The aim of this study was to investigate new materials from organosolv fibers, organosolv lignin, kraft fibers, and their blends. The organosolv fibers showed reprecipitated lignin on the surface, a comparably low fiber length of 0.565 mm on average, and a high fines content of 82.3%. Handsheets were formed and thermopressed at 175 °C and 50 MPa, yielding dense materials (1050-1100 kg/m3) with properties different to that of regular paper products. The thermopressing of organosolv fibers alone produced materials with similar or better tensile strength (σb = 18.6 MPa) and stiffness (E* = 2.8 GPa) to the softwood Kraft reference pulp (σb = 14.8 MPa, E* = 1.8 GPa). The surface morphology was also smoother with fewer cavities. As a result, the thermopressed organosolv fibers exhibited higher hydrophobicity (contact angle > 95°) and had the lowest overall water uptake. Combinations of Kraft fibers with organosolv fibers or organosolv lignin showed reduced wetting and a higher density than the Kraft fibers alone. Furthermore, the addition of organosolv lignin to Kraft fibers greatly improved tensile stiffness and strength (σb = 23.8 MPa, E* = 10.5 GPa), likely due to the lignin acting as a binder to the fiber network. In conclusion, new thermopressed materials were developed and tested, which show promising potential for sustainable fiber materials with improved water resistance.
Keywords: Kraft pulp; added-lignin thermoformed pulps; green materials; molded pulp; organosolv fibers; thermoforming.