Cell wall loading of never-dried pulp fibers

Claim 2

A process for the production of filled pulp fiber comprising: immersing a never-dried pulp having an internal cell wall pore volume while remaining wet after pulping in a first solution wherein the first solution comprises a soluble salt or salts, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water; reimmersing the never-dried pulp in a second solution wherein the second solution comprises a soluble salt or salts different from the soluble salt or salts of the first solution, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water, and with the proviso that the interaction of the salt or salts from the first solution and the salt or salts from the second solution form an insoluble precipitate that acts as a filler within the cell wall of the never-dried pulp; and filtering and washing the filled never-dried pulp to form the filled pulp fiber.

Claim 3

The process of claim 1, further comprising drying the filled pulp fiber after the filtering and washing step.

Claim 4

The process of claim 1 wherein the never-dried pulp is derived from hardwoods, softwoods, annual plants, or combinations thereof.

Claim 5

The process of claim 1 wherein the insoluble precipitate is selected from the group consisting of CaCO 3 , AlPO 4 , Zn(NH 4 )PO 4 , CaHPO 4 , Ca(H 2 PO 4 ) 2 , Mg(NH 4 )PO 4 , Ca(BO 2 ) 2 , BiPO 4 , MgCO 3 , Zr(HPO 4 ) 2 , ZrO(H 2 PO 4 ), Al(OH) 3 , Bi(OH) 3 , Zn(OH) 2 , Ti(OH) 4 , Zr(OH) 4 , CaSiO 3 , BaSO 4 , BaSiF 6 , Ba(OH) 2 , Ba 3 (PO 4 ) 2 , Ba 2 P 4 O 7 , BaSiO 3 , BaCO 3 , BiO 2 CO 3 , CdCO 3 , Ca(BO 2 ) 2 .6H 2 O, Ca(OH) 2 , Ca 3 (PO 4 ) 2 , Ca 2 P 2 O 7 .5H 2 O, CaSO 4 , PbCO 3 , Mg(BO 2 ) 2 .8H 2 O, Mg(OH) 2 , Mg 3 (PO 4 ) 2 , SrCo 3 , SrSiO 3 , SrSiO 4 , Th(OH) 4 , ZnCO 3 , Zn 3 (PO 4 ) 2 .4H 2 O, ZnSiO 3 , Fe 4 [Fe(CN) 6 ] 3 , Fe 3 [Fe(CN) 6 ] 2 , Cu 3 (PO 4 ) 2 , Cu(OH) 2 , CuCO 3 Cu(OH) 2 , CrPO 4 .6H 2 O, Hg 2 I 2 , HgI 2 , AgCrO 4 , BiI 2 , BiI 3 , CoCO 3 , Co 3 (PO 4 ) 2 .8H 2 O, Co[Fe(CN) 6 ] 2 , Cu 3 Fe(CN) 6 .2H 2 O, SnI 2 , Co 3 (PO 4 ) 2 , Mn(NH 4 )PO 4 , Co 3 (PO 4 ) 2 .2H 2 O, MnCO 3 , CdS, CdMoO 4 , BaCrO 4 , Sb 2 S 3 , CaCrO 4 .2H 2 O, Cu 3 [Fe(CN) 6 ] 2 .14H 2 O, PbCrO 4 , PbI 2 , Hg 2 CO 3 , Mo(PO 3 ) 6 , AgI, Ag 3 PO 4 , SnS 2 , Cr 4 (P 2 O 7 ) 3 , Cu(BO 2 ) 2 , CuCO 3 Cu(OH) 2 , Ni(PO 4 ) 2 .8H 2 O, NiCO 3 , CrPO 4 , CuS, and combinations thereof.

Claim 6

The process of claim 1 wherein the insoluble precipitate is calcium carbonate.

Claim 7

The process of claim 1 wherein the insoluble precipitate is calcium sulfate.

Claim 8

The process of claim 1 wherein the insoluble precipitate is calcium silicate.

Claim 9

The process of claim 1 wherein the insoluble precipitate is calcium phosphate.

Claim 10

A process for the production of filled paper wherein the starting pulp is a never-dried pulp having an internal cell wall pore volume while remaining wet after pulping, comprising: immersing the never-dried pulp is a first solution wherein the first solution comprises a soluble salt or salts, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water; filtering the never-dried pulp from the first solution; reimmersing the never-dried pulp in a second solution wherein the second solution comprises a soluble salt or salts different from the soluble salt or salts of the first solution, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water, and with the proviso that the interaction of the salt or salts from the first solution and the salt or salts from the second solution from an insoluble precipitate that acts as a filler within the cell wall of the never-dried pulp; filtering and washing the filled, never-dried pulp to form a filled pulp; and forming paper with the filled pulp.

Claim 11

A process for the production of filled paper wherein the starting pulp is a never-dried pulp having an internal cell wall pore volume while remaining wet after pulping, comprising: immersing the never-dried pulp is a first solution wherein the first solution comprises a soluble salt or salts, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water; filtering the never-dried pulp from the first solution; reimmersing the never-dried pulp in a second solution wherein the second solution comprises a soluble salt or salts different from the soluble salt or salts of the first solution, and wherein the internal cell wall pore volume of the never-dried pulp has not been substantially lost by collapse of the pores due to loss of water, and with the proviso that the interaction of the salt or salts from the first solution and the salt or salts from the second solution from an insoluble precipitate that acts as a filler within the cell wall of the never-dried pulp; filtering and washing the filled, never-dried pulp to form a filled pulp; and forming paper with the filled pulp.

Claim 12

The process of claim 9 wherein the never-dried pulp is derived from hardwoods, softwoods, annual plants, or combinations thereof.

Claim 13

The process of claim 9 wherein the insoluble precipitate is selected from the group consisting of CaCO 3 , AlPO 4 , Zn(NH 4 )PO 4 , CaHPO 4 , Ca(H 2 PO 4 ) 2 , Mg(NH 4 )PO 4 , Ca(BO 2 ) 2 , BiPO 4 , MgCO 3 , Zr(HPO 4 ) 2 , ZrO(H 2 PO 4 ), AL(OH) 3 , Bi(OH) 3 , Zn(OH) 2 , Ti(OH) 4 , Zr(OH) 4 , CaSiO 3 , BaSO 4 , BaSiF 6 , Ba(OH) 2 , Ba 3 (PO 4 ) 2 , Ba 2 P 4 O 7 , BaSiO 3 , BaCO 3 , BiO 2 CO 3 , CdCO 3 , Ca(BO 2 ) 2 .6H 2 O, Ca(OH) 2 , Ca 3 (PO 4 ) 2 , Ca 2 P 2 O 7 .5H 2 O, CaSO 4 , PbCO 3 , Mg(BO 2 ) 2 .8H 2 O, Mg(OH) 2 , Mg 3 (PO 4 ) 2 , SrCO 3 , SrSiO 3 , SrSiO 4 , Th(OH) 4 , ZnCO 3 , Zn(PO 4 ) 2 .4H 2 O, ZnSiO 3 , Fe 4 [Fe(Cn) 6 ] 3 , Fe 3 [Fe(Cn) 6 ] 2 , Cu 3 (PO 4 ) 2 , Cu(OH) 2 , CuCO 3 Cu(OH) 2 , CrPO 4 .6H 2 O, Hg 2 I 2 , HgI 2 , AgCrO 4 , BiI 2 , BiI 3 , CoCO 3 , CO 3 (PO 4 ) 2 .8H 2 O, Co[Fe(CN) 6 ] 2 , Cu 3 Fe(CN) 6 .2H 2 O, SnI 2 , Co 3 (PO 4 ) 2 , Mn(NH 4 )PO 4 , Co 3 (PO 4 ) 2 .2H 2 O, MnCo 3 , CdS, CdMoO 4 , BaCrO 4 , Sb 2 S 3 , CaCrO 4 .2H 2 O, Cu 3 [Fe(Cn) 6 ] 2 .14H 2 O, PbCrO 4 , PbI 2 , Hg 2 CO 3 , Mo(PO 3 ) 6 , AgI, Ag 3 PO 4 , SnS 2 , Cr 4 (P 2 O 7 ) 3 , Cu(BO 2 ) 2 , CuCO 3 Cu(OH) 2 , Ni(PO 4 ) 2 .8H 2 O, NiCO 3 , CrPO 4 , CuS, and combinations thereof.

Claim 14

The process of claim 9 wherein the insoluble precipitate is calcium carbonate.

Claim 15

The process of claim 9 wherein the insoluble precipitate is calcium sulfate.

Claim 16

The process of claim 9 wherein the insoluble precipitate is calcium silicate.

Claim 17

The process of claim 9 wherein the insoluble precipitate is calcium phosphate.