Paperboard product and process

A sheet material for use in the manufacture of shoe insoles having a forepart portion and heel seat and shank portion, said sheet material having at least two opposing edges, said material being a laminated paperboard product comprising:

• a first and a second ply, each ply comprising a first wet laid layer formed from a slurried mixture of polyolefin fibers and long fiber softwood pulp, the quantity of polyolefin fiber being less than the quantity of wood pulp fiber and a second wet laid layer formed from a slurried mixture of polyolefin fibers and long fiber softwood pulp, the quantity of polyolefin fiber being greater than the quantity of wood pulp;
• said plies being arranged in partial overlapping relationship with the high polyolefin layers providing surface contact and being bonded together by melting the polyolefin of the wet laid layers so that they merge and flow into the fiber matrix of the adjacent layer and compressing the plies, wherein the first ply is narrow in relation to the second ply so that in the region of overlap, the plies are more compressed whereby to provide a die-cuttable sheet material in which the physical characteristics of rigidity and flexibility are different in the areas provided by the two plies than those provided by only one ply.

A sheet material for use in the manufacture of shoe insoles having a forepart portion and a heel seat and shank portion, comprising:

• a first and a second ply, each ply comprising a first wet laid layer formed from a slurried mixture of polyolefin fibers and long fiber softwood pulp, the quantity of polyolefin fiber being less than the quantity of wood pulp fiber (the low polyolefin layer) and a second wet laid layer formed from a slurried mixture of polyolefin fibers and long fiber softwood pulp, the quantity of polyolefin fiber being greater than the quantity of wood pulp (the high polyolefin layer);
• the plies being arranged in overlapping relationship with the high polyolefin layers thereof in surface contact and being bonded together by compressing the plies and melting the polyolefin of the layers so that they merge and flow into the fiber matrix of adjacent layers thus forming face and obverse sides of the material.

A laminated paperboard product comprising:

• a first and a second ply, each ply comprising a first wet laid layer formed from a slurried mixture of polyolefin fibers and long fiber softwood pulp, the quantity of polyolefin fiber being less than the quantity of wood pulp fiber in the mixture, and a second wet laid layer formed from a slurried mixture of a polyolefin fiber and a long fiber softwood pulp, the quantity of polyolefin fiber being greater than the quantity of wood pulp (the high polyolefin layer);
• the plies being arranged in overlapping relationship with the high polyolefin layers thereof in surface contact with each other and being bonded together by compressing the plies and melting the polyolefin of the layers so that they merge and flow into the fiber matrix of abutting layers, thus forming face and obverse sides of the product.