WO2024256917A1 - Procédé de fabrication d'un insert d'emballage pour un produit, système de fabrication d'un insert d'emballage pour un produit et insert d'emballage pour un produit - Google Patents

Procédé de fabrication d'un insert d'emballage pour un produit, système de fabrication d'un insert d'emballage pour un produit et insert d'emballage pour un produit Download PDF

Info

Publication number
WO2024256917A1
WO2024256917A1 PCT/IB2024/055480 IB2024055480W WO2024256917A1 WO 2024256917 A1 WO2024256917 A1 WO 2024256917A1 IB 2024055480 W IB2024055480 W IB 2024055480W WO 2024256917 A1 WO2024256917 A1 WO 2024256917A1
Authority
WO
WIPO (PCT)
Prior art keywords
air
unbonded
laid
imprint
laid web
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/IB2024/055480
Other languages
English (en)
Inventor
Julia BROSZAT
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Stora Enso Oyj
Original Assignee
Stora Enso Oyj
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Stora Enso Oyj filed Critical Stora Enso Oyj
Publication of WO2024256917A1 publication Critical patent/WO2024256917A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
    • D04H1/732—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/14—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by a layer differing constitutionally or physically in different parts, e.g. denser near its faces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/107—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using blocks of shock-absorbing material
    • B65D81/113—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using blocks of shock-absorbing material of a shape specially adapted to accommodate contents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/26—Wood pulp
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/025—Containers made of sheet-like material and having a shape to accommodate contents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/05—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/127—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material
    • B65D81/133—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage maintaining contents at spaced relation from package walls, or from other contents using rigid or semi-rigid sheets of shock-absorbing material of a shape specially adapted to accommodate contents, e.g. trays
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W90/00—Enabling technologies or technologies with a potential or indirect contribution to greenhouse gas [GHG] emissions mitigation
    • Y02W90/10—Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics

Definitions

  • a method for producing a packaging insert for a product a system for producing a packaging insert for a product and a packaging insert for a product.
  • the present embodiments generally relate to packaging inserts, and in particular to methods and systems for producing such packaging inserts from unbonded air-laid webs.
  • WO 2022/238484 relates to a dry cellulose forming method for forming a non-flat cellulose product from cellulose fibers.
  • the method comprises separating cellulose fibers from a dry cellulose material in at least one separating unit, providing the separated cellulose fibers onto a support structure for forming a sheet of cellulose fibers, and forming the non-flat cellulose product by pressing the cellulose blank with a molding tool.
  • the sheet of cellulose fibers is imprinted with an imprinted pattern before forming the non-flat cellulose product.
  • WO 2022/043779 discloses an air-laid blank comprising natural fibers and a thermoplastic polymer binder.
  • a portion of the air-laid blank has a density different from an average density of the air-laid blank.
  • the air-laid blank is produced by modifying the air-permeability of a portion of an air-permeable collector to form the portion of the air-laid blank having a density different from the average density.
  • a three- dimensional shaped product suitable for cushioning of packaged goods is produced from the air-laid blank by hot pressing a male tool comprising a protrusion into the air-laid blank so that the protrusion is aligned with the portion of the air-laid blank having a density different from the average density.
  • An aspect of the invention relates to a method of producing a packaging insert for a product.
  • the method comprises introducing natural fibers and a thermoplastic polymer binder into a forming head and capturing the natural fibers and the thermoplastic polymer binder as an unbonded air-laid web on an air- permeable conveyor arranged in connection with an outlet of the forming head.
  • the method also comprises generating at least one imprint in the unbonded air-laid web and heating the unbonded air-laid web to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form a bonded air-laid blank conserving the at least one imprint.
  • the method further comprises cutting the bonded airlaid blank following heating or cutting the unbonded air-laid web prior to heating to form a packaging insert comprising an imprint configured to accommodate at least a portion of the product.
  • the system comprises a forming head comprising at least one inlet configured to receive natural fibers and a thermoplastic polymer binder and an outlet.
  • the system also comprises an air-permeable conveyor arranged in connection with the outlet to capture the natural fibers and the thermoplastic polymer binder as an unbonded air-laid web.
  • the system further comprises an imprinting device arranged to generate at least one imprint in the unbonded air-laid web.
  • the system additionally comprises a heating device arranged to heat the unbonded air-laid web to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form a bonded air-laid blank conserving the at least one imprint.
  • the system also comprises a cutting device arranged to cut the bonded air-laid blank downstream of the heating device or cut the unbonded air-laid web upstream of the heating device to form a packaging insert comprising an imprint configured to accommodate at least a portion of the product.
  • a further aspect of the invention relates to a packaging insert for a product.
  • the packaging insert is made from a cut bonded air-laid blank formed by heating an unbonded air-laid web comprising a mixture of natural fibers and a thermoplastic polymer binder and at least one imprint .
  • the packaging insert comprises an imprint configured to accommodate at least a portion of the product. The imprint is conserved during heating the unbonded air-laid web.
  • the present invention relates to packaging inserts produced from unbonded air-laid webs.
  • the packaging inserts are highly suitable for cushioning of packaged products providing excellent shock absorbing and damping properties.
  • the unbonded air-laid webs and thereby the packaging inserts produced therefrom comprise one or more imprints conserved in the air-laid material during the production process.
  • the imprint(s) are designed to house or accommodate at least a portion of the products to be packaged in the packaging inserts.
  • the packaging inserts thereby provide excellent shock absorbing and damping protection and also thermal insulation for the packaged products.
  • Fig. 1 A is a perspective view of an unbonded air-laid web according to an embodiment
  • Fig. 1 B is a cross-sectional view of a portion of the unbonded air-laid web in Fig. 1 A;
  • Fig. 2 is a perspective view of a bonded air-laid blank according to an embodiment
  • Fig. 3A is a perspective view of a packaging insert according to an embodiment
  • Fig. 3B is a perspective view of a packaging insert according to an embodiment and a product to be at least partly accommodated in the imprint of the packaging insert
  • Fig. 3C is a perspective view of a packaging insert according to an embodiment and a product partly accommodated in the imprint of the packaging insert;
  • Fig. 4 is packaging box comprising a packaging insert according to an embodiment
  • Fig. 5 is a flow chart illustrating a method of producing a packaging insert according to an embodiment
  • Fig. 6 is a flow chart illustrating an embodiment of generating an imprint in Fig. 5;
  • Fig. 7 is a flow chart illustrating another embodiment of generating an imprint in Fig. 5;
  • Fig. 8 is a flow chart illustrating a further embodiment of generating an imprint in Fig. 5;
  • Fig. 9 is a schematic illustration of a system of producing a packaging insert according to an embodiment
  • Fig. 10 is a schematic illustration of a system of producing a packaging insert according to another embodiment
  • Fig. 11 is an illustration of an imprinting device according to an embodiment.
  • Fig. 12 is an illustration of an imprinting device according to another embodiment.
  • the present embodiments generally relate to packaging inserts, and in particular to methods and systems for producing such packaging inserts from unbonded air-laid webs.
  • Unbonded air-laid webs of the present embodiments are useful for production of packaging inserts, also referred to as packaging inlays or elements in the art, for packaging of products, articles, or goods.
  • packaging inserts can then be used as more environmentally friendly replacements to corresponding packaging inserts made of or from foamed polymers, for instance expanded polystyrene (EPS) or foamed polyurethane (PU).
  • EPS expanded polystyrene
  • PU foamed polyurethane
  • the packaging inserts as produced according to the present invention at least partly maintain properties of the unbonded air-laid webs, from which they are produced, such as the open cell foam structure.
  • the packaging inserts provide excellent shock absorption or damping and/or thermal insulation.
  • the packaging inserts are well designed to protect products packaged in the packaging products from, among others, impacts during transport and storage.
  • the good thermal insulating properties of the packaging inserts further imply that the packaging inserts could be used to protect temperature sensitive or tempered products, such as food or beverages, which should be kept within defined temperature ranges.
  • the packaging inserts are produced to include one or more imprints, also referred to as cavity herein, corresponding to or matching at least a portion of a product to be packaged in the packaging insert.
  • the packaging inserts are designed to at least partly house one or more products in the imprinted portion(s) of the packaging inserts.
  • the product is thereby well protected from shocks or impacts, and also thermally insulated, by being at least partly inserted in the packaging insert due to the presence of at least one imprint.
  • the traditional approach of producing cavities in packaging inserts is to first form a sheet or block of a foam-like material, such as EPS or PU, and then tooling the cavities in the foam-like sheet or block, such as by milling, water jet cutting, die-cutting or computer numerical control (CNC) cutting.
  • CNC computer numerical control
  • the present invention forms cavities in the packaging inserts by generating imprints in the unbonded airlaid web and then conserving the imprints during the production of the packaging inserts from the unbonded air-laid web.
  • the present invention reduces the need for any additional process step in terms of milling or cutting cavities into packaging inserts.
  • An additional benefit of the invention is that no or very little dust is generated during the imprinting step.
  • the resulting packaging product will thereby not contain any loose dust that may contaminate the product to be packaged in the packaging insert or constitute an aesthetic problem.
  • Another advantage of the invention generating imprints in the unbonded air-laid web and conserving the imprints during the production of the packaging inserts is that the outer surface of the packaging insert, including the imprinted surface of the packaging insert, is soft and achieves a high cushioning effect.
  • Such a hot pressing will, due to the application of heat and pressure, at least partly melt the thermoplastic polymer binder in the air-laid web forming a closed plastic-like surface layer on the hot-pressed air-laid blank.
  • Such a surface is generally very smooth but also stiff due to the formation of the plastic-like surface layer.
  • such a hot-pressed surface has more limited cushioning effect as compared to the air-laid web prior to hot-pressing.
  • the present invention therefore relates to a method of producing a packaging insert 30 for a product 50, see Figs. 1A, 1 B, 2, 3A, 3B, 3C, 5, 9-10.
  • the method comprises introducing, in step S1, natural fibers and a thermoplastic polymer binder into a forming head 110.
  • the natural fibers and the thermoplastic polymer binder are captured in step S2 as an unbonded air-laid web 10 on an air-permeable conveyor 120 arranged in connection with an outlet 113 of the forming head 110.
  • the method also comprises generating at least one imprint 15 in the unbonded air-laid web 10 in step S3.
  • the unbonded air-laid web 10 is heated in step S5 to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form a bonded air-laid blank 10 conserving the at least one imprint 25.
  • the method further comprises cutting the bonded air-laid blank 20 following heating in step S6 or cutting the unbonded air-laid web 10 prior to heating in step S4 to form a packaging insert 30 comprising an imprint 35 configured to accommodate at least a portion of the product 50.
  • the present invention thereby produces an unbonded air-laid web 10 from natural fibers and thermoplastic polymer binder.
  • This unbonded air-laid web 10 is typically in the form of a sheet of a mixture of the natural fibers and the thermoplastic polymer binder as captured on the air-permeable conveyor 120.
  • one or multiple, i.e., at least two, imprints 15 are generated in the unbonded air-laid web 10 in step S3.
  • the at least one imprint 15 has a size and shape selected to at least partly match a size and shape of at least a portion of the product 50 to be packaged in the packaging insert 30 produced by the method as shown in Fig. 5.
  • the at least one imprint 15 generated in the unbonded airlaid web 10 in step S3 is conserved through the following processing steps S4 to S6.
  • the bonded air-laid blank 20 formed by heating the unbonded air-laid web 10 in step S5 also comprises at least one imprint 25, see Fig. 2.
  • the packaging insert 30 obtained following the heating step S5 and the cutting step S4 or S6 also comprises at least one imprint 35, see Fig. 3.
  • the unbonded air-laid web 10 comprising a mixture of the natural fibers and the thermoplastic polymer binder and captured on the air-permeable conveyor 120 has excellent properties in terms of conserving imprints 15 generated in the unbonded air-laid web 10. Accordingly, pressing an object into the unbonded air-laid web 10 creates an imprint 15 therein and this imprint 15 is substantially preserved following removal of the object pressed into the unbonded air-laid web 10. This means that an imprint 15 having the general shape of the portion of the object pressed into the unbonded air-laid web 10 and a size equal to or slightly smaller than the size of the portion of the object pressed into the unbonded air-laid web 10 is produced and maintained in the unbonded air-laid web 10.
  • the fiber material in the unbonded air-laid web 10 contributes to resilient or elastic properties of the unbonded airlaid web 10 meaning that the mixture of natural fibers and thermoplastic polymer binder will spring back slightly when the pressed object is removed. Accordingly, although the general shape of the portion of the object pressed into the unbonded air-laid web 10 is preserved in the imprint 15, the imprint 15 may, due to this springing back, have a size that is slightly smaller than the size of the portion of the object pressed into the unbonded air-laid web 10.
  • the at least one imprint 15 generated in the unbonded air-laid web 10 in step S3 is conserved through the heating step S5 and the cutting step S4 or S6.
  • the bonded airlaid blank 20 formed by heating the unbonded air-laid web 10 will thereby also comprise at least one imprint 25 that has been conserved in the heating step S5.
  • the packaging insert 30 obtained by cutting the bonded air-laid blank 20 or by first cutting and then heating the unbonded air-laid web 10 will also comprise an imprint 35 conserved through the production process as shown in Fig. 1.
  • step S3 comprises generating at least one imprint 15 of at least a portion of the product 50 in the unbonded air-laid web 10.
  • step S5 comprises heating the unbonded air-laid web 10 to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form a bonded air-laid blank 10 conserving the at least one imprint 25 of the at least a portion of the product 50.
  • This embodiment also comprises cutting the bonded air-laid blank 20 following heating in step S6 or cutting the unbonded air-laid web 10 prior to heating in step S4 to form a packaging insert 30 comprising an imprint 35 of the least a portion of the product 50.
  • the natural fibers and the thermoplastic polymer binder are introduced in step S1 into a forming head 110, also referred to as forming chamber in the art.
  • the natural fibers and the thermoplastic polymer binder are input or introduced into the forming head 110 as one or more discrete input streams and/or as one or more mixed input streams at one or more inlets 1 11.
  • the forming head 110 may, such as in connection with its upper end 112 or further down in the forming head 110, comprise one stream inlet for the natural fibers and one stream inlet for the thermoplastic polymer binder.
  • the forming head 110 comprises multiple stream inlets for the natural fibers and one stream inlet for the thermoplastic polymer binder, one stream inlet for the natural fibers and multiple stream inlets for the thermoplastic polymer binder or multiple stream inlets for the natural fibers and multiple stream inlets for the thermoplastic polymer binder.
  • the natural fibers and the thermoplastic polymer binder are mixed and blended during the passage through the forming head 110 ultimately forming an unbonded air-laid web 10 on the air-permeable conveyor 120.
  • step S1 in Fig. 5 comprises introducing a mixture of the natural fibers and the thermoplastic polymer binder into at least one inlet 111 of the forming head 110.
  • the forming head 110 may include equipment arranged inside the forming head 110 to promote separation and mixing of the natural fibers and the thermoplastic polymer binder, and/or the mixture thereof during the passage through the forming head 110.
  • equipment may comprise, for instance, rolls with interlocking spikes, one or more drums, such as slit drums, and/or one or more strainers.
  • the natural fibers and the thermoplastic polymer binder and/or the mixture thereof are(is) transported to the forming head 110 by air and enter(s) the forming head 110 in the at least one inlet 111 , such as arranged in connection with the upper end 112 of the forming head 110, or further down in the forming head 110.
  • the natural fibers and the thermoplastic polymer binder and/or the mixture thereof then pass(es) through the forming head 110 to the outlet 113, such as arranged in connection with a lower end 114 of the forming head 110.
  • the natural fibers and the thermoplastic polymer binder and/or the mixture are(is) then captured on the air-permeable collector 120.
  • the natural fibers and the thermoplastic polymer binder and/or the mixture are(is) captured at least partly by a vacuum, i.e. , an air suction or under-pressure, applied across the air-permeable collector 120 that is disposed in connection with the outlet 113 of the forming head 110.
  • a vacuum i.e. , an air suction or under-pressure
  • the method of Fig. 1 may optionally, but preferably, comprise passing the natural fibers and the thermoplastic polymer binder to the outlet 113 of the forming head 110 while applying a gas suction through the air-permeable conveyor 120 in connection with the outlet 113 of the forming head 110.
  • Such a gas suction or vacuum is applied through the air-permeable conveyor 120.
  • the gas suction or vacuum applied across the air-permeable conveyor 120 thus, draws the natural fibers and the thermoplastic polymer binder down onto the air-permeable conveyor 120.
  • the air-permeable conveyor 120 could comprise a plurality of openings, through holes or channels allowing air to be sucked or drawn through the air-permeable conveyor 120.
  • the air- permeable conveyor 120 could be a mesh conveyor, a wire conveyor or a belt conveyor with a belt comprising a plurality of minute through holes.
  • any such openings are preferably small enough to prevent the natural fibers and the thermoplastic polymer binder from passing through the air-permeable conveyor 120.
  • the natural fibers and the thermoplastic polymer binder are instead deposited as a mixture onto the air-permeable conveyor 120 in the form of an unbonded air-laid web 10.
  • the air-permeable conveyor 120 is an endless air-permeable conveyor.
  • the air-permeable conveyor 120 could comprise an endless air-permeable conveyor belt 122 running along driver rollers 124, 126 as shown in Figs. 9-10.
  • An endless air-permeable conveyor belt 122 is an air-permeable conveyor belt 122 that has been made into an endless air-permeable belt 122 without joints.
  • Such an endless air-permeable conveyor belt 122 is also referred to as jointless air-permeable conveyor belt in the art.
  • step S3 in Fig. 5 comprises generating at least one imprint 15 having a maximum extension Ti into the unbonded air-laid web 10 of at least 5 mm.
  • Fig. 1 B is a cross-sectional view of a portion of the unbonded air-laid web 10 showing an imprint 15.
  • the maximum extension Ti of the imprint 15 is indicated in the figure and corresponds to the maximum extension of the imprint 15 from a first main surface 12 of the unbonded air-laid web 10.
  • This maximum extension Ti could be equal to an average extension of the imprint 15 if the imprint 15 has a substantially flat bottom substantially parallel with the first main surface 12 and a second, opposite main surface 14 of the unbonded air-laid web 10.
  • FIG. 1B illustrates another case in which a central portion of the imprint 15 extends deeper into the unbonded airlaid web 10 as compared to a circumferential portion of the imprint 15.
  • the extension of the central portion of the imprint 15 into the unbonded air-laid web 10 is indicated by Ti in Fig. 1 B, whereas the extension of the circumferential or peripheral portion of the imprint 15 is indicated by Tc.
  • the maximum extension of the imprint 15 into the unbonded air-laid web 10 is Ti and the minimum extension of the imprint 15 into the unbonded air-laid web 10 is Tc.
  • the maximum extension Ti of the at least one imprint 15 into the unbonded air-laid web 10 is at least 7.5 mm, preferably at least 10 mm.
  • the maximum extension Ti of the at least one imprint 15 may also, depending on the average thickness T of the unbonded air-laid web 10, be deeper, such as at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, at least 35 or at least 50 mm, or indeed even deeper.
  • the maximum extension Ti of the at least one imprint 15 into the unbonded air-laid web 10 could be up to 90 % of the average thickness T of the unbonded air-laid web 10, such as up to 80%, up to 75 %, up 70 %, up to 65 %, up to 60 %, up to 55 %, or up to 50 % of the average thickness T of the unbonded air-laid web 10.
  • the minimum extension Tc of the at least one imprint 15 into the unbonded air-laid web 10 is at least 2.5 mm, preferably at least 5 mm, and more preferably at least 7.5 mm.
  • the minimum extension Tc of the at least one imprint 15 may also, depending on the average thickness T of the unbonded air-laid web 10, be deeper, such as at least 10 mm, at least 12.5 mm, at least 15 mm, at least
  • the minimum extension Tc in particular when the at least one imprint 15 is flat, the minimum extension Tc will be equal to the maximum extension Ti.
  • the at least one imprint 15 preferably has sufficient depth into the unbonded air-laid web 10 to at least partly accommodate a portion of a product 50 to be packaged. This should be compared to surface patterns that may be imprinted into paper products to provide an aesthetic effect or other property but not designed to package products and provide cushioning and/or insulation to such packaged products.
  • step S3 in Fig. 5 comprises generating at least one imprint 15 having a maximum extension Ti into the unbonded air-laid web 10 so that a difference between an average thickness T of the unbonded air-laid web 10 and the maximum extension Ti is at least 5 mm, preferably at least 7.5 mm and more preferably at least 10 mm. In some embodiments, also larger differences between the average thickness T of the unbonded air-laid web 10 and the maximum extension Ti could be used if particular cushioning effect is desired at the imprinted portion 16.
  • the difference could be at least 12.5 mm, at least 15 mm, at least 17.5 mm, at least 20 mm, at least 22.5 mm, at least 25 mm, at least 27.5 mm, at least 30 mm, at least 32.5 mm or at least 35 mm.
  • the at least one imprint 15 preferably extends into a portion but not the complete thickness T of the unbonded air-laid web 10.
  • the imprinted portion 16 of the unbonded air-laid web 10 thereby has a minimum thickness T of at least 5 mm.
  • Imprinted portion 16 as used herein means the portion of the unbonded air-laid web 10 beneath an imprint 15 when the unbonded air-laid web 10 is positioned on a flat surface with the imprint(s) 15 facing upwards, see Fig. 1 A.
  • a non-imprinted portion 17, see Fig. 1A, of the unbonded air-laid web 10 corresponds to the remaining portion of the unbonded air-laid web 10 excluding the imprinted portion(s) 16.
  • This non-imprinted portion 17 thereby has a thickness T corresponding to the thickness of the unbonded air-laid web 10 as shown in Fig. 1 B.
  • the remaining thickness TA of air-laid material beneath the at least one imprint 15 in the unbonded airlaid web 10 is preferably sufficiently thick to provide cushioning and/or insulation to a product that is at least partly inserted in the corresponding imprint 35 in the packaging insert 30 produced from the unbonded air-laid web 10.
  • This remaining thickness TA is, thus, preferably at least 5 mm and more preferably even thicker, such as at least 7.5 mm or at least 10 mm.
  • thicker remaining thicknesses TA could be used, such as at least 12.5 mm, at least 15 mm, at least 17.5 mm, at least 20 mm, at least 22.5 mm, at least 25 mm, at least 27.5 mm, at least 30 mm, at least 32.5 mm or at least 35 mm.
  • An imprinted portion 16 of the unbonded air-laid web 10 is best seen in Fig. 1 B and corresponds to the portion of the unbonded air-laid web 10 beneath an imprint 15 when the unbonded air-laid web 10 is positioned on a flat surface with the imprint(s) 15 facing upwards.
  • This imprinted portion 16 extends, in the thickness direction, from the second main surface 14 of the unbonded air-laid web 10 up to the imprinted part 12A of the first main surface 12.
  • the imprinted portion 16 comprises the natural fibers and thermoplastic polymer binder material as present between this imprinted part 12A of the first main surface 12 and the second, opposite main surface 14 and has extensions in the width (W) and length (L) direction corresponding to the size and shape of the imprint 15, i.e., width Wi and length Li for the particular imprint 15 as shown in Figs. 1A and 1 B.
  • the unbonded air-laid web 10 is imprinted in step S3 to comprise at least one imprint 15.
  • the unbonded air-laid web 10 could comprise a single such imprint 15 but preferably comprises multiple imprints 15 along its first main surface 12 as indicated in Fig. 1A.
  • the multiple imprints 15 could be distributed in a defined pattern in the first main surface 12, such as in an array or matrix, or indeed in some other defined pattern.
  • each imprint 15 has substantially the same shape and size.
  • the imprints 15 in one of the two columns of imprints 15 preferably have the same shape and size and the imprints 15 in the other of the two columns of imprints 15 preferably have the same shape and size.
  • the imprints 15 in one of the two columns do not necessarily have to have the same shape and/or size as the imprints in the other column.
  • the size and/or shape of the imprints 15 in the respective column may vary. In these examples, it could be possible to produce different types of packaging inserts 30 from the same unbonded air-laid web 10 in terms of producing packaging inserts 30 with differently shaped and/or sized imprints 35 or indeed producing packaging inserts 30 with two or more imprints 35 having different size and/or shape.
  • the unbonded air-laid web 10 has an average thickness T of at least 10 mm, preferably at least 25 mm and more preferably at least 50 mm prior to generating the at least one imprint 15 of the at least a portion of the product 50 in the unbonded air-laid web 10 in step S3.
  • the non-imprinted portion 17 of the unbonded air-laid web 10 has an average thickness T of at least 10 mm, preferably at least 25 mm and more preferably at least 50 mm.
  • unbonded air-laid webs 10 with thicker non-imprinted portions 17 than 50 mm could be produced and used according to the invention, such as having an average thickness of at least 60 mm, at least 70 mm, at least 80 mm, at least 90 mm, at least 100 mm or even thicker.
  • the average thickness of the unbonded air-laid web 10 will define the average thickness of the produced packaging insert 30 and is thereby preferably selected based on a desired thickness of the packaging insert 30, such as depending on the particular product 50 to be packaged in the packaging insert 30 and/or based on the packaging box 40, in which the packaging insert 30 will be inserted as indicated in Fig. 4.
  • Each imprinted portion 16 of the unbonded air-laid web 10 has an average density that is higher than an average density of the non-imprinted portion 17 of the unbonded air-laid web 10. This is schematically illustrated in Fig. 1 B by a higher density of the imprinted portion 16 of the unbonded air-laid web 10 beneath the imprint 15 as compared to the non-imprinted portion 17 outside of imprinted portion 16 (to the left and right of the imprint 15 in Fig. 1 B).
  • the higher average density of the air-laid material in the imprinted portion(s) 16 is due to the imprinting operation in step S3, in which an object is pressed into the unbonded air-laid web 10 causing a compaction of the air-laid material, i.e. , the mixture of natural fibers and thermoplastic polymer binder, in this portion 16 of the unbonded air-laid web 10 as compared to the remaining non-compacted portion 17.
  • each imprinted portion 26 of the bonded air-laid blank 20 will have an average density that is higher than an average density of a non-imprinted portion 27 of the bonded air-laid blank 20, see Fig. 2.
  • an imprinted portion 36 of the packaging insert 30 will have an average density that is higher than an average density of a non-imprinted portion 37 of the packaging insert 30, see Fig. 3.
  • Imprinted portion 26 of the bonded air-laid blank 20 is the portion or part of the bonded air-laid blank 20 that corresponds to an imprinted portion 16 of the unbonded air-laid web 10, from which it is produced.
  • the imprinted portion 26 of the bonded air-laid blank 20 comprises the bonded natural fiber and thermoplastic material in the portion of the bonded air-laid blank 20 beneath an imprint 25 when the bonded air-laid blank 20 is positioned on a flat surface with the imprint(s) 25 facing upwards.
  • an imprinted portion 36 of the packaging insert 30 comprises the bonded natural fiber and thermoplastic material in the portion of the packaging insert 30 beneath an imprint 35 when the packaging insert 30 is positioned on a flat surface with the imprint(s) 35 facing upwards.
  • each imprinted portion 26 of the bonded air-laid blank 20 has an average density of above 30 kg/m 3 , preferably of at least 40 kg/m 3 , more preferably of at least 50 kg/m 3 , and most preferably of at least 60 kg/m 3 , such as selected within an interval of from 60 up to 100 kg/m 3 .
  • the non-imprinted portion 27 of the bonded air-laid blank 20 has an average density of up to 60 kg/m 3 , such as selected within an interval of from 30 up to 60 kg/m 3 .
  • the average density of the imprinted portion(s) 26 is, though, higher than the average density of the non-imprinted portion 27.
  • the ratio between the average density of the imprinted portion 26 of the bonded airlaid blank 20 and the average density of the non-imprinted portion 27 of the bonded air-laid blank 20 is at least 1.1 , preferably at least 1.2, more preferably at least 1.3, and most preferably at least 1.4, such as at least 1.5, at least 1.6, at least 1.7, at least 1.8, at least 1.9 or even higher, such as at least 2.0, or indeed higher such as at least 2.5, at least 3.0, at least 4.0, at least 5.0, at least 6.0, at least 7.0, at least 8.0, at least 9.0, at least 10.0 or indeed even higher.
  • the non-imprinted portion 27 of the bonded air-laid blank 20 thereby has a comparatively low density to thereby provide sufficient cushioning and/or insulation effect to any product 50 to be packaged in the packaging insert 30 produced from the bonded air-laid blank 20.
  • the imprinted portion(s) 26 though, has(have) a higher average density due to the compaction of the air-laid material in this(these) portion(s) in step S3 of Fig. 5. However, as the imprinted portion(s) 26 still has(have) a sufficient thickness as discussed above, also the imprinted portion(s) 26 of the bonded air-laid blank 20 and the corresponding imprinted portion 36 in the packaging insert 30 will protect any packaged products 50.
  • the at least one imprint 15 in the unbonded air-laid web 10 could be generated according to various embodiments.
  • Fig. 6 is a flow chart illustrating such an embodiment of step S3, see also Fig. 11.
  • the method continues from step S2 in Fig. 5.
  • a next step S10 comprises contacting a first main surface 12 of the unbonded air-laid web 10, see Figs. 1A and 1 B, with an imprinting roll 131 comprising at least one protrusion 132, preferably in the form of the at least a portion of the product 50, to generate the at least one imprint 15 in the unbonded air-laid web 10.
  • the method then continues to step S4 or S5 in Fig. 5.
  • one or more so-called imprinting rolls 131 are arranged to imprint the unbonded airlaid web 10 as the unbonded air-laid web 10 is passing the imprinting roll(s) 131 on the air-permeable conveyor 120.
  • the one or more imprinting rolls 131 are then arranged to rotate as the unbonded air-laid web 10 is passing the imprinting roll(s) 131 to thereby press the at least one protrusion 132 into the first main surface 12 of the unbonded air-laid web 10.
  • the unbonded air-laid web 10 is typically in the form of a sheet having a comparatively longer length L and width W as compared to thickness T.
  • the unbonded air-laid web 10 comprises a first main surface 12 and an opposite, second main surface 14.
  • the unbonded air-laid web 10 is transported on the air-permeable conveyor 120 with the second main surface 14 facing the conveyor belt 122 of the air-permeable conveyor 120.
  • the first main surface 12, contacted by the imprinting roll(s) 131 and into which the imprinting roll(s) 131 produce one or more imprints 15, is thereby facing away from the conveyor belt 122.
  • This embodiment of producing the one or more imprints 15 using one or more imprinting rolls 131 typically does not lead to any general compaction or compression of the unbonded air-laid blank 10 outside of the imprints 15.
  • the non-imprinted portion 17 of the unbonded airlaid blank 10 is typically not compressed by the imprinting roll(s) 131.
  • Fig. 7 illustrates a particular embodiment of step S10 in Fig. 6.
  • the unbonded air-laid web 10 is compressed by the imprinting roll 131 in step S11 to thereby generate the at least one imprint 15 in the unbonded air-laid web 10 and compress the unbonded air-laid web 10.
  • the at least one imprinting roll 131 not only produces the at least one imprint 15 in the unbonded air-laid web 10 but also at least partly compresses, i.e., compacts, the unbonded air-laid web 10. This means that the average thickness T of the unbonded air-laid web 10 will typically be reduced by this compressing operation in step S11. Hence, the unbonded air-laid web 10 on the air- permeable conveyor 120 passes one or more imprinting rolls 131 in order to generate the at least one imprint 15 and compress the unbonded air-laid web 10.
  • the imprinting roll(s) 131 is(are) provided with an imprinting pattern of at least one protrusion 132 extending or protruding from the curved or cylinder surface 133 of the imprinting roll(s) 131 for compressing and imprinting the unbonded air-laid web 10.
  • the unbonded air-laid web 10 is thereby imprinted at the same time as the unbonded air-laid web 10 is partially compressed.
  • the dual role of the imprinting roll 131 in this embodiment could be of advantage to produce an unbonded air-laid web 10 comprising at least one imprint 15 and where the unbonded air-laid web 10 has a substantially uniform thickness.
  • the present invention is, however, not limited to using imprinting rolls 131 or combined compression and imprinting rolls for generating the at least one imprint 15 in the unbonded air-laid web 10.
  • any process that generates at least one imprint 15 in the unbonded air-laid web 10 by pressing at least one object into the first main surface 12 of the unbonded air-laid web 10 could be used.
  • An example of such an object is a stamping device 135 as shown in Fig. 12.
  • step S3 of Fig. 5 could be performed as shown in Fig. 8. The method continues from step S2 in Fig. 5.
  • a next step S20 comprises pressing a stamping device 135 comprising at least one protrusion 136, preferably in the form of the at least a portion of the product 50, into the first main surface 12 of the unbonded air-laid web 10 to generate the at least one imprint 15 in the unbonded air-laid web 10.
  • the method then continues to step S4 or S5 in Fig. 5.
  • the stamping device 135 then typically comprise a, typically substantially flat, surface 137, from which one or more protrusions 136 extend or protrude.
  • the stamping device 135 could then be pressed towards the first main surface 12 of the unbonded air-laid web 10 so that the at least one protrusion 136 protrude(s) into the unbonded air-laid web 10 thereby producing one or more imprints 15.
  • the stamping device 135 could be pressed towards the first main surface 12 of the unbonded air-laid web 10 while moving the stamping device 135 in synchrony with movement of the unbonded airlaid web 10 on the air-permeable conveyor 120.
  • the stamping device 135 is preferably pressed towards the first main surface 12 of the unbonded air-laid web 10 as the unbonded air-laid web 10 is moving on the air-permeable conveyor 120.
  • the stamping device 135 is preferably kept with the at least one protrusion 136 pressed into the first main surface 12 for a short period and is thereby moving in synchrony with the unbonded air-laid web 10.
  • the stamping device 135 is then lifted up and moved back to a starting position to thereby be ready for pressing once more into the unbonded air-laid web 10.
  • This means that the stamping device 135 is preferably arranged to be moved not only vertically up and down but also horizontally in synchrony with the unbonded air-laid web 10.
  • Step S5 of Fig. 5 comprises heating the unbonded air-laid web 10 to at least partly melt the thermoplastic polymer binder and form the bonded air-laid blank 20.
  • the heating or heat treatment applied in step S5 performs a bonding operation, in which the unbonded air-laid web 10 is introduced into or otherwise passes a heating device 140, also referred to as a bonding oven, see Figs. 9-10, where heat, such as in the form of heated or hot air, is blown into, sucked into and/or circulated through the unbonded air-laid web 10 to melt or partially melt the thermoplastic polymer binder.
  • the thermoplastic polymer binder thereby becomes tacky and adheres to the natural fibers and, thus, holds the fiber material together and thereby results in a bonded air-laid blank 20.
  • Heating the unbonded air-laid web 10 by blowing and/or sucking hot air into the unbonded air-laid web 10 is a preferred embodiment to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form the bonded air-laid blank 20 comprising the at least one imprint 25.
  • the hot air provided in this embodiment of step S5 not only at least partly melts the thermoplastic polymer binder but also conserves the at least one imprint 15.
  • the formed bonded air-laid blank 20 will comprise at least one imprint 25 corresponding to the at least one imprint 15 in the unbonded air-laid web 10 and thereby conserved during the heating process in step S5.
  • the cutting operation in Fig. 5 could be performed after the heating in step S5, i.e.
  • step S5 by cutting the bonded air-laid blank 20 or before the heating in step S5, i.e., by cutting the unbonded air-laid blank 10.
  • the method as shown in Fig. 5 comprises step S6 but not necessarily step S4.
  • the cutting operation comprises cutting the bonded air-laid blank 20 following heating the unbonded air-laid web 10 to form the packaging insert 30.
  • the method as shown in Fig. 5 comprises step S4 but not necessarily step S6.
  • the cutting operation comprises cutting the unbonded air-laid blank 10 before heating the unbonded air-laid web 10 to form a cut unbonded air-laid web 10.
  • This cut unbonded air-laid web 10 is then heated in step S5 to form the bonded air-laid blank 20 with conserved imprint 25 and thereby also form the packaging insert 30 with conserved imprint 35.
  • the bonded air-laid blank 20 as obtained following heat treatment in step S5 is the packaging insert 30.
  • step S4 it is also possible to combine the cutting operation in step S4 with the cutting operation in step S6.
  • the unbonded air-laid blank 10 is cut in step S4 before heating the unbonded airlaid web 10 to form a cut unbonded air-laid web 10.
  • This cut unbonded air-laid web 10 is then heated in step S5 to form the bonded air-laid blank 20 with conserved imprint(s) 25.
  • the bonded air-laid blank 20 is then cut in step S6 to form the packaging insert 30 with conserved imprint 35.
  • step S4 and/or S6 could be performed using any suitable cutter or cutting device 150.
  • Illustrative, but non-limiting examples, of such cutting device 150 include a saw, a punch, a knife, etc.
  • the cutting in step S4 or S6 divides the (continuous) unbonded air-laid web 10 or the bonded air-laid blank 20 into suitable sizes for the packaging insert 30.
  • the cutting could be across the width of the unbonded air-laid web 10 or the bonded air-laid blank 20 to get, for instance, rectangular or quadratic pieces.
  • the cutting may also be along a portion of the length of the unbonded air-laid web 10 or the bonded air-laid blank 20.
  • an unbonded air-laid web 10 as shown in Fig. 1A and a corresponding bonded air-laid blank 20 as shown in Fig. 2 comprises a matrix of imprints 15, 25 divided into two columns and a plurality of rows.
  • the cutting operation in S4 or S6 or the cutting operations in S4 and S6 could cut the unbonded air-laid web 10 or the bonded air-laid blank 20 to produce packaging inserts 30 as shown in Fig. 3, i.e., comprising a single imprint 35 each.
  • the cutting could first be along the width W of the unbonded air-laid web 10 or the bonded air-laid blank 20 to get a piece comprising two imprints 15, 25 and then along the perpendicular direction, i.e., along the length L in Figs. 1A and 2, to divide the piece into two pieces each comprising a respective imprint 15, 25.
  • first cutting operation and the second cutting operation could both be performed in step S4, both performed in step S6 or the first cutting operation is performed in step S4 and the second cutting operation is performed in step S6. In another embodiment, these two cutting operations are performed simultaneously.
  • the cutting in step S4 and/or S6 is preferably performed while the unbonded air-laid web 10 or the bonded air-laid blank 20 is transported in the production line, e.g., on the air-permeable conveyor 120.
  • the cutting device 150 is moved in synchrony with the unbonded air-laid web 20, see hatched arrow in Fig. 10, or with the bonded air-laid blank 20, see hatched arrow in Fig. 9, during the cutting in step S4 and/or S6.
  • the cutting device 150 is starting the cutting in step S4 and/or S6 from a start position and then moves in synchrony with the unbonded air-laid web 10 or the bonded air-laid blank 20 in the longitudinal direction of the unbonded air-laid web 10 or the bonded air-laid blank 20 until the cutting is completed at a stop position.
  • the cutting device 150 is then preferably transported back to the start position to be ready for a next cutting operation.
  • the air-permeable conveyor 120 could include bend rollers 121 and one or two take-up rollers 123 arranged to divert the air-permeable conveyor belt 122 away from the cutting device 150. This means that the conveyor belt 122 turns away from the cutting device 150 to enable the cutting device 150 to cut through the complete thickness of the unbonded air-laid blank 10 or the bonded air-laid blank 20 without the risk of engaging and damaging the conveyor belt 122.
  • the bend rollers 121 could be in the form of bend pulleys or bend idlers and the take-up roller(s) 123 could be in the form of take-up pulley(s) or take-up idler(s).
  • the cutting device 150 and the bend rollers 121 and take-up roller(s) 123 are preferably movable relative to the air-permeable conveyor 120 to be moved, preferably in synchrony, with the unbonded air-laid web 10 or the bonded air-laid blank 20 transported by the air-permeable conveyor 120.
  • This is schematically illustrated by the hatched arrow in Figs. 9-10. It is also possible to perform the cutting in step S6 off-line, i.e. , not necessarily while the bonded air-laid blank 20 is transported in the production line, e.g., on the air-permeable conveyor 120.
  • the bonded air-laid blank 20 could be rolled up, for instance on a roll, downstream of the heating device 140. The roll could then be transported to another facility or another site at the same facility where the cutting in step S6 is conducted. In such a case, the rolled up bonded air-laid blank 20 is preferably rolled out onto a cutting line, such as a conveyor 120, and cut by the cutting device 150.
  • a cutting line such as a conveyor 120
  • the natural fibers are or comprise wood fibers.
  • the natural fibers are or comprise cellulose and/or lignocellulose fibers.
  • the natural fibers contain cellulose, such as in the form of cellulose and/or lignocellulose, i.e., a mixture of cellulose and lignin.
  • the natural fibers may also contain lignin, such as in the form of lignocellulose.
  • the natural fibers may additionally contain hemicellulose.
  • the natural fibers are cellulose and/or lignocellulose pulp fibers produced by chemical, mechanical and/or chemi-mechanical pulping of softwood and/or hardwood.
  • the cellulose and/or lignocellulose pulp fibers are in a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical fiber intended for medium density fiberboard (MDF-fiber), chemi-thermomechanical pulp (CTMP), high temperature chemi-thermomechanical pulp (HTCTMP), and a combination thereof.
  • the natural fibers such as cellulose and/or lignocellulose pulp fibers, may be bleached or unbleached.
  • the natural fibers can also be produced by other pulping methods and/or from other cellulosic or lignocellulosic raw materials, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw, or rice husk. It is also possible to use natural fibers that are a mixture of fibers from different raw materials, such as a mixture of wood and any of the materials mentioned above.
  • the unbonded air-laid web 10 may also comprise a minor portion of synthetic material or fibers that are mixed with the natural fibers.
  • Such synthetic material or fibers that may be mixed with the natural fibers include, for instance, glass or mineral wool, and/or carbon fibers. Any such synthetic material or fibers may be added at an amount of no more than 10 % (w/w) of the bonded air-laid blank 10, preferably no more than 8 % (w/w), such as no more than 6 % (w/w), or preferably no more than 4 % (w/w) of the bonded air-laid blank 10.
  • the natural fibers have a length weighted average fiber length of up to 10 mm, preferably of up to 8 mm, more preferably of up to 6 mm, and most preferably of up to 5 mm.
  • the natural fibers have a length weighted average fiber length selected within an interval of from 1 mm up to 10 mm, preferably selected within an interval of from 1 mm up to 8 mm, more preferably selected within an interval of from 1 mm up to 6 mm, and most preferably selected within an interval of from 1 mm up to 5 mm.
  • Length of fibers such as natural fibers, as referred to herein is length weighted average fiber length.
  • Length weighted average fiber length is calculated as the sum of individual fiber lengths squared divided by the sum of the individual fiber lengths as described in e.g., ISO 16065-1 :2014, Pulps - Determination of fibre length by automated optical analysis- Part 1 : Polarized light method, or ISO 16065-2:2014, Pulps - Determination of fibre length by automated optical analysis - Part 2: Unpolarized light method.
  • thermoplastic polymer binder is included to bind the bonded air-laid blank 20 together and preserve its form and structure during use, handling, and storage.
  • the thermoplastic polymer binder may also assist in building up the foam-like structure of the bonded air-laid blank 20.
  • the thermoplastic polymer binder is, in such an embodiment, intermingled with the natural fibers during the air-laying process forming a fiber mixture.
  • the thermoplastic polymer binder may be added in the form of a powder but is more often added in the form of fibers that are intermingled with the natural fibers in the air-laying process.
  • thermoplastic polymer binder is selected from the group consisting of a thermoplastic polymer powder, thermoplastic polymer fibers and a combination thereof.
  • thermoplastic polymer binder comprises thermoplastic polymer fibers.
  • the thermoplastic polymer binder is made from i) a thermoplastic material selected from the group consisting of polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), such as styrene-butadiene rubber (SBR) or styrene acrylate copolymer, polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly (2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), polyvinyl acetate (PVAc), polyurethane
  • PE
  • thermoplastic material is selected from the group consisting of PE, PP, PET, PLA, PVA, copolymers thereof and mixtures thereof, and more preferably selected from the group consisting of PE, PP, PET, copolymers thereof and mixtures thereof.
  • the thermoplastic polymer binder is made of a thermoplastic material selected from the above-mentioned group.
  • the thermoplastic polymer binder is made of a thermoplastic material selected from the above-mentioned group and one or more additives.
  • thermoplastic polymer binder is or comprises, such as consists of, monocomponent and/or bi-component thermoplastic polymer fibers.
  • Bi-component thermoplastic polymer fibers also known as bico fibers, comprise a first thermoplastic polymer, copolymer and/or polymer mixture and a second, different thermoplastic polymer, copolymer and/or polymer mixture.
  • the bi-component thermoplastic polymer fiber comprises a core made of the first thermoplastic polymer, copolymer and/or polymer mixture and a sheath made of the second thermoplastic polymer, copolymer and/or polymer mixture, although other combinations of two or even more thermoplastic polymers, copolymers and/or polymer mixtures are possible.
  • the thermoplastic polymer binder is or comprises, such as consists of, monocomponent thermoplastic polymer fibers made of i) a thermoplastic material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.
  • a thermoplastic material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.
  • thermoplastic polymer binder is or comprises, such as consists of, bi- component thermoplastic polymer fibers having a first thermoplastic material, such as a core made of i) a first thermoplastic material, selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives, and a second thermoplastic material, such as a sheath made of i) a second thermoplastic material, typically a different material, selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives
  • thermoplastic polymer binder is or comprises, such as consists of, a combination or mixture of mono-component thermoplastic polymer fibers made of i) a thermoplastic material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives, and bi-component thermoplastic polymer fibers having i) thermoplastic materials, such as of the core and/or sheath, selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and II) optionally one or more additives.
  • a thermoplastic material selected from the group
  • thermoplastic polymer binder could be made of a single type of thermoplastic polymer fibers, i.e., made of a same thermoplastic material in the case of mono-component thermoplastic polymer fibers or made of the same thermoplastic materials in the case of bi-component thermoplastic polymer fibers.
  • thermoplastic polymer binder made of one or multiple, i.e., two or more, different mono-component thermoplastic polymer fibers made of different thermoplastic materials and/or one or multiple different bi-component thermoplastic polymer fibers made of different thermoplastic materials.
  • thermoplastic polymer fibers can have a core with a higher melting point that keeps its fiber form during the binding operation, whereas the sheath melts and becomes tacky.
  • the intact core will support the three-dimensional structure of the bonded air-laid blank 20 and, thus, promote porosity while the melted or tackified sheath will attach to the natural fibers and preserve the strength of the bonded air-laid blank 20.
  • the thermoplastic polymer binder is a thermoplastic polymer powder made of i) a thermoplastic material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.
  • a thermoplastic material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.
  • thermoplastic polymer binder that is a combination of thermoplastic polymer fibers and thermoplastic polymer powder.
  • the unbonded air-laid web 10 comprises the thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30 % by weight of the unbonded air-laid web 10, preferably within an interval of from 5 up to 30 % by weight of the unbonded air-laid web 10, more preferably selected within an interval of from 10 up to 25 % by weight of the unbonded air-laid web 10, such as from 12.5 up to 22.5 % by weight of the unbonded air-laid web 10, or more preferably within an interval of from 15 up to 20 % by weight of the unbonded air-laid web 10
  • the unbonded air-laid web 10 comprises the natural fibers at a concentration of at least 70 % by weight of the unbonded air-laid web 10.
  • the unbonded air-laid web 10 comprises the natural fibers in a concentration of at least 72.5 %, more preferably at least 75 %, such as at least 77.5 %, at least 80 %, at least 82.5 %, or at least 85 % by weight of the unbonded airlaid web 10.
  • the unbonded air-laid web 10 may comprise one or more additives in addition to the natural fibers and the thermoplastic polymer binder.
  • One or more additives could be added to the thermoplastic polymer binder and/or added when producing the thermoplastic polymer binder.
  • one or more additives could be added to the natural fibers.
  • one or more additives could be added to the natural fibers and the thermoplastic polymer binder, such as during the air-laying process or prior to the air-laying process.
  • additives include electrically conducting or semiconducting fillers, coupling agents, flame retardants, dyes, impact modifiers, etc.
  • the system 100 comprises a forming head 110 comprising at least one inlet 111 configured to receive natural fibers and a thermoplastic polymer binder.
  • the forming head 110 also comprises an outlet 113.
  • the system 100 also comprises an air-permeable conveyor 120 arranged in connection with the outlet 113 to capture the natural fibers and the thermoplastic polymer binder as an unbonded air-laid web 10.
  • the system 100 further comprises an imprinting device 130 arranged to generate at least one imprint 15 in the unbonded air-laid web 10.
  • the system 100 additionally comprises a heating device 140 arranged to heat the unbonded air-laid web 10 to at least partly melt the thermoplastic polymer binder and bind the natural fibers to form a bonded air-laid blank 20 conserving the at least one imprint 25.
  • a cutting device 150 is arranged to cut the bonded air-laid blank 20 downstream of the heating device 140, see Fig. 9, or cut the unbonded air-laid web 10 upstream of the heating device 140, see Fig. 10, for form a packaging insert 30 comprising an imprint 35 configured to accommodate at least a portion of the product 50.
  • Fig. 9 illustrates an embodiment of the system 100.
  • the forming head 110 comprises an inlet 111 arranged in connection with its upper end 112 of the forming head 110 to receive a mixture of the natural fibers and the thermoplastic polymer binder.
  • the embodiment is not limited thereto.
  • multiple such inlets 111 could be arranged from the upper end 112 towards the bottom end 114 of the forming head 110 to receive the mixture of the natural fibers and the thermoplastic polymer binder or indeed at least one such inlet 111 for the natural fibers and at least one inlet 111 for the thermoplastic polymer binder.
  • the outlet 113 of the forming head 110 is typically arranged in connection with the lower end 114 of the forming head 110 and in vicinity of the air-permeable conveyor 120. This means that the natural fibers and the thermoplastic polymer binder passing through the forming head 110 are captured as an unbonded air-laid web 10 on the air-permeable conveyor 120.
  • the system 100 comprises a vacuum source 160 arranged beneath the air-permeable conveyor 120 to provide a gas suction through the air-permeable conveyor 120 in connection with the outlet 113 of the forming head 110.
  • the vacuum source 160 is arranged to draw the natural fibers and the thermoplastic polymer binder onto the air-permeable conveyor 120 to deposit them thereon and at least partly compact them forming the unbonded air-laid web 10.
  • the vacuum source 160 is arranged to apply a vacuum or gas suction over the air-permeable conveyor 120 and, thus, draws the natural fibers and the thermoplastic polymer binder down onto the air-permeable conveyor 120.
  • the air-permeable conveyor 120 could be any type of conveyor 120, over which a vacuum or gas suction can be applied by the vacuum source 130 and onto which the natural fibers and the thermoplastic polymer binder can be captured to form the unbonded air-laid web 10.
  • Typical examples of such air-permeable conveyors 120 that could be used include belt conveyors, in which the belt 122 comprises a plurality of openings, through holes or channels for allowing air to be sucked or drawn through the belt, wire conveyors and mesh conveyors with meshes that are small enough to allow capturing of the natural fibers and the thermoplastic polymer binder.
  • the belt, wire network or mesh is preferably an endless or jointless belt, wire network or mesh running between drive rollers 124, 126, also referred to as tail pulley 124 and head pulley 126.
  • the captured unbonded air-laid web 10 is then transported by the air-permeable conveyor 120 towards the imprinting device 130.
  • the imprinting device 130 could be any imprinting device 130 arranged to generate at least one imprint 15 in the unbonded air-laid web 10 and in particular in the first main surface 12 of the unbonded air-laid web 10.
  • the unbonded air-laid web 10 is positioned on the belt 122 with its second, opposite main surface 14 facing the belt 122.
  • the first and second main surfaces 12, 14 are extending along the width W and length T of the unbonded air-laid web 10 as shown in Fig.
  • the imprinting device 130 is preferably arranged in the system 100 to generate the at least one imprint 15 in the unbonded air-laid web 10 while the unbonded air-laid web 10 is moved by the air-permeable conveyor 120.
  • the imprinting device 130 is thereby preferably a so-called inline imprinting device 130.
  • Inline imprinting device 130 as used herein means that the imprinting device 130 is arranged to be used within the production process of the packaging insert 30. Hence, as shown in Figs. 9-10 the inline imprinting device 130 forms part of the system 100 and thereby part of the production line for the packaging insert 30.
  • Fig. 11 illustrates an embodiment of the imprinting device 130.
  • the imprinting device 130 comprises an imprinting roll 131 comprising at least one protrusion 132, preferably in the form of the at least a portion of the product 50.
  • the imprinting roll 131 is then arranged to contact the first main surface 12 of the unbonded air-laid web 10 to generate the at least one imprint 15 in the unbonded airlaid web 10.
  • the imprinting roll 131 is then preferably arranged to rotate relative to the unbonded air-laid web 10 as the unbonded air-laid web 10 is transported on the air-permeable conveyor 120 past the imprinting roll 131 .
  • the at least one protrusion 132 will thereby be pressed into the first main surface 12 and into a given depth of the unbonded air-laid web 10 to generate at least one imprint 15.
  • the imprinting roll 131 is also arranged to compress the unbonded air-laid web 10 to generate the at least one imprint 15 in the unbonded air-laid web 10.
  • the imprinting roll 131 not only generates imprints 15 in the unbonded air-laid web 10 but also at least partly compresses the unbonded air-laid web 10.
  • the unbonded air-laid web 10 is thereby compressed between the cylinder surface 133 of the imprinting roll 131 and the air-permeable conveyor 120 resulting in a compaction of the air-laid material.
  • the imprinting roll 131 has dual effects, i.e., imprinting and compaction or compressing.
  • Fig. 12 illustrates another embodiment of the imprinting device 130.
  • the imprinting device 130 comprises a stamping device 135 comprising at least one protrusion 136, preferably in the form of the at least a portion of the product.
  • the stamping device 135 is then arranged to press into the first main surface 12 of the unbonded air-laid web 10 to generate the at least one imprint 15 in the unbonded air-laid web 10.
  • the stamping device 135 is arranged to press into the first main surface 12 of the unbonded air-laid web 10 while moving in synchrony with movement of the unbonded air-laid web 10 on the air-permeable conveyor 120.
  • the stamping device 135 could be moveable both vertically towards and away from the unbonded air-laid web 10 and horizontally along the direction of the movement of the unbonded air-laid web 10 on the air-permeable conveyor 120 and in the opposite horizontal direction.
  • the stamping device 135 is initially in a starting position levelled above the unbonded air-laid web 10 and is then moved towards the unbonded air-laid web 10 to press the at least one protrusion 136 into the first main surface 12 of the unbonded air-laid web 10.
  • the stamping device 135 is then preferably transported horizontally together with the unbonded air-laid web 10 while maintaining the at least one protrusion 136 pressed into the unbonded air-laid web 10 for a given period of time, such as one or a few seconds.
  • the stamping device 135 is then preferably raised away from the unbonded air-laid web 10 and transported back to the starting position to start a new imprinting operation.
  • the stamping device 135 could have dual functions, i.e., imprinting and compressing.
  • the substantially flat surface 137 of the stamping device 135 could at least partly compress the unbonded air-laid web 10 as the at least one protrusion 136 is pressed into the unbonded air-laid web 10.
  • the system 100 also comprises the heating device 140 arranged downstream of the imprinting device 130. Upstream and downstream as used herein relate to the general direction of movement of the unbonded air-laid web 10 and the bonded air-laid blank 20 during production, i.e., from the forming head 110 towards the cutting device 150 in Fig. 9 or the heating device 140 in Fig. 10.
  • the heating device 140 may, for instance, be in the form of a bonding oven.
  • the heating device 140 is arranged to provide heat, such as in the form of hot air that is circulated through the unbonded air-laid web 10 to melt or partly melt the thermoplastic polymer binder.
  • the thermoplastic polymer binder thereby becomes tacky and adheres to the natural fibers and, thus, holds the fiber material together and thereby results in the bonded air-laid blank 20.
  • the heating device 140 is arranged to heat the unbonded air-laid web 10 to a temperature selected within an interval of from 100°C up to 210°C, preferably within an interval of from 100°C up to 190°C, and more preferably within an interval of from 100°C up to 165°C.
  • a too high temperature may damage and deteriorate the natural fibers in the unbonded air-laid web 10.
  • the hot air blown and/or sucked into the unbonded air-laid web 10 in the heating device 140 conserves the at least one imprint 15 generated in the unbonded air-laid web 10.
  • the bonded airlaid blank 20 obtained following heating will comprise at least one corresponding imprint 25.
  • the heat treatment conserves any imprints 15 in the unbonded air-laid web 10 to form a bonded air-laid blank 20 with conserved imprint(s) 25.
  • the cutting device 150 is arranged to cut the bonded air-laid blank 20 downstream of the heating device 140 to form the packaging insert 30, see Fig. 9.
  • the cutting device 150 is arranged to cut the unbonded air-laid web 10 upstream of the heating device 140 to form a cut unbonded air-laid web 10.
  • the cut unbonded air-laid web 10 is then heat treated in the heating device 140 to produce the bonded air-laid blank 20 in the form of the packaging insert 30.
  • a first cutting device is arranged to cut the unbonded air-laid web 10 upstream of the heating device 140 to form a cut unbonded air-laid web 10.
  • the cut unbonded air-laid web 10 is then heat treated in the heating device 140 to produce the bonded air-laid blank 20.
  • a second cutting device 150 is arranged to cut the bonded air-laid blank 20 downstream of the heating device 140 to form the packaging insert 30.
  • the cutting device 150 could be any type of cutter that is capable of cutting unbonded air-laid webs 10 or bonded air-laid blanks 20.
  • Illustrative, but non-limiting examples, of such cutting devices 150 include a saw, a punch, a knife, etc.
  • the cutting device 150 is arranged to cut the bonded air-laid blank 20 or the unbonded air-laid web 10 while moving in synchrony with movement of the bonded air-laid blank 20 or the unbonded air-laid web 10 on the air-permeable conveyor 120.
  • the air-permeable conveyor 120 could include bend rollers 121 and one or more take-up roller 123 arranged to divert the air-permeable conveyor belt 122 away from the cutting device 150.
  • the bend rollers 121 could be in the form of bend pulleys or bend idlers and the take-up roller(s) 123 could be in the form of take-up pulley(s) or take-up idler(s).
  • the cutting device 150 and the bend rollers 121 and take-up roller(s) 123 are preferably movable relative to the conveyor(s) 120 to be moved, preferably in synchrony, with the unbonded air-laid web 10 or the bonded air-laid blank 20 transported by the air-permeable conveyor 120. This is schematically illustrated by the hatched arrow in Figs. 9-10.
  • the cutting device 150 could be supported by a transport system, such as in the form of a stationary frame or guide, along which a movable support is movable.
  • This movable support is connected to and supports the cutting device 150 to transport the cutting device 150 along the stationary frame or guide and in synchrony with the unbonded air-laid web 10 or the bonded air-laid blank 20.
  • the transport system typically comprises a motor configured to move the movable support and the cutting device 150 and preferably also the bend rollers 121 and the take-up roller(s) 123.
  • a further aspect of the invention relates to a packaging insert 30 for a product 50.
  • the packaging insert 30 is made from a cut bonded air-laid blank 20 formed by heating an unbonded air-laid web 10 comprising (i) a mixture of natural fibers and a thermoplastic polymer binder and (ii) an imprint 15.
  • the packaging insert 30 comprises an imprint 35 configured to accommodate least a portion of the product 50. The imprint 35 is conserved during heating the unbonded air-laid web 10.
  • the imprint 35 in the packaging insert 30 corresponds to an imprint 15 in the unbonded air-laid web 10 and is conserved during the production of the packaging insert 30 from the unbonded air-laid web 10 through the cut bonded air-laid blank 20.
  • the packaging insert 30 could comprise a single imprint 35 or multiple imprints 35, wherein each imprint 35 in the packaging insert 30 is conserved in the fiber and thermoplastic material during the production of the packaging insert 30.
  • the one or more imprints 15 generated in the unbonded air-laid web 10 in step S3 of Fig. 5 is or are conserved during heating in step S5 to produce the bonded air-laid blank 20 comprising one or more conserved imprints 25.
  • the one or more imprints 25 in the bonded air-laid blank 20 remains in the fiber and thermoplastic material during cutting in step S6 to produce the packaging insert(s) 30 each comprising one or more imprints 35.
  • the one or more imprints 15 generated in the unbonded air-laid web 10 in step S3 of Fig. 5 remain(s) in the fiber and thermoplastic material during cutting in step S4 and is or are conserved during the following heating in step S5 so that each packaging insert 30 obtained in such an embodiment comprise one or more conserved imprints 35.
  • the one or more imprints 35 in the packaging insert 30 could be configured, i.e., shaped and sized, to accommodate one or more complete products 50 to be packaged or a respective portion, such as part or parts, of the one or more products 50, see Fig. 3B.
  • a complete product 50, or at least a major portion could be inserted into an imprint 35 in the packaging insert 30.
  • a part of the product 50 can be inserted into the imprint 35, whereas a remaining part or portion of the product 50 would then be present outside of the imprint 35 as shown in Fig. 3C, such as positioned on the packaging insert 30.
  • the packaging insert 30 comprises multiple imprints 35
  • these multiple imprints 35 could be of the same size and shape, and thereby preferably configured to house the same type of products 50.
  • the embodiments are, however, not limited thereto.
  • the multiple imprints 35 may be different, such as of different size and/or different shape.
  • different products 50 can be packaged in the different imprints 35 of a given packaging insert 30.
  • multiple product parts could be packaged in multiple imprints 35 of a packaging insert 30. These multiple product parts are designed to be assembled into a final product or product assembly. This then means that a single packaging insert 30 could then be used for packaging the multiple different product parts by having multiple different imprints 35.
  • an imprinted portion 36 of the packaging insert 30 has an average density that is higher than an average density of a non-imprinted portion 37 of the packaging insert 30.
  • the imprinted portion 36 of the packaging insert 30 has an average density of above 30 kg/m 3 , preferably of at least 40 kg/m 3 , more preferably of at least 50 kg/m 3 , and most preferably of at least 60 kg/m 3 , such as selected within an interval of from 60 up to 100 kg/m 3 .
  • the non-imprinted portion 37 of the packaging insert 30 has an average density of up to 60 kg/m 3 , preferably selected within an interval of from 30 up to 60 kg/m 3 .
  • the average density of the imprinted portion 36 of the packaging insert 30 is higher than the average density of the non-imprinted portion 37 of the packaging insert 30.
  • the ratio between the average density of the imprinted portion 36 of the packaging insert 30 and the average density of the non-imprinted portion 37 of the packaging insert 30 is at least 1.1, preferably at least 1.2, more preferably at least 1.3, and most preferably at least 1.4, such as at least 1 .5, at least 1 .6, at least 1 .7, at least 1 .8, at least 1 .9 or even higher, such as at least 2.0, or indeed higher such as at least 2.5, at least 3.0, at least 4.0, at least 5.0, at least 6.0, at least 7.0, at least 8.0, at least 9.0, at least 10.0 or indeed even higher.
  • the non-imprinted portion 37 of the packaging insert 30 has an average thickness of at least 10 mm, preferably at least 25 mm, and more preferably at least 50 mm.
  • packaging inserts 30 with thicker non-imprinted portions 37 than 50 mm could be produced and used according to the invention, such as having an average thickness of at least 60 mm, at least 70 mm, at least 80 mm, at least 90 mm, at least 100 mm or even thicker.
  • the imprint 35 has a maximum extension into the packaging insert 30 of at least 5 mm, preferably at least 7.5 mm and more preferably at least 10 mm. In a particular embodiment, the imprint 35 has a maximum extension into the packaging insert 30 of at least 15 mm, at least 20 mm, at least 25 mm, at least 30 mm, at least 35 or at least 50 mm, or indeed even higher.
  • the maximum extension of the imprint 35 into the packaging insert 30 could be up to 90 % of the average thickness of the packaging insert 30, such as up to 80%, up to 75 %, up 70 %, up to 65 %, up to 60 %, up to 55 %, or up to 50 % of the average thickness of the packaging insert 30.
  • the imprint 35 has a minimum extension into the packaging insert 30 of at least 2.5 mm, preferably at least 5 mm, such as at least 7.5 mm. In an embodiment, the imprint 35 has a minimum extension into the packaging insert 30 of at least 10 mm, at least 12.5 mm, at least 15 mm, at least 17.5 mm, at least 20 mm, at least 22.5 mm, at least 25 mm, at least 27.5 mm, at least 30 mm, at least 32.5 mm or at least 35 mm.
  • the minimum extension into the packaging insert 30 will be equal to the maximum extension into the packaging insert 30.
  • a difference in an average thickness of the packaging insert 30 and a maximum extension of the imprint 35 into the packaging insert 30 is at least 5 mm, preferably at least 7.5 mm, and more preferably at least 10 mm.
  • the difference in the average thickness of the packaging insert 30 and the maximum extension of the imprint 35 into the packaging insert 30 is at least 12.5 mm, at least 15 mm, at least 17.5 mm, at least 20 mm, at least 22.5 mm, at least 25 mm, at least 27.5 mm, at least 30 mm, at least 32.5 mm or at least 35 mm.
  • the unbonded air-laid web 10 comprises the thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30 % by weight of the unbonded air-laid web 10, preferably selected within an interval of from 5 up to 30 % by weight of the unbonded air-laid web 10, more preferably selected within an interval of from 10 up to 25 % by weight of the unbonded air-laid web 10, such as from 12.5 up to 22.5 % by weight of the unbonded air-laid web 10, and most preferably selected within an interval of from 15 up to 20 % by weight of the unbonded air-laid web 10.
  • the unbonded air-laid web 10 comprises the natural fibers at a concentration of at least 70 % by weight of the unbonded air-laid web 10.
  • the unbonded air-laid web 10 comprises the natural fibers in a concentration of at least 72.5 %, more preferably at least 75 %, such as at least 77.5 %, at least 80 %, at least 82.5 %, or at least 85 % by weight of the unbonded airlaid web 10.
  • the natural fibers comprise wood fibers, preferably cellulose and/or lignocellulose fibers, and more preferably cellulose and/or lignocellulose pulp fibers produced by chemical, mechanical and/or chemi-mechanical pulping of softwood and/or hardwood.
  • the natural fibers are cellulose and/or lignocellulose pulp fibers in a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical fiber intended for medium density fiberboard (MDF-fiber), chemi-thermomechanical pulp (CTMP), high temperature chemi-thermomechanical pulp (HTCTMP), and a combination thereof.
  • TMP thermomechanical pulp
  • HTMP high temperature thermomechanical pulp
  • MDF-fiber mechanical fiber intended for medium density fiberboard
  • CTMP chemi-thermomechanical pulp
  • HTCTMP high temperature chemi-thermomechanical pulp
  • thermoplastic polymer binder comprises thermoplastic polymer fibers.
  • the thermoplastic polymer binder is made from I) a thermoplastic material selected from the group consisting of polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), polyvinyl acetate (PVAc), polyurethane (PU), copolymers thereof and mixtures thereof, and ii) optionally one or more additives.
  • PE polyethylene
  • EAA ethylene
  • thermoplastic material is selected from the group consisting of PE, PP, PET, PLA, PVA, copolymers thereof and mixtures thereof, and more preferably selected from the group consisting of PE, PP, PET, copolymers thereof and mixtures thereof.
  • the packaging insert 30 is obtainable by the method discussed in the foregoing in connection with Figs. 5-8.
  • the invention also relates to a packaging assembly comprising a packaging box 40 and a packaging insert 30, see Fig. 4.
  • the packaging box 40 has a bottom and at least one side wall attached to the bottom.
  • the bottom and the at least one side wall define a packaging volume 45.
  • the packaging insert 30 according to the invention is arranged on the bottom of the packaging box 40 with the imprint 35 facing away from the bottom of the packaging box 40 as shown in Fig. 4.
  • the packaging assembly also comprises another packaging insert 30 according to the invention.
  • the other packaging insert is arranged in the packaging volume 45 with the imprint 35 facing the first packaging insert 30.
  • Any goods or products 50 to be packaged in the packaging assembly are positioned in between the two packaging inserts 30.
  • the imprints 35 of the two packaging inserts 30 then face each other and the goods or products 50 placed therebetween.
  • the packaging assembly could be used to pack a single product 50 or goods or multiple products 50 or goods in the packaging box 40.
  • the packaging box 40 also referred to as container herein, could comprise a single side wall attached to the bottom, for instance, if the packaging box 40 is in the form of cylinder with a circular or elliptical bottom. The side wall is then a curved side wall encircling a circular or elliptical bottom.
  • the packaging box 40 is a cylindrical packaging box 40.
  • the packaging box 40 could be in form of a cube or rectangular cuboid.
  • the packaging box 40 comprises four side walls attached to the bottom.
  • the packaging box 40 can be made of various materials including, but not limited to, paper-based material, including, but not limited to, paperboard material, such as a cardboard material, cartonboard material or corrugated board material, also referred to as containerboard material.
  • paperboard material such as a cardboard material, cartonboard material or corrugated board material, also referred to as containerboard material.
  • the packaging box 40 is a cardboard box or a corrugated board box. Another material for the packaging box 40 could be wood.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Buffer Packaging (AREA)
  • Laminated Bodies (AREA)
  • Nonwoven Fabrics (AREA)

Abstract

Selon l'invention, un insert d'emballage (30) pour un produit (50) est produit par génération d'au moins une empreinte (15) dans un voile formé par voie sèche non collé (10) constitué de fibres naturelles et d'un liant polymère thermoplastique. Le voile formé par voie sèche non collé (10) est chauffé pour faire fondre au moins partiellement le liant polymère thermoplastique et lier les fibres naturelles pour former une ébauche formée par voie sèche collée (20) conservant l'empreinte ou les empreintes (25). L'insert d'emballage (30) est formé par découpe de l'ébauche formée par voie sèche collée (20) après chauffage ou par le voile formé par voie sèche non collé (10) avant chauffage et comprend une empreinte (35) configurée pour recevoir au moins une partie du produit (50). L'insert d'emballage (30) présente d'excellentes propriétés d'absorption des chocs et d'isolation.
PCT/IB2024/055480 2023-06-14 2024-06-05 Procédé de fabrication d'un insert d'emballage pour un produit, système de fabrication d'un insert d'emballage pour un produit et insert d'emballage pour un produit Pending WO2024256917A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
SE2330281A SE547844C2 (en) 2023-06-14 2023-06-14 A packaging insert made from a cut bonded air-laid blank and a method of producing the packaging insert
SE2330281-3 2023-06-14

Publications (1)

Publication Number Publication Date
WO2024256917A1 true WO2024256917A1 (fr) 2024-12-19

Family

ID=93851421

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2024/055480 Pending WO2024256917A1 (fr) 2023-06-14 2024-06-05 Procédé de fabrication d'un insert d'emballage pour un produit, système de fabrication d'un insert d'emballage pour un produit et insert d'emballage pour un produit

Country Status (2)

Country Link
SE (1) SE547844C2 (fr)
WO (1) WO2024256917A1 (fr)

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3977928A (en) * 1973-08-18 1976-08-31 Kabushiki Kaisha Tomoku Process and apparatus for producing a soft fibrous sheet
JP2005139582A (ja) * 2003-11-07 2005-06-02 Toppan Printing Co Ltd パルプ成形体およびその製造方法
US20190352851A1 (en) * 2017-02-24 2019-11-21 Voith Patent Gmbh Method and device for the production of a fibrous material web in a papermaking machine
WO2022009129A1 (fr) * 2020-07-09 2022-01-13 Stora Enso Oyj Produit d'emballage de forme 3d à partir d'une découpe de feuille formée par voie pneumatique
WO2022043779A1 (fr) * 2020-08-24 2022-03-03 Stora Enso Oyj Ébauche formée par voie sèche, procédé de production d'une ébauche formée par voie sèche et procédé de production d'un produit en trois dimensions à partir de ladite ébauche formée par voie sèche
WO2022123439A1 (fr) * 2020-12-08 2022-06-16 Stora Enso Oyj Ébauche formée par voie pneumatique pour insonorisation ou isolation phonique, et procédés et appareils pour une production de celle-ci
WO2022238484A1 (fr) * 2021-05-12 2022-11-17 Yangi Ab Procédé et appareil pour la fabrication à sec de produits de cellulose rigides

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3977928A (en) * 1973-08-18 1976-08-31 Kabushiki Kaisha Tomoku Process and apparatus for producing a soft fibrous sheet
JP2005139582A (ja) * 2003-11-07 2005-06-02 Toppan Printing Co Ltd パルプ成形体およびその製造方法
US20190352851A1 (en) * 2017-02-24 2019-11-21 Voith Patent Gmbh Method and device for the production of a fibrous material web in a papermaking machine
WO2022009129A1 (fr) * 2020-07-09 2022-01-13 Stora Enso Oyj Produit d'emballage de forme 3d à partir d'une découpe de feuille formée par voie pneumatique
WO2022043779A1 (fr) * 2020-08-24 2022-03-03 Stora Enso Oyj Ébauche formée par voie sèche, procédé de production d'une ébauche formée par voie sèche et procédé de production d'un produit en trois dimensions à partir de ladite ébauche formée par voie sèche
WO2022123439A1 (fr) * 2020-12-08 2022-06-16 Stora Enso Oyj Ébauche formée par voie pneumatique pour insonorisation ou isolation phonique, et procédés et appareils pour une production de celle-ci
WO2022238484A1 (fr) * 2021-05-12 2022-11-17 Yangi Ab Procédé et appareil pour la fabrication à sec de produits de cellulose rigides

Also Published As

Publication number Publication date
SE547844C2 (en) 2025-12-09
SE2330281A1 (en) 2024-12-15

Similar Documents

Publication Publication Date Title
US20230249889A1 (en) Folded 3d shaped packaging product from an air-laid blank
EP4200472B1 (fr) Ébauche formée par voie sèche, procédé de production d'une ébauche formée par voie sèche et procédé de production d'un produit en trois dimensions à partir de ladite ébauche formée par voie sèche
US20230249890A1 (en) 3d shaped packaging product from an air-laid blank
EP4259870B1 (fr) Ébauche formée par voie pneumatique pour insonorisation ou isolation phonique, et procédés et appareils pour une production de celle-ci
SE545562C2 (en) Folded 3D shaped packaging product for cushioning and/or thermal insulation of packaged goods
US20230256702A1 (en) Recyclable 3d shaped product from an air-laid blank
WO2024256917A1 (fr) Procédé de fabrication d'un insert d'emballage pour un produit, système de fabrication d'un insert d'emballage pour un produit et insert d'emballage pour un produit
US20250340355A1 (en) Air-laid blanks and cushioning inserts
WO2023105311A1 (fr) Procédé et appareil de fabrication de produits d'emballage pliés
US12595603B2 (en) Air-laid blank, a method of producing an air-laid blank and a method of producing a three dimensional product from said air-laid blank
SE545542C2 (en) 3D shaped packaging product for cushioning and/or thermal insulation of packaged goods
WO2024209310A1 (fr) Production d'ébauches liées à l'air

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 24822905

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: 2024822905

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 2024822905

Country of ref document: EP

Effective date: 20260114

ENP Entry into the national phase

Ref document number: 2024822905

Country of ref document: EP

Effective date: 20260114

ENP Entry into the national phase

Ref document number: 2024822905

Country of ref document: EP

Effective date: 20260114

ENP Entry into the national phase

Ref document number: 2024822905

Country of ref document: EP

Effective date: 20260114