form sheets—
B
C
45.0
45.7
19.3
19.1
as was found with Sample C.
D 38.7 15.2
E 47.3 22.5 Material Properties: Physical/Strength Properties
F 57.3 33.2

0.066 Samples A to F were ground as described above and

0062. Further measurements of the diameter, wall thick mixed with water in a mixer to a solids concentration in the
ness and calculated (curvature) parameters using the Fibrelab range between 0.3 and 0.4 wt % (3 to 4 g/L) as per Table 8
equipment show that samples A to E derived from wastepaper below.
have similar values whereas sample F derived from hemp
cellulose has Smaller fibre dimensions and a smaller curva TABLE 8
ture. This result corresponds with the fibre lengths deter
mined as well as with the fibre fragments present. Sample A. B C D E F

TABLE 4
Solids Concentra- wt % 0.367 O.379 0.351 O.379 0.354 0.351
Further fibre data tion in the mixer

Fibre width Fibre wall thickness Fibre curvature

Sample In In %
A. 16.5 3.8 17.9 0067. The objective was to produce test sheets with an
B 16.2 3.8 18.1 average grammage of m of 80+2 g/m, for use in Subsequent
C 16.4 3.8 17.3 strength testing according to the Rapid-Köthen method (in
D 17.0 4.1 19.3
E 17.0 4.0 18.0 accordance with ISO 5269-2). It is noted that due to the very
F 13.9 3.3 16.2 low dehydration capability of all of the Samples, the ISO
5269-2 test specifications had to be adapted by reducing the
volume of filling water in the cylinder and varying the period
Determination of the Water Retention Capacity (WRC) of drop and Suction to Suit the required conditions for sheet
According to Zellcheming Fact Sheet IV/33/57 forming for each of Samples A to F.
0063 All Samples A to F (after grinding described above) 0068. After producing the test sheets for each of the
were homogenised by mixing prior to sampling for determi Samples, the test sheets were acclimatised in Standard climate
nation of their Water Retention Capacity (WRC). conditions (23 C./50% relative air humidity).
0064. The Samples of fibrous material were dehydrated 0069. The grammage of the acclimatised test sheets was
(to a solids content of approximately 25 wt %) on a G2 frit in ten determined according to DIN EN ISO 536. The results of
the absence of a vacuum and transferred to a swell tube the grammage testing are shown in Table 9.
(according to DIN 53814). The swell tube was filled to
approximately two-thirds capacity (resulting in a solids con TABLE 9
tent of approximately 0.150 wt %). The swell tube was sealed
with a plug and subjected to a centrifugal force of 3000 g for Sample Grammage
15 minutes. Six parallel determinations were performed. Sample A. B C D E F
0065. The water not participating in the swelling of the
fibres was removed from the fibrous material by the centrifu Grammage g/m 79.3 81.2 74.4 81.0 78.5 77.6
gation. The Swelling water and the water retention capacity
were gravimetrically determined by drying the fibrous mate
rial at 105° C. until a constant mass solids content was 0070. Due to the characteristics of the materials it was very
achieved. The results are shown in Table 5. difficult to produce test sheets with uniform grammage. This
was especially the case of sample C wherein the targeted
TABLE 5 value (80+2 g/m) could not be realised despite repeated
Water Retention Capacity corrections. This is due to the very high Water Retention
Capacity (WRC) of the Samples. In order to compensate for
Sample A. B C D E F the non-uniformity in grammage between the test sheets, the
Water Reten- % 841 742 1532 774 1138 1052 strength values have been corrected with respect to gram
tion Capacity mage.
0071. The test sheets were subjected to thickness and
The values of the water retention capacity are extremely high apparent sheet density testing, the results of which are shown
and atypical particularly compared to commercially avail in Table 10.
US 2014/0352903A1 Dec. 4, 2014

TABLE 10 to express language or necessary implication, the word "com

prise' or variations such as “comprises' or "comprising is
Sheet thickness and apparent sheet density used in an inclusive sense, i.e. to specify the presence of the
Sample A. B C D E F stated features but not to preclude the presence or addition of
further features in various embodiments.
Thickness In 84 88 78 89 8O 81 0079. It is to be understood that, if any prior art publication
Apparent sheet gicm3 O.94 O.92 O.95 0.91 O.98 0.96
density is referred to herein, such reference does not constitute an
admission that the publication forms part of the common
general knowledge in the art, in Australia or any other coun
0072 By virtue of the high proportion of very short, fine try.
fibres, the thickness at the grammage strived for was Small 1. A cellulosic composition comprising fibres having
and the density very high. This corresponds to the normal length weighted average fibre length (“LWAFL) of 0.25 0.40
behaviour at high packing densities that are achieved with .
very short fibres.
0073. The test sheets were subjected to tensile testing 2. The cellulosic composition as claimed in claim 1, the
according to DIN EN ISO 1924-2, the results of which are composition comprising, by weight:
shown in Table 11 below. (a) 15% to 25% fibres of a length weighted average fibre
0074 The values for breaking force, elongation, breaking length of 0.001 mm to 0.2 mm:
length and Young's modulus determined from this testing are (b) 40% to 60% fibres of a length weighted average fibre
not corrected with respect to the grammage, but are corrected length of 0.2 mm to 0.5 mm;
with respect to the breaking length (represented as the Tensile (c) 8% to 35% fibres of a length weighted average fibre
Index): length of 0.5 mm to 1.2 and
TABLE 11
Tensile test results

Sample A. B C D E F

Breaking force N 81.1 85.5 71.8 84.3 74.5 77.5

Elongation % 3.0 3.0 2.2 3.3 2.3 3.5
Breaking length l 7050 7250 6SOO 7100 6SOO 67OO
Tensile Index Nmig 69.1 71.O 63.7 69.7 63.7 65.9
Young's modulus GPa. 7.85 7.77 7.88 7.48 7.92 7.92

0075. From the results in Table 11, the tensile strength, (d) less than 3% fibres of a length weighted average fibre
expressed as tensile index, corresponds to that of ground length of 1.2 mm to 2.0 mm.
cellulose. Whilst the tensile strength values for the Samples 3. A cellulosic composition comprising, by weight:
differ, there is little variation in the Young's modulus of the (a) 15% to 25% fibres of a length weighted average fibre
Samples which is high. The high Young's modulus of each of length of 0.001 mm to 0.2 mm:
the Samples is indicative that the Samples can withstand (b) 40% to 60% fibres of a length weighted average fibre
tensile loads elastically for long periods of time. Without length of 0.2 mm to 0.5 mm;
wishing to be bound by theory, it is expected that this is due to (c) 8% to 35% fibres of a length weighted average fibre
the high amount offibrillation of the fibres and the subsequent length of 0.5 mm to 1.2 and
linkages between the fibrillated fibres.
0076. The test sheets were cut into strips and subjected to (d) less than 3% fibres of a length weighted average fibre
tear resistance testing according to DIN EN 21974. The length of 1.2 mm to 2.0 mm.
results are shown in Table 12. The resistance to tearing is not 4. The cellulosic composition as claimed in claim 1,
corrected according to the grammage, only according to the wherein the composition has a Water Retention Value (WRV)
tear index. of 600% to 2000%.
TABLE 12
Tear Resistance

Sample A. B C D E

Tear resistance (E) mN 222 28O 181 294 195 215

Tear index Mn m/g 2.67 3.41 2.46 3.62 2.55 2.80

0077. The tearing strength of all samples, measured on 5. The cellulosic composition as claimed in claim 1,
“standard” celluloses, is at a very low level, i.e. the resistance wherein the composition comprises, by weight:
to tear is low. This can be attributed primarily to very short (a) 15% to 25% fibres of a length weighted average fibre
fibres. length of 0.001 mm to 0.2 mm:
0078. In the claim which follows and in the preceding (b) 45% to 55% fibres of an a length weighted average fibre
description, except where the context requires otherwise due length of 0.2 mm to 0.5 mm;
US 2014/0352903A1
(c) 20% to about 30% fibres of a length weighted average
fibre length of 0.5 mm to 1.2 mm and
(d) less than 1% fibres of a length weighted average fibre
length of 1.2 mm to 2.0 mm.
6. The cellulosic composition as claimed in claim 1,
wherein the cellulosic composition is in the form of pellets,
granules or powder.
7. The cellulosic composition as claimed in claim 1,
wherein the composition also comprises one or more func
tional additives.
8. The cellulosic composition as claimed in claim 7.
wherein the functional additives are selected from dyes and
pigments for colouring, resins and waxes for waterproofing,
lime, fire retardants including natron, silicate, glues, metal
powders and graphites for electrical conductivity, latex for
flex and waterproofing, fillers and very long fibres of 1.5-6.0
mm in length for increased tensile strength.
9. The cellulosic composition as claimed in claim 1,
wherein the composition is prepared by any one or combina
tion of processing methods including ultra friction grinding,
high pressure homogenizing, cryo grinding, extrusion, Steam
explosion, ultra Sonic treatment, enzyme-fibre separation,
high consistency/medium consistency/low consistency refin
ing, chemical treatment or Whitewater fines recovery.
Dec. 4, 2014
10. The cellulosic composition as claimed in claim 1,
wherein components of the composition are prepared sepa
rately and mixed together.
11. The cellulosic composition as claimed in claim 10,
wherein two or more intermediary compositions with differ
ent fibre length distributions are prepared and mixed in the
required proportions to form the composition.
12. The cellulosic composition as claimed in claim 1,
wherein the raw material used in the preparation of the com
positions comprises one or more of short/ultra short cellulose
fibres/fines recovered from waste streams, recovered paper,
recovered fines in Whitewater from paper & pulp processing
and recovered cotton fibres, any cellulosic fibres used in pulp
& paper processing and plant fibres having a high cellulosic
content such as hemp, flax, cotton, abaca, sisal and jute.
13. A product made from a composition as claimed in claim
1.
14. The product as claimed in claim 13, wherein the density
of the product is from 0.5 g/cm3 to 1.5 g/cm3.
15. The product as claimed in claim 13, wherein the tensile
modulus of the product is from 3500 MPa to 10800 MPa.
16. The product as claimed in claim 13, wherein the tensile
strength of the product is from 27 MPa to 115 MPa.
k k k k k