Folded 3d shaped packaging product from air-laid blank

Abstract

A folded 3D shaped packaging product (30) is folded at at least one crease (22A, 22B, 22C, 22D, 22E) constituting a fold line in a 3D shaped product (20) formed by hot pressing of an air-laid blank (10) comprising natural fibers in a concentration of at least 70% by weight of the air-laid blank (10) and a thermoplastic polymer binder selected within a concentration interval of 4 up to 30% by weight of the air-laid blank (10). The folded 3D shaped packaging product (30) can be used for cushioning and / or thermal insulation of a packaged cargo and can protect multiple sides of the packaged cargo.

Description

Technical Field

[0001] Embodiments of the present invention generally relate to three-dimensional (3D) shaped packaging products, and particularly to foldable 3D shaped packaging products for cushioning and / or thermal insulation of goods. Background Technology

[0002] With growing awareness of the environment and human-induced climate change, the use of single-use plastic items and products has become increasingly questionable. However, despite these concerns, their use has increased dramatically due to new trends in lifestyles and consumer habits over the past decade. One reason for this is the increasing volume of goods shipped worldwide, requiring protection against shocks, vibrations, and / or extreme temperatures. A common way to protect goods is by including cushioning and / or insulating elements or products, such as inserts in appropriate forms within packaging. These can be made from various materials, but are typically made from expanded polystyrene (EPS), which is by far the cheapest and most common. In some cases, the entire package may be made of EPS. One example is shipping boxes used for foods that must be stored within a specified temperature range (such as cold foods like fish, or hot foods like ready-to-eat meals). However, EPS is one of the most questioned plastic materials, and many brand owners are seeking more sustainable solutions for these packaging applications. Many countries have also begun legislative action against single-use plastic items and products, increasing the pressure to find alternative solutions.

[0003] More sustainable alternatives to polymer products exist today, such as inserts manufactured through a process called pulp molding, in which a fiber suspension is vacuum-drawn onto a wire mold. Another technique for forming such inserts, described in U.S. Patent Application No. 2010 / 0190020, European Patent No. 1 446 286, and International Application No. 2014 / 142714, involves hot-pressing porous fiber mats produced by a process called air-laid fabrication into 3D structures using a matching rigid mold or by membrane molding.

[0004] There is still a need for improved 3D-formed packaging products, especially those that can be folded around the packaged goods to protect them from shocks and / or ultimately insulate them. Summary of the Invention

[0005] One objective is to provide foldable 3D-formed packaging products for use in packaging goods, providing cushioning and / or thermal insulation.

[0006] One specific objective is to provide this type of foldable 3D-shaped packaging product that can be made from natural fibers.

[0007] These and other objectives are achieved through embodiments of the present invention.

[0008] This invention is defined in the independent claims. Other embodiments of the invention are defined in the dependent claims.

[0009] One aspect of the invention relates to an air-laid preform comprising natural fibers at a concentration of at least 70% by weight of the air-laid preform and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform. The air-laid preform includes at least one crease forming a folding line for folding a 3D-formed product into a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods. The 3D-formed product is formed by hot-pressing the air-laid preform containing the at least one crease. Alternatively, the at least one crease forms a folding line for hot-pressing and folding the air-laid preform to form a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods.

[0010] Another aspect of the invention relates to a method for manufacturing an air-laid preform comprising natural fibers at a concentration of at least 70% by weight of the air-laid preform and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform. The method includes pressing a mold having at least one rod into the air-laid preform to form at least one crease, the crease constituting a folding line for folding a 3D-formed product into a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods. The 3D-formed product is formed by hot-pressing the air-laid preform containing the at least one crease. Alternatively, the at least one crease constitutes a folding line for hot-pressing and folding the air-laid preform containing the at least one crease to form a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods.

[0011] Another aspect of the invention relates to a method for manufacturing an air-laid preform comprising natural fibers at a concentration of at least 70% by weight of the air-laid preform and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform. The method includes sawing or cutting at least one crease in the air-laid preform. The at least one crease constitutes a folding line for folding a 3D-formed product into a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods. The 3D-formed product is formed by hot-pressing the air-laid preform containing the at least one crease. Alternatively, the at least one crease constitutes a folding line for hot-pressing and folding the air-laid preform containing the at least one crease to form a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods.

[0012] Another aspect of the invention relates to a method for manufacturing a foldable 3D-formed packaging product. The method includes manufacturing an air-laid preform according to the above. The method further includes hot-pressing a male tool into the air-laid preform containing at least one crease to form a 3D-formed product containing at least one crease and having a 3D shape at least partially defined by the male tool, and folding the 3D-formed product at said at least one crease to form a foldable 3D-formed packaging product for cushioning and / or thermal insulation of goods. Alternatively, the method includes hot-pressing a male tool into an air-laid preform containing at least one crease and positioned on a female tool, and folding the air-laid preform at said at least one crease to form a foldable 3D-formed packaging product for cushioning and / or thermal insulation of goods, wherein the foldable 3D-formed packaging product has a 3D shape at least partially defined by the male and female tools.

[0013] Another aspect of the invention relates to a foldable 3D-formed packaging product for cushioning and / or thermal insulation of packaged goods. The foldable 3D-formed packaging product is folded at at least one crease forming a fold line in a 3D-formed product formed by hot pressing an air-laid preform comprising at least 70% by weight of natural fibers and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform.

[0014] Another aspect of the invention relates to a 3D-formed product. The 3D-formed product is formed by hot pressing an air-laid preform comprising at least 70% natural fibers by weight of the preform and a thermoplastic polymer binder selected from a concentration in the range of 4% to 30% by weight of the preform. The 3D-formed product includes at least one crease forming a folding line for folding the 3D-formed product into a folded 3D-formed packaging product for cushioning and / or thermal insulation of goods.

[0015] Another aspect of the invention relates to a method for manufacturing a 3D-formed product. The method includes hot-pressing a male die tool into an air-laid preform comprising natural fibers at a concentration of at least 70% by weight of the air-laid preform and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform, to form a 3D-formed product having a 3D shape at least partially defined by the male die tool. The method further includes, simultaneously with the hot pressing of the male die tool, pressing at least one rod into the air-laid preform to form at least one crease, the crease constituting a folding line for folding the 3D-formed product into a folded 3D-formed packaged product for cushioning and / or thermal insulation of goods.

[0016] This invention relates to foldable 3D-formed packaging products, highly suitable for cushioning packaged goods, providing excellent shock absorption and damping characteristics. The foldable 3D-formed packaging products also possess thermal insulation properties, thus making them suitable for storing and / or transporting temperature-controlled (e.g., cold or hot) goods, such as provisions and foodstuffs. Furthermore, the foldable 3D-formed packaging products, suitable for cushioning and / or thermal protection, are made from environmentally friendly natural fibers, in stark contrast to existing foam inserts made of polystyrene and other polymers. Attached Figure Description

[0017] The implementation scheme and its other objects and advantages can be best understood by referring to the following description in conjunction with the accompanying drawings, wherein:

[0018] Figure 1 An exemplary embodiment of a mold that can be used to manufacture an air-laid blank having at least one crease before being pressed onto the air-laid blank;

[0019] Figure 2 It is pressed into the air-laid web blank. Figure 1 An exemplary embodiment of the mold in the example;

[0020] Figure 3An exemplary embodiment of another mold that can be used to manufacture an air-laid blank with at least one crease during simultaneous cutting, prior to being pressed into the air-laid blank;

[0021] Figure 4 It is pressed into the air-laid web blank. Figure 3 An exemplary embodiment of the mold in the example;

[0022] Figure 5 and 6 The diagram schematically illustrates the folding of the airflow web forming blank at the crease;

[0023] Figure 7 This is a cross-sectional view of an exemplary embodiment of a folded 3D-formed packaging product;

[0024] Figure 8 An exemplary embodiment of a male and female mold tool is provided before hot pressing a male mold tool into an air-blown preform, which can be used to produce foldable 3D-formed packaging products;

[0025] Figure 9 It is a male mold tool that is hot-pressed into the air-blown web blank. Figure 8 An exemplary implementation of the male mold tool and female mold tool in the diagram;

[0026] Figure 10 An exemplary embodiment of a male mold tool is provided before hot pressing the male mold tool into an air-blown web blank, which can be used to produce 3D molded products;

[0027] Figure 11 It is a male mold tool that is hot-pressed into the air-blown web blank. Figure 10 An exemplary implementation scheme for the male mold tool in the diagram;

[0028] Figure 12 This is a cross-sectional view of an exemplary embodiment of a 3D-molded product;

[0029] Figure 13 and 14 The illustration shows the folding of a 3D-molded product at the crease.

[0030] Figure 15 This is a flowchart illustrating a method for manufacturing an air-blown web blank according to one embodiment;

[0031] Figure 16 This is a flowchart illustrating a method for manufacturing an air-blown web blank according to another embodiment;

[0032] Figure 17 This is a flowchart illustrating a method for manufacturing a foldable 3D-formed packaging product according to one embodiment;

[0033] Figure 18 This is a flowchart illustrating a method for manufacturing a foldable 3D-formed packaging product according to another embodiment; and

[0034] Figure 19 This is a flowchart illustrating a method for manufacturing 3D-shaped products. Detailed Implementation

[0035] Embodiments of the present invention generally relate to 3D-formed packaging products, and particularly to foldable 3D-formed packaging products for cushioning and / or thermal insulation of packaged goods.

[0036] The foldable 3D-formed packaging products of embodiments of the present invention can serve as a more environmentally friendly alternative to corresponding 3D-formed packaging products made of or from foamed polymers (e.g., expanded polystyrene (EPS)). More sustainable alternatives to polymer products have been proposed in U.S. Patent Application No. 2010 / 0190020 and European Patent No. 1 446 286, and these involve using a matching rigid mold or thermoforming a porous fiber mat produced by a process called airflow web forming into a 3D structure. However, the 3D-formed products produced in the aforementioned documents are dense, have thin cross-sections, and therefore have limited shock absorption or damping capabilities and relatively poor thermal insulation. Furthermore, these prior art 3D-formed products have limited ability to protect multiple sides of the cargo for shock absorption or damping and / or thermal insulation. Therefore, multiple 3D-formed products may be required to fully encapsulate and protect a given cargo.

[0037] The foldable 3D-formed packaging product of embodiments of the present invention is formed by hot pressing an air-laid preform comprising natural fibers and a binder. The air-laid preform (sometimes also referred to as a dry-laid preform, air-laid mat, dry-laid pad, air-laid web, or dry-laid web) is formed by a process called air-laid forming, in which natural fibers and a binder are mixed with air to form a porous fiber mixture deposited onto a carrier and solidified or bonded by heating or thermoforming. The air-laid preform is characterized by being porous, exhibiting characteristics of open-cell foam, and is produced using a so-called dry-forming method, i.e., typically without the addition of water. The air-laid process was originally described in U.S. Patent No. 3,575,749. The air-laid preform may be in the form produced in the air-laid process. Alternatively, the air-laid preform may be in a form that is at least partially processed, such as by cutting into a given shape before hot pressing.

[0038] According to embodiments of the invention, fold lines are formed in the air-laid preform or in a 3D-formed product formed by hot pressing the air-laid preform. This means that the 3D-formed product can be folded to form a folded 3D-formed product that can protect multiple sides of packaged goods and even completely enclose such packaged goods. Therefore, compared to conventional 3D-formed products that can only protect a portion of the packaged goods and thus require multiple 3D-formed products to fully protect the packaged goods, the packaged goods are more effectively protected against vibration and high or low temperatures. Furthermore, by folding the 3D-formed product around the packaged goods, larger packaged goods that are too large to be installed in the cavity pressed into the 3D-formed product or can be protected by a deeply drawn 3D-formed product can be protected. Therefore, compared to the non-foldable 3D-formed products of the prior art, the folded 3D-formed product of the present invention has improved shock absorption and damping effects and / or improved thermal insulation.

[0039] One aspect of the present invention relates to an airflow web forming blank 10, see [link to previous document]. Figures 1 to 6 The air-laid preform 10 comprises natural fibers at a concentration of at least 70% by weight of the air-laid preform 10. The air-laid preform 10 also comprises a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform 10. According to the invention, the air-laid preform 10 comprises at least one crease 12A, 12B, 12C, 12D, which forms fold lines for folding the 3D-formed product 20 (see...). Figure 12-14 ) 30 Foldable 3D-formed packaging products for cushioning and / or thermal insulation of packaged goods (see Figure 7 The 3D-formed product 20 is formed by hot pressing an air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D. Alternatively, the at least one crease 12A, 12B, 12C, 12D of the air-laid blank 10 constitutes a fold line for hot pressing and folding the air-laid blank 10 (see...). Figure 8-9 ), to form a folded 3D-shaped packaging product 30 for cushioning and / or thermal insulation of goods.

[0040] Therefore, the air-laid preform 10 of the present invention includes at least one crease 12A, 12B, 12C, 12D, which forms fold lines to fold the 3D-formed product 20 obtained by hot-pressing the air-laid preform 10, thereby obtaining a folded 3D-formed packaging product 30. Alternatively, the folded 3D-formed packaging product 30 is obtained by simultaneously hot-pressing and folding the air-laid preform 10 along at least one crease 12A, 12B, 12C, 12D. Whether hot-pressing followed by folding or hot-pressing and folding in the same operation, the result is a folded 3D-formed packaging product 30 suitable for cushioning and / or thermal insulation of packaged goods.

[0041] At least one crease 12A, 12B, 12C, 12D can be any form of indentation, groove, or fold in the air-laid preform 10, enabling the air-laid preform 10 to be folded along the creases 12A, 12B, 12C, 12D, or folded by hot pressing the air-laid preform 10 to form the 3D-formed product 20. At least one crease 12A, 12B, 12C, 12D can have various cross-sectional shapes and sizes, depending on the specific tool used to form at least one crease 12A, 12B, 12C, 12D in the air-laid preform 10. For example, as an illustrative but non-limiting example, at least one crease 12A, 12B, 12C, 12D can have a V-shaped or wedge-shaped cross-section, a U-shaped cross-section, or a rectangular cross-section. If the air-laid preform 10 has multiple (i.e., at least two) creases 12A, 12B, 12C, 12D, they can all have the same cross-sectional shape and size. However, in practice, different creases 12A, 12B, 12C, 12D with different cross-sectional shapes and / or different sizes can be found in a single air-laid blank 10.

[0042] At least one crease 12A, 12B, 12C, 12D extends through a portion of the thickness of the air-laid blank 10, but not through the full thickness of the air-laid blank 10, such that portions 14, 16A, 16B, 16C, 16D of the air-laid blank 10 remain together.

[0043] In one embodiment, the air-laid web blank 10 includes at least two creases 12A, 12B, 12C, and 12D that form corresponding fold lines, see [reference]. Figure 5-6 In such an implementation, the folded 3D-formed packaging product 30 includes at least two sidewalls 36A, 36B and a central section 34, see [link to relevant documentation]. Figure 7At least two sidewalls 36A, 36B are angled relative to the intermediate section 34 at corresponding angles, which are independently selected in the range of 10° to 170°. In one embodiment, at least two sidewalls 36A, 36B are angled relative to the intermediate section 34 at corresponding angles, which are independently selected in the range of 45° to 135°, preferably in the range of 80° to 100°, and more preferably about 90°.

[0044] Figure 5 An example of an air-laid web blank 10 with two creases 12A, 12B according to the present invention is shown. The air-laid web blank 10 can be considered to comprise two end portions 16A, 16B and a middle portion 14. The figure also illustrates how the air-laid web blank 10 can be folded along the two creases 12A, 12B to obtain, after hot pressing, the desired result. Figure 7 The folded 3D-formed packaging product 30 is shown. In this case, the two end portions 16A, 16B correspond to the side walls 36A, 36B of the folded 3D-formed packaging product 30, and the middle portion 14 corresponds to the middle section 34. Such a folded 3D-formed packaging product 30 can be used to enclose packaged goods and protect three sides of the packaged goods. The folded 3D-formed packaging product 30 then forms a pocket-like structure. Two such folded 3D-formed packaging products 30 can be combined to enclose all six sides of the packaged goods. However, if the packaged goods partially extend into the cavities in the side walls 36A, 36B of the folded 3D-formed packaging product 30, such that the side walls 36A, 36B at least partially extend around the packaged goods, then... Figure 5 The thick, folded 3D-formed packaging product 30, as shown, formed by the airflow web blank 10, can completely protect three sides of the packaged goods and at least partially protect two other sides of the packaged goods.

[0045] Figure 6 Another embodiment of the air-laid preform 10 according to the invention, having four creases 12A, 12B, 12C, and 12D, is shown. This embodiment of the air-laid preform 10 has four end portions 16A, 16B, 16C, and 16D, as well as a middle or central portion 14. The folded 3D-formed packaging product 30 produced from this air-laid preform 10 will thus protect the five sides of the packaged goods and form a lidless box-like structure.

[0046] In one embodiment, the natural fiber of the air-laid web blank 10 is wood fiber. In a specific embodiment, the natural fiber is cellulose and / or lignocellulose fiber. Thus, in one embodiment, the natural fiber contains cellulose, such as in the form of cellulose and / or lignocellulose (i.e., a mixture of cellulose and lignin). The natural fiber may also contain lignin, such as in the form of lignocellulose. The natural fiber may additionally contain hemicellulose. In a specific embodiment, the natural fiber is cellulose and / or lignocellulose pulp fiber produced by chemical, mechanical, and / or chemimechanical pulping of softwood and / or hardwood. For example, the cellulose and / or lignocellulose pulp fiber is selected from the following forms: sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fibers (MDF-fibers) intended for use in medium-density fiberboard, chemimechanical pulp (CTMP), high-temperature chemimechanical pulp (HTCTMP), and combinations thereof.

[0047] Natural fibers can also be produced through other pulping methods and / or from other cellulosic or lignocellulosic raw materials such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw, or rice husks.

[0048] The air-laid preform 10 contains at least 70% natural fibers by weight. In a preferred embodiment, the air-laid preform 10 contains at least 72.5% natural fibers by weight, more preferably at least 75%, such as at least 77.5%, at least 80%, at least 82.5%, or at least 85%. In some applications, even higher concentrations of natural fibers may be used, such as at least 87.5%, at least 90%, at least 92.5%, at least 95%, or at least 96% by weight of the air-laid preform 10.

[0049] A thermoplastic polymer binder is included as an adhesive in the air-laid preform 10 to bond the air-laid preform 10 together and maintain its shape and structure during processing and storage. The thermoplastic polymer binder may also contribute to the formation of a foam-like structure in the air-laid preform 10. The thermoplastic polymer binder intertwines with natural fibers during the air-laid process to form a fiber mixture. The thermoplastic polymer binder can be added in powder form, but is more commonly added in fiber form, intertwined with natural fibers during the air-laid process. Alternatively or additionally, the thermoplastic polymer binder may be added as a solution, emulsion, or dispersion to and on the air-laid preform 10 during the air-laid process. The latter technique is best suited for thin air-laid preforms 10.

[0050] In one specific embodiment, the thermoplastic polymer binder is selected from thermoplastic polymer powders, thermoplastic polymer fibers, and combinations thereof.

[0051] In one embodiment, the thermoplastic polymer adhesive, or at least a portion thereof, has a softening point that does not exceed the degradation temperature of the natural fibers. Therefore, the thermoplastic polymer adhesive, or at least a portion thereof, softens at a processing temperature that does not exceed the degradation temperature of the natural fibers during hot pressing. This means that at least a portion of the thermoplastic polymer adhesive becomes ductile but preferably non-melting, which enables hot pressing while maintaining at least partially the porous structure of the air-laid preform 10 within the folded 3D-formed packaging product 30, wherein the hot pressing is performed at a temperature that does not degrade the natural fibers in the air-laid preform 10.

[0052] In one embodiment, the thermoplastic polymer binder is or comprises thermoplastic polymer fibers cut to a fixed length, typically referred to as short fibers. It is generally preferred if the length of the thermoplastic polymer fibers is on the same order of magnitude as or longer than the length of the natural fibers, for mixing in the air-laid process, and thus for the properties of the resulting air-laid preform 10. The lengths of the thermoplastic polymer fibers and natural fibers mentioned herein are length-weighted average fiber lengths. The length-weighted average fiber length is calculated as the sum of the squares of the individual fiber lengths divided by the sum of the individual fiber lengths.

[0053] In one embodiment, the thermoplastic polymer adhesive is or comprises thermoplastic polymer fibers selected in the range of 100 to 600%, preferably 125 to 500%, and more preferably 150 to 450% of the length-weighted average fiber length of natural fibers. In a specific embodiment, the thermoplastic polymer adhesive is or comprises thermoplastic polymer fibers selected in the range of 200 to 400%, preferably 250 to 350%, of the length-weighted average fiber length of natural fibers. In a specific embodiment, the length-weighted average fiber length of the thermoplastic polymer fibers is in the range of 1 to 12 mm, such as in the range of 1 to 10 mm, preferably in the range of 2 to 8 mm, and more preferably in the range of 2 to 6 mm.

[0054] The length-weighted average fiber length of natural fibers depends on the source of the natural fibers (such as the tree species from which they originate) and the pulping process. The typical range of the length-weighted average fiber length of natural fibers is from about 0.8 mm to about 5 mm.

[0055] In one embodiment, the thermoplastic polymer adhesive is or comprises monocomponent and / or bicomponent thermoplastic polymer fibers, such as those composed of monocomponent and / or bicomponent thermoplastic polymer fibers. Bicomponent thermoplastic polymer fibers (also known as bico fibers) comprise a core and sheath structure, wherein the core is made of a first polymer, copolymer, and / or polymer mixture, and the sheath is made of a second, different polymer, copolymer, and / or polymer mixture.

[0056] In one embodiment, the thermoplastic polymer binder is or comprises a bicomponent polymer fiber, such as a bicomponent polymer fiber comprising a core component made of a material having a melt temperature higher than the temperature at which the air-laid preform 10 is heated during hot pressing. The bicomponent polymer fiber also comprises a sheath component made of a material having a melt temperature lower than the temperature at which the air-laid preform 10 is heated during hot pressing.

[0057] In this embodiment, the melt temperature of the core component of the bicomponent polymer fiber is higher than that of the sheath component. Furthermore, the melt temperature of the core component is higher than the processing temperature at which the air-laid preform is heated during hot pressing, while the melt temperature of the sheath component is lower. This means that the core component does not melt but advantageously becomes ductile during hot pressing, while the sheath component melts or at least significantly thickens. Therefore, the sheath component adheres to the natural fibers, while the unmelted but ductile core component provides structural support. This bicomponent polymer fiber achieves good adhesion to the natural fibers and simultaneously maintains the porous structure of the air-laid preform, even during hot pressing.

[0058] In one embodiment, the thermoplastic polymer adhesive is or comprises a single-component thermoplastic polymer fiber, such as a single-component thermoplastic polymer fiber made of: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0059] Therefore, in one embodiment, the thermoplastic polymer fiber is made of a material selected from the group mentioned above. In another embodiment, the thermoplastic polymer fiber is made of a material selected from the group mentioned above, plus one or more additives.

[0060] In another embodiment, the thermoplastic polymer adhesive is or comprises a two-component thermoplastic polymer fiber, such as a two-component thermoplastic polymer fiber having a core and / or sheath made of: i) one or more materials selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives. In another embodiment, the thermoplastic polymer adhesive is or comprises a combination or mixture of the following, such as a single-component thermoplastic polymer fiber made of: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives; and a two-component thermoplastic polymer fiber having a core and / or sheath made of: i) one or more materials selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0061] Thermoplastic polymer adhesives can be made from a single type of thermoplastic polymer fiber, i.e., from the same material in the case of single-component thermoplastic polymer fibers, or from the same one or more materials in the case of two-component thermoplastic polymer fibers. However, thermoplastic polymer adhesives made from one or more (i.e., at least two) different single-component thermoplastic polymer fibers made from different materials and / or one or more different two-component thermoplastic polymer fibers made from different materials can also be used.

[0062] In one embodiment, the thermoplastic polymer binder is or comprises a thermoplastic polymer powder made from: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0063] As mentioned earlier, thermoplastic polymer adhesives, which are combinations of thermoplastic polymer fibers and thermoplastic polymer powders, can also be used.

[0064] Generally, air-laid preforms and the folded 3D-formed packaging products made from them can be recycled if they can disintegrate in an opener for that specific purpose and run through the air-laid process again, possibly with the addition of additional adhesives. This is practically only possible for edge trims and other process waste that are recycled within the production facility. It is not an option for consumers and other end-users because air-laid processes are not present in existing recycling schemes. A better option would be if products produced by or through air-laid processes could be classified into one of the existing recycling classes (for which there are already operational collection and recycling systems). These would be the naturally existing classes collected from air-laid preforms and 3D-formed packaging products, as most of the material is made from wood fibers that can enter the paper or paperboard manufacturing process. In the case of printing paper that is sensitive to impurities that may cause defects (failures) in the printing process or darker paper specifications, paperboard classes are typically a better option. Recycled paperboard is typically used as the middle layer in multi-layered boxboard or as the corrugated paper in corrugated board. These are less sensitive to impurities, even those that reduce the strength of recycled materials.

[0065] A prerequisite for a material to be used in paperboard recycling is that it is repulpable, meaning that when sheared with water in a repulping process, it will largely break down into individual fibers and thus pass screening to obtain usable pulp with a good yield. Conventional thermoplastic fiber binders used for air-laid preforms adhere too well to cellulose and / or lignocellulose fibers. Therefore, these thermoplastic fibers somewhat inhibit disintegration, making the yield of the repulping process too low to be economically viable.

[0066] Thermoplastic polymer adhesives with high adhesion and low melting points, typically used for sheaths of monocomponent and bicomponent fibers, present additional problems in paperboard recycling. These can turn into stickies and classify the material as unsuitable for recycling in repulping processes. One way to address these two issues is to use adhesives that dissolve in water during the repulping process (i.e., are water-soluble at repulping temperatures). Simultaneously, the adhesive needs to be thermoplastic, with a melting point not exceeding the degradation temperature of the natural fibers, and should maintain excellent adhesion to natural fibers after reheating and cooling. Furthermore, the adhesive should not have harmful effects on the paperboard manufacturing process. It is also advantageous if they are safe for use in food contact applications.

[0067] In paper or paperboard processes, "repulpingability" and "recyclability" are most widely tested using the PTS method, PTS-RH 021 / 97, from the German Papiertechnische Stiftung. For paperboard products, the PTS method tests recyclability in two steps, with the first step being a repulpingability test. In the repulpingability test, 50g of material is disintegrated for 20 minutes in a standard disintegrator under the conditions specified in PTS-RH 021 / 97. Undispersed residue is screened out and its weight is measured. If the weight of the undispersed residue corresponds to less than 20% of the initial weight (50g), the material is classified as "recyclable." If the weight of the undispersed residue is 20-50% of the initial weight, the material is classified as "recyclable but warrants product design improvement." Part II of PRS-Method PTS-RH 021 / 97 for paperboard products tests for impurities, particularly substances that become extremely sticky when heated to 130°C during testing. In paperboard manufacturing processes, such sticky or tacky substances can adhere to machine fabrics and other essential components of the paperboard machine, causing operational problems and requiring extended, costly cleaning downtime. In the paper and paperboard industry, this type of impurity is commonly referred to as "adhesive." The presence of such adhesive in an unscreened, disintegrating sample classifies the material as "not recyclable due to adhesive." The presence of other impurities may limit the availability of recycled pulp from the material but is not considered entirely harmful.

[0068] Therefore, in one embodiment, the thermoplastic polymer adhesive, or at least a portion thereof, is water-soluble at the resizing temperature selected for resizing the air-laid preform 10. In this case, the air-laid preform 10 and the folded 3D-shaped packaging product 30 made therefrom can be recycled in the resizing process as mentioned.

[0069] As used herein, water solubility means that the thermoplastic polymer binder dissolves or disperses in water during the repulping process. For example, the thermoplastic polymer binder may dissolve or disperse in water at the repulping temperature of the repulping process, i.e., forming a solution or colloidal dispersion in which the thermoplastic polymer binder exists as a single molecule and / or forms colloidal aggregates. In one embodiment, as used herein, water solubility means a solubility greater than 0.5 g thermoplastic polymer binder / 100 ml water, preferably at least 1 g thermoplastic polymer binder / 100 ml water, and more preferably at least 5 g thermoplastic polymer binder / 100 ml water, such as at least 10 g thermoplastic polymer binder / 100 ml water. Therefore, in one embodiment, at least a portion of the water-soluble thermoplastic polymer binder preferably has water solubility according to the above.

[0070] Examples of such water-soluble thermoplastic polymer materials are polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, and mixtures thereof.

[0071] In one embodiment, the thermoplastic polymer adhesive is or comprises a single-component thermoplastic polymer fiber, such as a single-component thermoplastic polymer fiber made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives. In another embodiment, the thermoplastic polymer adhesive is or comprises a two-component thermoplastic polymer fiber, such as a two-component thermoplastic polymer fiber having a sheath or sheath and core made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives. In a specific embodiment, at least the sheath of the two-component thermoplastic polymer fiber is made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives. In such a specific embodiment, the core of the bicomponent thermoplastic polymer fiber may also be selected from this group. However, if the core of the bicomponent thermoplastic polymer fiber does not soften in hot pressing to become sticky and adhere to the natural fiber, the core can actually be made of fiber that is not necessarily water-soluble at the repulping temperature. This means that the core can be made of the thermoplastic polymer materials mentioned above. Therefore, in this specific embodiment, the bicomponent thermoplastic polymer fiber comprises a core component made of: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives; and a sheath component made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives. In another embodiment, the thermoplastic polymer adhesive is or comprises a combination of the following, such as a single-component polymer fiber made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives; and a two-component polymer fiber having a core and / or sheath made of: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.

[0072] In one embodiment, the thermoplastic polymer binder is or comprises a thermoplastic polymer powder made from: i) a material selected from PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0073] In one specific embodiment, the air-laid preform 10 and preferably folded 3D-formed packaging product 30 are resizing or recyclable, preferably as defined according to PTS-method PTS-RH 021 / 97 from German Papiertechnische Stiftung. Therefore, in one specific embodiment, under the conditions specified in PTS-method PTS-RH 021 / 97, after disintegrating 50g of the air-laid preform 10 or the folded 3D-formed packaging product 30 in a standard disintegrator for 20 minutes, the air-laid preform 10 and preferably folded 3D-formed packaging product 30 result in less than 50% (weight / weight), preferably less than 20% (weight / weight) of undispersed residue.

[0074] The repulping temperature used in the repulping process is typically in the range of 20°C to 100°C, such as in the range of 30°C to 90°C, and typically in the range of 30°C to 70°C. Therefore, in one embodiment, at least a portion of the thermoplastic polymer adhesive is water-soluble at a temperature selected from the range of 20°C to 100°C, preferably in the range of 30°C to 90°C, and more preferably in the range of 30°C to 70°C. In one specific embodiment, according to PTS-method PTS-RH 021 / 97, the temperature of the water used in the repulping process is about 40°C. Therefore, in one embodiment, at least a portion of the thermoplastic polymer adhesive is water-soluble at 40°C.

[0075] In summary, the PTS method, PTS-RH 021 / 97, involves disintegrating the sample according to DIN EN ISO 5263-1:2004-12, but using tap water at 40°C. Diluent is poured onto the sample material, which is placed in a disintegrator (the standard disintegrator of DIN EN ISO 5263-1:2004-12) without pre-swelling. The sample material disintegrates to a consistency of 2.5% od, corresponding to a weighing of 50 g od and a slurry volume of 2 L. The disintegration period is 20 minutes (60,000 rpm). After disintegration, the slurry (total stock solution) is completely transferred to a standard dispenser (the standard dispenser of ZELLCHEMING Technical Information Sheet ZM V / 6 / 61) and diluted with tap water to a total volume of 10 L, corresponding to a consistency of 0.5%. Screening was performed according to ZELLCHEMING Technical Information Sheet ZM V / 18 / 62, using a perforated plate with a 0.7 mm pore size. The test apparatus was set to "low stroke" mode. A test portion (400 ml) corresponding to 2 g od of slurry was removed from the dispenser and diluted to a total volume of 1000 ml. This was then filled into the sieve over a period of 30 seconds and sieved for 5 minutes at a wash water pressure of 0.3 bar. After 5 minutes, the water supply and membrane displacement motor were shut off. The valve on the retainer was opened to drain the water that had accumulated below the test chamber. The locking screw was loosened and the test chamber was tilted upwards. The rear nozzle was covered with one hand to prevent water droplets from falling onto the unprotected perforated plate with residue on it. The residue from the perforated plate was washed into a 2 L tank and dehydrated through a filter inserted into a Buchner funnel. The filter was folded once and placed in a desiccator to dry at 105°C to constant weight. If the disintegration residue is no more than 20% of the input, the product is rated as "recyclable". However, if the disintegration residue is between 20% and 50% of the input, it is rated as "recyclable but warrants product design improvement".

[0076] In one embodiment, the air-laid preform 10 contains a thermoplastic polymer binder selected at a concentration of 10 to 30% by weight of the air-laid preform 10, such as 15 to 30%. In a specific embodiment, the air-laid preform 10 contains more than 15% by weight but not more than 30% by weight of the thermoplastic polymer binder. For example, the air-laid preform 10 contains a thermoplastic polymer binder selected at a concentration of 15 or 17.5% by weight of the air-laid preform 10, such as 30%. In a specific embodiment, the air-laid preform 10 contains a thermoplastic polymer binder selected at a concentration of 15 or 17.5% by weight of the air-laid preform 10, such as 20 to 25%.

[0077] In some applications, it may be advantageous to have a relatively high concentration of thermoplastic polymer binder, such as greater than 15% by weight of the air-laid preform 10, so as to maintain the integrity and foam-like structure of the air-laid preform 10 even when it is pressed at lower pressures to obtain a porous 3D-formed product 20. Therefore, if a thermoplastic polymer binder with an excessively low concentration, i.e., less than 4% by weight of the air-laid preform 10, is included, the resulting 3D-formed product 20 may unintentionally disintegrate or break down because the combination of the excessively low concentration of the thermoplastic polymer binder and the “soft” hot pressing of the air-laid preform 10 is insufficient to maintain the structure of the 3D-formed product 20.

[0078] In some embodiments, the air-laid preform 10 contains a thermoplastic polymer binder selected at a concentration in the range of 4 to 15% by weight of the air-laid preform 10, preferably in the range of 5 to 15% by weight of the air-laid preform 10, such as in the range of 7.5 to 15% by weight of the air-laid preform 10, and more preferably in the range of 10 to 15% by weight of the air-laid preform 10.

[0079] In one embodiment, the density of the folded 3D-formed packaging product 30 and the 3D-formed product 20 is equal to or less than four times the density of the air-laid preform 10. In a specific embodiment, the density of the folded 3D-formed packaging product 30 and the 3D-formed product 20 is equal to or less than three times the density of the air-laid preform 10, preferably equal to or less than twice the density of the air-laid preform 10.

[0080] In one specific embodiment, the density of the air-laid blank 10, as mentioned herein, is preferably the density of the air-laid blank 10 before at least one crease 12A, 12B, 12C, 12D is formed in the air-laid blank 10.

[0081] In one embodiment, the folded 3D-formed packaging product 30 is produced in a hot-pressing process from an air-laid preform 10, which retains at least some of the porosity of the air-laid preform 10. Therefore, the density of the folded 3D-formed packaging product 30 is less than four times the density of the air-laid preform 10. Prior art hot-pressing processes for producing dense 3D-formed packaging products with thin cross-sections typically increase the density of the 3D-formed packaging product to tens of times, such as 10 to 50 times, the density of the air-laid preform. This significant increase in density in prior art 3D-formed packaging products implies a substantial loss of porosity in the air-laid preform, resulting in a dense and compact fibrous structure. In stark contrast, the relatively low density increase according to this embodiment also maintains the porous structure of the air-laid preform 10 in the folded 3D-formed packaging product 30.

[0082] As used herein, the density of the folded 3D-formed packaging product 30 is the average or average density of the folded 3D-formed packaging product 30. This means that the folded 3D-formed packaging product 30 may contain portions or parts with different porosities and thus different densities. This is due to the shape of the male mold tool 60 used in hot pressing, which hot presses different portions of the air-laid blank 10 at different levels or amounts, see [link to relevant documentation]. Figure 8-11 However, the density of the folded 3D-formed packaging product 30 is the average or average density, not the density of its different portions, and represents the total mass of the folded 3D-formed packaging product 30 divided by the volume of the 3D-formed packaging product 30 (excluding the volume generated during hot pressing by the male mold tool 60 and / or female mold tool 70, see [link to relevant documentation]). Figure 8-9 ) and / or during the folding of the 3D-formed product 20 (see Figure 12 (any cavity in the folded 3D molded packaging product 30 formed by the product).

[0083] In one specific embodiment, the hot pressing of the air-laid preform 10 preferably results in an increase in density of the folded 3D-shaped packaged product 30 of no more than 300%, preferably no more than 250%, and more preferably no more than 200%, 150%, or most preferably no more than 100%, compared to the density of the air-laid preform 10.

[0084] However, since the male mold tool 60 or both the male mold tool 60 and the female mold tool 70 are hot-pressed into the air-laid preform 10, the hot pressing preferably results in an increase in the density of the 3D-formed product 20 compared to the density of the air-laid preform 10. The density increase due to hot pressing is preferably at least 5%, such as at least 7.5%, at least 10%, at least 12.5%, at least 15%, at least 17.5%, at least 20%, at least 22.5%, at least 25%, or even higher, such as at least 30%, at least 40%, at least 50%, at least 60%, at least 70%, at least 80%, at least 90%, or at least 100%.

[0085] In various embodiments, the density increase due to hot pressing is at least 12.5% ​​but not more than 300%, such as at least 15% but not more than 275%, at least 17.5% but not more than 250%, at least 20% but not more than 225%, such as at least 22.5% but not more than 200%.

[0086] In one specific embodiment, no part of the 3D-formed product 20 formed by hot pressing the air-laid preform 10 has a high density. Therefore, cushioning and / or thermal insulation properties are preferably achieved for all parts of the 3D-formed product 20. In one embodiment, the density of any part of the 3D-formed product 20 is no greater than ten times the average density of the air-laid preform 10, preferably greater than nine times, such as greater than eight, seven, six, or five times, and more preferably greater than four times, such as three or two times.

[0087] As used herein, hot pressing refers to exposing the air-laid preform 10 to pressure applied by pressing the male die tool 60 or the male die tool 60 and female die tool 70 into the air-laid preform 10, or pressing the male die tool 60 and female die tool 70 with the air-laid preform 10 placed therebetween, while simultaneously heating or exposing the air-laid preform 10 to heat. Therefore, hot pressing means pressing at a temperature above room temperature, preferably at a temperature where the thermoplastic polymer adhesive or at least a portion thereof is malleable. This document incorporates... Figures 17 to 19 The use of heated tools 60, 70 and / or heated airflow web-forming blank 10 for hot pressing is further described.

[0088] In one embodiment, the density of the air-blown blank 10 is selected to be between 10 and 60 kg / m³. 3 Within the range.

[0089] In one embodiment, the density of the 3D-formed product 20 and the folded 3D-formed packaged product 30 is selected to be between 15 and 240 kg / m³. 3 Within a preferred embodiment, the density of the 3D molded product 20 and the folded 3D molded packaging product 30 is selected to be between 15 and 200 kg / m³. 3 Within the range of 15 to 150 kg / m 3 Within the range, and more preferably between 15 and 100 kg / m 3 Within a specific embodiment, the density of the 3D-formed product 20 and the folded 3D-formed packaging product 30 is selected to be between 20 and 75 kg / m³. 3 Within the range, preferably between 25 and 70 kg / m 3 Within the range, and more preferably between 25 and 65 kg / m 3 Within the range.

[0090] In one embodiment, the thickness of the air-laid preform 10 is at least 10 mm, preferably at least 20 mm, and more preferably at least 30 mm, such as at least 40 mm, or even thicker, such as at least 50 mm, at least 60 mm, at least 70 mm, at least 80 mm, or at least 90 mm. In a specific embodiment, the thickness of the air-laid preform 10 is at least 100 mm, such as at least 150 mm, at least 200 mm, or at least 250 mm. Very thick air-laid preforms 10, with a thickness of at least 300 mm, are also possible. Thus, in such an embodiment, a considerably thick air-laid preform 10 is used to obtain a folded 3D-formed package product 30 suitable for cushioning and / or thermal insulation, even after hot pressing. The thickness of the air-laid preform 10 can be selected based on the specific application of the resulting folded 3D-formed package product 30, such as based on the cushioning and / or isolation requirements of the folded 3D-formed package product 30 and / or based on the geometry of the packaged goods to be protected by the folded 3D-formed package product 30.

[0091] Accordingly, the wall thickness of the folded 3D-formed packaging product 30 and / or the 3D-formed product 20 may be at least 10 mm, preferably at least 15 mm, such as at least 20 mm or at least 25 mm, and more preferably at least 30 mm, such as at least 35 mm, or at least 40 mm, or even thicker, such as at least 45 mm or at least 50 mm. In one embodiment, when the air-laid preform 10 is hot-pressed into the 3D-formed product 20 or the folded 3D-formed packaging product 30, a low average pressure preferably equal to or less than 200 kPa is used. This low average pressure maintains most of the thickness of the air-laid preform 10. As further described herein, the hot pressing of the air-laid preform 10 may hard-press different portions of the air-laid preform 10 differently. Therefore, the thickness of some portions of the 3D-formed product 20 or the folded 3D-formed packaging product 30 may be substantially the same as or only slightly less than the thickness of the air-laid preform 10. In one specific embodiment, at least those portions of the folded 3D-formed packaging product 30 that come into contact with the goods to be protected preferably have the thicknesses mentioned above.

[0092] In one embodiment, the folded 3D-formed packaging product 30 is configured to protect the packaged goods from electrostatic discharge (ESD). In such an embodiment, the air-laid preform 10 is conductive or semi-conductive. For example, the air-laid preform 10 may contain conductive polymers or conductive fibers to make the air-laid preform 10, and thus the folded 3D-formed packaging product 30 formed by hot-pressing the air-laid preform 10, conductive or semi-conductive. In this case, the air-laid preform 10 preferably contains conductive polymers or fibers at a concentration not exceeding 10% by weight of the air-laid preform 10, and more preferably not exceeding 5% by weight of the air-laid preform 10. In one embodiment, a portion of the natural fibers may be replaced with conductive polymers or fibers. In another embodiment, the adhesive is made of or contains conductive polymers. In another embodiment, both embodiments are combined. In one specific embodiment, the conductive polymer or fiber is carbon fiber. Instead of or as a supplement to having conductive polymers or fibers, the air-laid preform 10 may contain conductive or semi-conductive fillers, such as carbon black, which may be, for example, in the form of an additive to the adhesive.

[0093] Therefore, in addition to natural fibers and thermoplastic polymer binders, the air-laid preform 10 may also contain one or more additives. One or more additives may be added to the thermoplastic polymer binder and / or added during the production of the thermoplastic polymer binder. Alternatively or additionally, one or more additives may be added to the natural fibers. Alternatively or additionally, one or more additives may be added to both the natural fibers and the thermoplastic polymer binder, such as during the air-laid process.

[0094] Exemplary but non-limiting examples of such additives include conductive or semi-conductive fillers, coupling agents, flame retardants, dyes, impact modifiers, etc.

[0095] Another aspect of the implementation scheme relates to a method for manufacturing an air-laid web blank 10, see [link to implementation details]. Figure 1-4And 15. The air-laid preform 10 comprises natural fibers at a concentration of at least 70% by weight of the air-laid preform 10 and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform 10. The method includes pressing a mold 40 having at least one rod 42 into the air-laid preform 10 in step S1 to form at least one crease 12A, 12B, 12C, 12D. The at least one crease 12A, 12B, 12C, 12D constitutes a folding line for folding the 3D-formed product 20 into a folded 3D-formed packaged product 30 for cushioning and / or thermal insulation of packaged goods. The 3D-formed product 20 is formed by hot pressing the air-laid preform 10 containing at least one crease 12A, 12B, 12C, 12D. Alternatively, at least one crease 12A, 12B, 12C, 12D constitutes a folding line for hot pressing and folding an air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D to form a folded 3D-shaped packaged product 30 for cushioning and / or thermal insulation of goods.

[0096] As mentioned above, the shape of at least one rod 42 of the mold 40 defines the cross-sectional shape and size of at least one crease 12A, 12B, 12C, 12D in the airflow web blank 10. For example, as an illustrative but non-limiting example, at least one rod 42 may have a pointed cross-section, a V-shaped or wedge-shaped cross-section, a U-shaped cross-section, or a rectangular cross-section. In one embodiment, the tip 44 of at least one rod 42 is a rounded tip 44. Such a rounded tip 44 presses down onto rather than cuts through a portion of the thickness of the airflow web blank 10, thereby resulting in at least one crease 12A, 12B, 12C, 12D that is more suitable for folding than one with a sharp tip.

[0097] In step S1, a mold 40 having at least one rod 42 is pressed into the air-laid blank 10 to form at least one crease 12A, 12B, 12C, 12D. In this operation step S1, the at least one rod 42 is preferably pressed onto but not through the air-laid blank 10, thereby reducing the risk of unintentionally cutting the air-laid blank 10 in half instead of forming at least one crease line.

[0098] The mold 40 may include a single rod 42 or multiple rods 42. In a preferred embodiment, the mold 40 includes a rod 42 for each crease 12A, 12B, 12C, 12D to be formed in the air-laid blank 10.

[0099] In one embodiment, step S1 includes pressing a heated mold 40 having at least one rod 42 into the air-laid preform 10. Heating the mold 40, or more precisely, at least one rod 42, causes the thermoplastic polymer binder in one or more portions of the air-laid preform 10 joined by the at least one rod 42 to soften. This softening of the thermoplastic polymer binder means that at least one crease 12A, 12B, 12C, 12D formed remains indented in the air-laid preform 10 even after cooling, and even during processing of the air-laid preform 10 before and after hot pressing.

[0100] In one embodiment, the mold 40 includes heating elements 46, which are preferably controllable heating elements 46, to heat the mold 40, or more specifically, at least one mold 42, to a desired temperature. The temperature of the mold 40 typically depends on the type of natural fibers and thermoplastic polymer binder in the air-laid preform 10 and the pressing cycle time in step S1. In one specific embodiment, the heated mold 40 is preferably heated to a temperature selected in the range of 120°C to 210°C, and more preferably in the range of 120°C to 190°C. At these temperatures, many thermoplastic polymer binders are in a ductile but unmelted state.

[0101] When at least one rod 42 of the mold 40 is pressed into the air-blown preform 10, the air-blown preform 10 is preferably positioned on the base pressure plate 50, such as Figures 1 to 4 As shown in the diagram. In one embodiment, the base plate 50 is at ambient temperature. In another embodiment, the base plate 50, or at least a portion thereof, is heated. For example, the base plate 50 may be divided into different sections or areas, wherein at least one section or area is heated while the remaining section or area is not heated, or the different sections or areas of the base plate 50 may be heated at different temperatures. In one specific embodiment, one or more sections or areas of the base plate 50 aligned with at least one rod 42 of the mold 40 are preferably heated, or preferably heated to a higher temperature than the remaining sections or areas of the base plate 50.

[0102] exist Figure 1 and 2 In this process, the air-blown blank 10 can be in a pre-cut form, that is, it has already been cut into the desired shape by means of a saw, cutter, or stamping die. Alternatively, any such cutting operation can be performed after the pressing operation in step S1.

[0103] Figure 3 and 4Alternative embodiments are shown. In this embodiment, the mold 40 includes at least one cutter 41 configured to cut at least a portion of the air-laid blank 10, preferably simultaneously with pressing at least one rod 42 into the air-laid blank 10. Thus, in this embodiment, the cutting of the air-laid blank 10 and the formation of at least one crease 12A, 12B, 12C, 12D are preferably performed in the same pressing operation in step S1, and using the same tool (i.e., the mold 40 containing both at least one rod 42 and at least one cutter 41).

[0104] Figure 16 This is a flowchart illustrating another embodiment of a method for manufacturing an air-laid preform 10, the air-laid preform comprising natural fibers at a concentration of at least 70% by weight of the air-laid preform 10 and a thermoplastic polymer binder selected at a concentration in the range of 4% to 30% by weight of the air-laid preform 10. The method includes sawing or cutting at least one crease 12A, 12B, 12C, 12D in the air-laid preform 10 in step S10. The at least one crease 12A, 12B, 12C, 12D constitutes a folding line for folding the 3D-formed product 20 into a folded 3D-formed packaged product 30 for cushioning and / or thermal insulation of goods. The 3D-formed product 20 is formed by hot-pressing the air-laid preform 10 containing at least one crease 12A, 12B, 12C, 12D. Alternatively, at least one crease 12A, 12B, 12C, 12D constitutes a folding line for hot pressing and folding an air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D to form a folded 3D-shaped packaged product 30 for cushioning and / or thermal insulation of goods.

[0105] Therefore, in this embodiment, at least one crease 12A, 12B, 12C, 12D is formed in the air-laid web blank 10 by sawing or cutting through a portion of the thickness of the air-laid web blank 10, rather than the entire thickness. The shape and size of at least one crease 12A, 12B, 12C, 12D are defined by the tool (e.g., a saw or cutter) used in step S10.

[0106] The tool (such as a saw or cutter) used in step S10 may be at ambient temperature or may be heated, such as to a temperature in the range of 120°C to 210°C, preferably in the range of 120°C to 190°C.

[0107] Another aspect of the present invention relates to a method for manufacturing a foldable 3D-molded packaging product 30, see [link to relevant documentation]. Figure 8 , 9 17 and 18. The method includes manufacturing the air-laid web blank 10 according to the invention in step S20, as described above. Figure 15 Or as described in 16. In one embodiment, the method includes as follows: Figure 17 The two additional steps S21 and S22 are shown. Step S21 includes hot-pressing a male mold tool 60 into an air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D to form a 3D-formed product 20 containing at least one crease 22A, 22B, 22C, 22D, 22E and having a 3D shape at least partially defined by the male mold tool 60. The method further includes, in step S22, folding the 3D-formed product 20 at at least one crease 22A, 22B, 22C, 22D, 22E to form a folded 3D-formed packaged product 30 for cushioning and / or thermal insulation of goods. In another embodiment, the method includes as follows Figure 18 The additional step S23 shown can also be found in [the document / reference]. Figure 8 and 9 Step S23 includes hot-pressing the male mold tool 60 into an airflow web blank 10 containing at least one crease 12A, 12B, 12C, 12D and positioned on the female mold tool 70, and folding the airflow web blank 10 at at least one crease 12A, 12B, 12C, 12D to form a folded 3D-formed packaging product 30 for cushioning and / or thermal insulation of goods. In this embodiment, the folded 3D-formed packaging product 30 has a 3D shape at least partially defined by the male mold tool 60 and the female mold tool 70.

[0108] exist Figure 17 In the embodiment shown, hot pressing and folding are performed as two separate operation or method steps. In the first step S21, the male mold tool 60 is hot-pressed into the air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D to form a 3D-formed product 20 containing at least one crease 22A, 22B, 22C, 22D, 22E, as shown in Figure 12 The cross-sectional view is schematically shown. In this cross-sectional view, the 3D-formed product 20 includes two folds 22A and 22B forming fold lines, two end portions 26A and 26B, and a middle portion 24. When pressed into the air-laid preform 10, the male mold tool 60 produces a 3D structure 21. Therefore, the 3D-formed product 20 has a 3D shape as indicated by 21, at least partially defined by the male mold tool 60.

[0109] During the hot pressing in step S21, the air-blown blank 10 is preferably positioned on the base plate 50.

[0110] Then, in step S22 and as Figure 12 As indicated by the arrow in the middle, Figure 17The 3D-formed product 20 created in step S21 is folded along creases 22A and 22B to form a folded 3D-formed packaging product 30. Figure 7 In the cross-sectional view, the folded 3D-formed packaging product 30 has a pocket-like structure with two sidewalls 36A, 36B corresponding to the end portions 26A, 26B of the 3D-formed product 20, and a middle section 34 corresponding to the middle portion 24 of the 3D-formed product 20. The folded 3D-formed packaging product 30 defines a cavity 35, and at least a portion 31 of the inner surface of the folded 3D-formed packaging product 30 has a 3D shape defined by a male mold tool 60 and adapted to the shape of the packaged goods to be protected by the folded 3D-formed packaging product 30. Figure 7 The folded 3D-formed packaging product 30 shown may have more than two side walls 36A, 36B, such as two, three, or four side walls, wherein... Figure 7 Only two are displayed.

[0111] exist Figure 18 In the illustrated embodiment, hot pressing and folding are performed at least partially simultaneously. An air-laid blank 10 having at least one crease 12A, 12B, 12C, 12D is then positioned on a female mold tool 70 instead of a base platen 50. A male mold tool 60 is then hot-pressed into the air-laid blank 10 to create a 3D shape in at least a portion of the air-laid blank 10. Thus, the male mold tool 60 includes at least one structure 62 to be hot-pressed into the air-laid blank 10 to create a 3D structure 31 in the air-laid blank 10 and the resulting folded 3D-formed packaged product 30. Hot-pressing the male mold tool 60 into the air-laid blank 10 not only creates a 3D structure in the air-laid blank 10 but also pushes the air-laid blank 10 into the female mold tool 70, as... Figure 8 As shown. Then, the air-formed preform 10 is folded along at least one crease 12A, 12B, 12C, 12D. In step S23, the internal shape and geometry of the resulting folded 3D-formed packaging product 30 are defined by the male mold tool 60, while the external shape and geometry of the folded 3D-formed packaging product 30 are defined by the female mold tool 70. In this operation, the end portions 16A, 16B of the air-formed preform 10 are folded up and pressed against the side of the male mold tool 60 to define the sidewalls 36A, 36B of the cavity 35. The bottom of the cavity 35 (i.e., Figure 7 The middle section 34) is simultaneously limited by the downward pressing action of the male mold tool 60.

[0112] The above description and Figure 7 , 8The methods shown in 9, 17 and 18 can be used to produce folded 3D-formed packaging products 30 with more than two sidewalls 36A, 36B (such as three or four sidewalls).

[0113] In one embodiment, the female mold tool 70 has a cavity 78, the depth of which is greater than the height of the side walls 36A, 36B of the folded 3D-formed packaging product 30. Therefore, the side walls 72, 74 of the female mold tool 70 are preferably higher than the side walls 36A, 36B of the folded 3D-formed packaging product 30. In such an embodiment, the airflow web-forming preform 10 will be completely pressed into the female mold tool 70, which acts as a mold, by the thermo-pressing action of the male mold tool 60. Figure 9 As shown, compared to the case where a portion of the initial airflow web blank 10 would protrude beyond the female mold tool 70 and thus not be pressed between the male mold tool 60 and the female mold tool 70, the resulting folded 3D-formed packaging product 30 typically has a more defined overall structure because it is fully pressed into the female mold tool 70.

[0114] In one embodiment, the edge 76 of the female mold tool 70 is curved outward to guide the airflow web-forming blank 10, containing at least one crease 12A, 12B, 12C, 12D, into the cavity 78 of the female mold tool 70. See also Figure 8 When the male mold tool 60 presses the airflow web blank 10 into the cavity 78 of the female mold tool 70, this curved edge 76 simplifies the folding of the airflow web blank 10 at at least one crease 12A, 12B, 12C, 12D.

[0115] In one implementation scheme Figure 17 Step S21 involves hot-pressing a heated male die tool 60 into the air-laid preform 10. In this embodiment, the heated male die tool 60 is preferably heated to a temperature selected in the range of 120°C to 210°C, and more preferably in the range of 120°C to 190°C. Therefore, in this embodiment, heating of the air-laid preform 10 is achieved using a heated male die tool 60. The male die tool 60 may include heating elements 66, which are preferably controllable heating elements 66 to heat the male die tool 60 to the desired temperature for hot pressing. The temperature of the male die tool 60 typically depends on the type of natural fibers and thermoplastic polymer binder in the air-laid preform 10 and the cycle time of hot pressing in step S21. However, the ranges presented above are suitable for most combinations of natural fibers, thermoplastic polymer binders, and cycle times.

[0116] In one embodiment, the air-blown blank 10 is positioned on the base plate 50. In another embodiment... Figure 17Step S21 includes hot-pressing a heated male mold tool 60 into an air-laid blank 10 positioned on a base plate 50 at a temperature equal to or lower than the ambient temperature.

[0117] In this embodiment, heating of the air-laid preform 10 is achieved via the male mold tool 60, while the base platen 50 is at ambient temperature, typically room temperature, or may even be cooled. Keeping the base platen 50 at ambient temperature or even cooled reduces the risk of overheating the air-laid preform 10 during hot pressing in step S21, which could otherwise have negative consequences such as degradation of natural fibers, molten thermoplastic polymer binders, and disruption of the porous structure of the air-laid preform 10 and the resulting 3D molded product 20.

[0118] However, during the hot pressing in step S21, even when combined with the heated male mold tool 60, the airflow web-forming blank 10 can be positioned on the heated base platen 50. In this case, during the hot pressing in step S21, the surface of the airflow web-forming blank 10 placed on the heated base platen 50 can be heat-sealed.

[0119] In a corresponding implementation plan. Figure 18 Step S23 involves hot-pressing the heated male mold tool 60 into the airflow web-forming blank 10 positioned on the female mold tool 70. The temperature range presented above is also suitable for the heated male mold tool 60 in this embodiment.

[0120] In one embodiment, step S23 includes hot-pressing the heated male mold tool 60 into the airflow web-forming blank 10 positioned on the heated female mold tool 70. In a specific embodiment, the heated female mold tool 70 is preferably heated to a temperature selected in the range of 120°C to 210°C, and more preferably in the range of 120°C to 190°C. In this case, during the hot-pressing in step S23, the surfaces of the airflow web-forming blank 10 facing the heated male mold tool 60 and the heated female mold tool 70 can be heat-sealed.

[0121] In one embodiment, both the male mold tool 60 and the female mold tool 70 are heated to a temperature preferably selected within the range of 120°C to 210°C, and more preferably within the range of 120°C to 190°C. The male mold tool 60 and the female mold tool 70 may be heated to the same or different temperatures. In another embodiment, one of the male mold tool 60 and the female mold tool 70 is heated, while the other is at ambient temperature or even cooled.

[0122] In the embodiments presented above, at least one of the tools 60, 70 used in the hot pressing in step S21 or S23 is heated. In another embodiment, in step S21 or S23, at least a portion of the air-laid blank 10 is heated before the male mold tool 60 is hot-pressed into the air-laid blank 10.

[0123] Therefore, it is preferable to heat the air-laid preform 10 before the hot pressing operation, rather than heating the male mold tool 60 and / or any female mold tool 70. Then, the air-laid preform 10 is preferably heated to a temperature at which the thermoplastic polymer adhesive or at least a portion thereof is in a malleable but unmelted state. For most thermoplastic polymer adhesives, this temperature is in the range of 80°C to 180°C, such as 100°C to 180°C or 120°C to 160°C. Therefore, in one embodiment, the air-laid preform 10 is preferably heated to a temperature in the range of 80°C to 180°C.

[0124] In this embodiment, the male mold tool 60 and the base platen 50 or the female mold tool 70 can be independently exposed to ambient temperature (such as room temperature) or cooled.

[0125] In one embodiment, heating of the airflow web blank 10 can be combined with the use of a heated male mold tool 60 or at least one of the heated male mold tool 60 and female mold tool 70.

[0126] Another aspect of the invention relates to a foldable 3D-formed packaging product 30 for cushioning and / or thermal insulation of packaged goods. The foldable 3D-formed packaging product 30 is folded at at least one crease 22A, 22B, 22C, 22D, 22E forming a fold line in a 3D-formed product 20 formed by hot pressing an air-laid preform 10, the air-laid preform comprising at least 70% natural fibers by weight of the air-laid preform 10 and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform 10.

[0127] In one embodiment, the folded 3D-formed packaging product 30 includes at least two sidewalls 36A, 36B and a middle section 34. The at least two sidewalls 36A, 36B are angled relative to the middle section 34 at corresponding angles, which are independently selected in the range of 10° to 170°, preferably in the range of 45° to 135°, and more preferably in the range of 80° to 100°, such as 90°.

[0128] Another aspect of the invention relates to a 3D-molded product 20. The 3D-molded product 20 is formed by hot pressing an air-laid preform 10 comprising at least 70% natural fibers by weight of the air-laid preform 10 and a thermoplastic polymer binder selected from a concentration in the range of 4% to 30% by weight of the air-laid preform 10. The 3D-molded product 20 includes at least one crease 22A, 22B, 22C, 22D, 22E, which forms fold lines for folding the 3D-molded product 20 into a folded 3D-molded packaged product 30 for cushioning and / or thermal insulation of goods.

[0129] In one embodiment, the density of the 3D-formed product 20 and the folded 3D-formed packaging product 30 is equal to or less than four times the density of the air-laid preform 10. In a specific embodiment, the density of the 3D-formed product 20 and the folded 3D-formed packaging product 30 is equal to or less than three times the density of the air-laid preform 10, and preferably equal to or less than twice the density of the air-laid preform 10.

[0130] Preferred embodiments regarding the density and thickness of the folded 3D-formed packaging product 30 and the 3D-formed product 20 are presented above.

[0131] Another aspect of the present invention relates to a method for manufacturing a 3D-molded product 20, see [link to previous article]. Figure 10-12 And 19. The method includes, in step S30, hot-pressing a male mold tool 60 into an air-laid preform 10, the air-laid preform comprising at least 70% by weight of natural fibers and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform 10, to form a 3D-formed product 20 having a 3D shape at least partially defined by the male mold tool 60. The method further includes, in step S31 and simultaneously with step S30, pressing at least one rod 64 into the air-laid preform 10 to form at least one crease 22A, 22B, 22C, 22D, 22E, the crease constituting a folding line for folding the 3D-formed product 20 into a folded 3D-formed packaged product 30 for cushioning and / or thermal insulation of goods.

[0132] Therefore, in this embodiment, the air-laid web blank 10, lacking any creases, is used as... Figure 19 The starting material for the manufacturing method in the process. Then, the air-laid blank 10 is hot-pressed while pressing at least one rod 64 into the air-laid blank 10 to form at least one crease 22A, 22B, 22C, 22D, 22E.

[0133] Then, the 3D-shaped product 20 formed after steps S30 and S31 can be folded along at least one crease 22A, 22B, 22C, 22D, 22E in step S32 to obtain a folded 3D-shaped packaged product 30.

[0134] Compared to, for example, hot pressing and folding of an air-laid blank 10 containing at least one crease 12A, 12B, 12C, 12D to directly obtain a folded 3D-formed packaging product 30, a 3D-formed product 20 having at least one crease 22A, 22B, 22C, 22D, 22E and being foldable into a folded 3D-formed packaging product 30 has several advantages. For example, compared with Figure 8 and 9 As shown, compared to hot pressing and folding in the same operation, more complex folded 3D-formed packaging products 30 can be produced by separating the hot pressing and folding operations. Therefore, as Figure 19 The method shown enables greater flexibility in the geometry and shape of the final folded 3D-formed packaging product 30. Furthermore, in situations such as... Figure 19 The manufacturing process shown typically involves less waste. Another advantage is that the 3D-molded product 20 is substantially flat, thus allowing for efficient storage and / or transport while occupying limited space, and folding into a folded 3D-molded packaged product 30 that requires more space when first combined with packaged goods.

[0135] In one embodiment, steps S30 and S31 are performed simultaneously as a method step. Such a method step includes pressing the male die tool 60, comprising at least one rod 64, into the air-laid preform 10 while simultaneously hot-pressing the male die tool 60 into the air-laid preform 10. Therefore, in this embodiment, the male die tool 60 includes both at least one structure 62 for generating a 3D structure in the air-laid preform 10 and at least one rod 64 for generating at least one crease 22A, 22B, 22C, 22D, 22E in the resulting 3D molded product 20.

[0136] It can also be done in Figure 19 The method shown uses two different tools, namely a male mold tool 60 and a separate mold with at least one rod, which are preferably pressed down into the air-blown blank 10 substantially simultaneously.

[0137] Figures 1 to 4 The above disclosure of at least one rod 42 of the mold 40, with necessary modifications, is applied to at least one rod 64 of the male mold tool 60, including the design of at least one rod 64, the design of the tip of at least one rod 64, and the heating of at least one rod 64.

[0138] Positive mold tool 60 may include Figure 10 and11 At least one cutter 61 is shown in the diagram. Then, the at least one cutter 61 is used in conjunction with... Figure 3 and 4 At least one cutter 41 of the mold 40 operates in a similar manner. In another embodiment, the male mold tool 60 does not contain any cutter.

[0139] In one embodiment, step S30 includes hot-pressing the heated male die tool 60 into the air-blown blank 10. The heated male die tool 60 is then preferably heated to a temperature selected in the range of 120°C to 210°C, and more preferably in the range of 120°C to 190°C.

[0140] In one embodiment, step S30 includes hot-pressing a heated male mold tool 60 into an air-laid blank 10 positioned on a base plate 50 or a heated base plate 50 at a temperature equal to or lower than ambient temperature.

[0141] In one embodiment, a relatively low pressure is used during the hot processing of the air-laid preform 10, thereby maintaining at least a portion of the porosity of the air-laid preform 10 in both the 3D-formed product 20 and the folded 3D-formed packaging product 30. In such an embodiment, the air-laid preform 10 is preferably hot-pressed in steps S21, S23, and S30 at an average pressure equal to or less than 200 kPa, such as equal to or less than 175 kPa, or preferably equal to or less than 150 kPa. In one embodiment, the average pressure is defined as the force applied during hot pressing divided by the area of ​​the air-laid preform 10.

[0142] In some applications, it may be desirable to seal some or all of the surfaces of folded 3D-formed packaging product 30 and / or 3D-formed product 20, such as by heating, to prevent linting from one or more surfaces onto the packaged goods. Surfaces that have undergone heat treatment in hot pressing will be sealed, and no additional (heat) sealing is required. At least one surface to be sealed can be sealed before or after the hot pressing operation, such as by heating. Therefore, in one embodiment, folded 3D-formed packaging product 30 and / or 3D-formed product 20 includes at least one surface that is heat-sealed to inhibit linting from at least one surface.

[0143] In some applications, the folded 3D-formed packaging product 30 and / or 3D-formed product 20, or at least a portion thereof, may be laminated with a surface layer such as a thermoplastic polymer film or nonwoven textile. This prevents linting and adds additional functionality to the surface, such as moisture resistance, tactile properties, color, and design. The film or nonwoven material can be made from any common thermoplastic polymer. Examples include the thermoplastic polymer materials previously mentioned as adhesives. The layer may be thermally laminated onto the air-laid preform 10, the folded 3D-formed packaging product 30 and / or 3D-formed product 20, and / or applied directly to the air-laid preform 10 and / or 3D-formed product 20, such as by extrusion. In one embodiment, the film laminated to at least one surface or a portion thereof of the folded 3D-formed packaging product 30 and / or 3D-formed product 20 is conductive or semi-conductive to provide ESD protection for the packaged goods.

[0144] Therefore, in one embodiment, the folded 3D-formed packaging product 30 and / or the 3D-formed product 20 includes at least one surface coated with a surface layer selected from a down-proof layer, a moisture-proof layer, a tactile layer, and a coloring layer.

[0145] Films, textiles, or surface layers can be attached to the air-laid preform 10, the folded 3D-formed packaging product 30, or the 3D-formed product 20 by means of a thin layer of hot melt adhesive, through an additional adhesive film, or by themselves becoming semi-molten and tacky during the hot lamination process. This operation can be performed before, after, or simultaneously with the hot pressing operation. If lamination is performed on at least one surface of the air-laid preform 10, which will subsequently be processed by hot pressing, the softening point of the surface laminate should not exceed the degradation temperature of the natural fibers of the air-laid preform 10. Any hot pressing operation performed after the surface layer is provided should preferably be performed at a temperature where the surface layer is in a semi-molten or ductile state but not in the molten stage. If hot pressing is performed at excessively high temperatures where the surface layer is in the molten stage, the surface layer may peel off from the surface, and if the temperature exceeds the degradation temperature of the natural fibers, the natural fibers may begin to degrade further.

[0146] In one embodiment, the surface layer is attached to at least one surface of the 3D-molded product 20 by hot melt adhesive and / or by an adhesive film.

[0147] In another embodiment, the surface layer can be applied by spraying it onto one or more surfaces of the folded 3D-formed packaging product 30 and / or the 3D-formed product 20. This layer may contain any substance that can be prepared as a solution, emulsion, or dispersion, such as thermoplastic polymers; natural polymers such as starch, agar, guar gum, or locust bean gum; microfibrillated or nanofibrillated cellulose or lignocellulose, or mixtures thereof. Furthermore, the surface layer may contain other substances that provide additional functionality to the surface layer and the folded 3D-formed packaging product 30, such as emulsifiers, stabilizers, conductive agents, etc.

[0148] The above embodiments should be understood as several exemplary examples of the present invention. Those skilled in the art will understand that various modifications, combinations, and changes can be made to the embodiments without departing from the scope of the present invention. In particular, where technically possible, different portions of solutions from different embodiments can be combined in other configurations.

Claims

1. An air-blown web blank (10), comprising: The concentration is at least 70% natural fiber based on the weight of the air-laid preform (10); and A thermoplastic polymer binder selected with a concentration in the range of 4% to 30% based on the weight of the air-laid preform (10), wherein The air-laid web blank (10) includes at least one crease (12A, 12B, 12C, 12D), which forms a fold line for use in... i) Folding a three-dimensional (3D) shaped product (20) into a folded three-dimensional (3D) shaped packaging product (30) for cushioning and / or thermal insulation of goods, wherein the three-dimensional (3D) shaped product (20) is formed by hot pressing the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D); or ii) Hot pressing and folding of the air-laid blank (10) containing at least one of the creases (12A, 12B, 12C, 12D) to form a folded three-dimensional (3D) shaped packaged product (30) for cushioning and / or thermal insulation of goods. The thermoplastic polymer adhesive comprises bicomponent polymer fibers, the bicomponent polymer fibers comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

2. The air-laid web blank according to claim 1, wherein... The air-laid blank (10) includes at least two creases (12A, 12B, 12C, 12D), which form corresponding fold lines; and The folded three-dimensional (3D) shaped packaging product (30) includes at least two sidewalls (36A, 36B) and a middle section (34), wherein the at least two sidewalls (36A, 36B) are angled relative to the middle section (34) at corresponding angles, the corresponding angles being independently selected in the range of 10° to up to 170°.

3. The air-laid web blank according to claim 2, wherein the corresponding angle is independently selected in the range of 45° to up to 135°.

4. The air-laid web blank according to claim 2, wherein the corresponding angle is independently selected in the range of 80° to up to 100°.

5. The air-laid web blank according to claim 2, wherein the corresponding angle is 90°.

6. The air-laid web blank according to any one of claims 1 to 5, wherein the natural fiber is wood fiber.

7. The air-laid web blank according to claim 6, wherein the natural fiber is cellulose and / or lignocellulose fiber.

8. The air-laid web blank according to claim 6, wherein the natural fiber is cellulose and / or lignocellulose pulp fiber produced by chemical, mechanical and / or chemimechanical pulping of softwood and / or hardwood.

9. The air-laid preform according to claim 6, wherein the natural fiber is a cellulose and / or lignocellulose pulp fiber selected from the following forms: sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fiber (MDF-fiber) intended for use in medium-density fiberboard, chemi-thermomechanical pulp (CTMP), high-temperature chemi-thermomechanical pulp (HTCTMP), or a combination thereof.

10. The air-laid preform according to any one of claims 1 to 9, wherein the air-laid preform (10) comprises the thermoplastic polymer binder selected in a concentration range of 15% to 30% by weight of the air-laid preform (10).

11. The air-laid preform according to claim 10, wherein the air-laid preform (10) comprises the thermoplastic polymer binder selected in a concentration range of 17.5% to 30% by weight of the air-laid preform (10).

12. The air-laid preform according to claim 10, wherein the air-laid preform (10) comprises the thermoplastic polymer binder selected in a concentration range of 17.5% to 25% by weight of the air-laid preform (10).

13. The air-laid preform according to any one of claims 1 to 12, wherein the thermoplastic polymer binder or at least a portion thereof has a softening point not exceeding the degradation temperature of the natural fibers.

14. The air-laid preform according to any one of claims 1 to 13, wherein the thermoplastic polymer binder is a bicomponent polymer fiber, the bicomponent polymer fiber comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

15. The air-laid preform according to any one of claims 1 to 14, wherein the thermoplastic polymer binder comprises one-component and two-component thermoplastic polymer fibers, the one-component and two-component thermoplastic polymer fibers being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

16. The air-laid preform according to any one of claims 1 to 14, wherein the thermoplastic polymer binder is a one-component and a two-component thermoplastic polymer fiber, the one-component and two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

17. The air-laid preform according to any one of claims 1 to 14, wherein at least a portion of the thermoplastic polymer binder is water-soluble at the resizing temperature selected for resizing the air-laid preform (10).

18. The air-laid preform according to any one of claims 1 to 14 and 17, wherein the thermoplastic polymer binder comprises one-component and two-component thermoplastic polymer fibers, the one-component and two-component thermoplastic polymer fibers being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

19. The air-laid preform according to any one of claims 1 to 14 and 17 to 18, wherein the thermoplastic polymer binder is a one-component and a two-component thermoplastic polymer fiber, the one-component and two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

20. The air-laid preform according to any one of claims 1 to 14 and 17 to 19, wherein the thermoplastic polymer binder comprises a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

21. The air-laid preform according to any one of claims 1 to 14 and 17 to 19, wherein the thermoplastic polymer binder is a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

22. The air-laid blank according to any one of claims 1 to 21, wherein the density of the air-laid blank (10) is selected within the interval of 10 to 60 kg / m 3 2.

23. The air-laid web blank according to any one of claims 1 to 22, wherein the air-laid web blank (10) has a thickness of at least 10 mm.

24. The air-laid web blank according to claim 23, wherein the air-laid web blank (10) has a thickness of at least 20 mm.

25. The air-laid web blank according to claim 23, wherein the air-laid web blank (10) has a thickness of at least 30 mm.

26. A method for manufacturing an air-laid web preform (10), the air-laid web preform comprising: The concentration is at least 70% natural fiber based on the weight of the air-laid preform (10); and The method involves pressing (S1) a mold (40) having at least one rod (42) into the air-laid preform (10) to form at least one crease (12A, 12B, 12C, 12D), the crease constituting a fold line for use in... i) Folding a three-dimensional (3D) shaped product (20) into a folded three-dimensional (3D) shaped packaging product (30) for cushioning and / or thermal insulation of goods, wherein the three-dimensional (3D) shaped product (20) is formed by hot pressing the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D); or ii) Hot pressing and folding of the air-laid blank (10) containing at least one of the creases (12A, 12B, 12C, 12D) to form a folded three-dimensional (3D) shaped packaged product (30) for cushioning and / or thermal insulation of goods.

27. The method according to claim 26, wherein pressing (S1) the mold (40) comprises pressing (S1) a heated mold (40) having at least one rod (42) into the air-blown blank (10).

28. The method of claim 27, wherein the heated mold (40) is heated to a temperature selected in the range of 120°C to 210°C.

29. A method for manufacturing an air-laid web preform (10), the air-laid web preform comprising: The concentration is at least 70% natural fiber based on the weight of the air-laid preform (10); and The method involves sawing or cutting (S10) at least one crease (12A, 12B, 12C, 12D) in the air-laid preform (10), the at least one crease (12A, 12B, 12C, 12D) forming a fold line for use in the air-laid preform (10). The thermoplastic polymer adhesive is selected with a concentration ranging from 4% to 30% by weight of the air-laid preform (10). i) Folding a three-dimensional (3D) shaped product (20) into a folded three-dimensional (3D) shaped packaging product (30) for cushioning and / or thermal insulation of goods, wherein the three-dimensional (3D) shaped product (20) is formed by hot pressing the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D); or ii) Hot pressing and folding of the air-laid blank (10) containing at least one of the creases (12A, 12B, 12C, 12D) to form a folded three-dimensional (3D) shaped packaged product (30) for cushioning and / or thermal insulation of goods.

30. A method for manufacturing a foldable three-dimensional (3D) molded packaging product (30), the method comprising: Manufacturing (S20) an air-laid web blank (10) according to any one of claims 1 to 25; ia) Hot-press (S21) the male mold tool (60) into the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D) to form a three-dimensional (3D) shaped product (20) containing at least one crease (22A, 22B, 22C, 22D, 22E) and having a three-dimensional (3D) shape at least partially defined by the male mold tool (60); and ib) Fold (S22) the three-dimensional (3D) shaped product (20) at at least one crease (22A, 22B, 22C, 22D, 22E) to form the folded three-dimensional (3D) shaped packaging product (30) for cushioning and / or thermal insulation of goods; or iia) The male mold tool (60) is hot-pressed (S23) into the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D) and positioned on the female mold tool (70), and the air-laid blank (10) is folded at the at least one crease (12A, 12B, 12C, 12D) to form the folded three-dimensional (3D) shaped packaging product (30) for cushioning and / or thermal insulation of goods, wherein the folded three-dimensional (3D) shaped packaging product (30) has a three-dimensional (3D) shape defined at least partially by the male mold tool (60) and the female mold tool (70).

31. The method according to claim 30, wherein the hot pressing (S21) of the male mold tool (60) comprises hot pressing (S21) the heated male mold tool (60) into the air-laid blank (10).

32. The method of claim 31, wherein the heated male mold tool (60) is heated to a temperature selected in the range of 120°C to up to 210°C.

33. The method according to claim 30, wherein the hot pressing (S23) of the male mold tool (60) comprises hot pressing (S23) the heated male mold tool (60) into the air-laid blank (10) positioned on the female mold tool (70).

34. The method of claim 33, wherein the heated male mold tool (60) is heated to a temperature selected in the range of 120°C to up to 210°C.

35. The method according to claim 33, wherein the hot pressing (S23) of the heated male mold tool (60) comprises hot pressing (S23) the heated male mold tool (60) into the air-laid blank (10) positioned on the heated female mold tool (70).

36. The method of claim 35, wherein the heated female mold tool (70) is heated to a temperature selected in the range of 120°C to up to 210°C.

37. The method according to any one of claims 30 to 36, wherein the female mold tool (70) has a cavity (78) the depth of which is greater than the height of the sidewalls (36A, 36B) of the folded three-dimensional (3D) shaped packaged product (30).

38. The method according to any one of claims 30 to 37, wherein the edge (76) of the female mold tool (70) is bent outward to guide the air-laid blank (10) containing at least one crease (12A, 12B, 12C, 12D) into the cavity (78) of the female mold tool (70).

39. The method according to any one of claims 30 to 38, wherein hot pressing (S21, S23, S30) comprises hot pressing (S21, S23, S30) the male mold tool (60) into the air-laid blank (10) at an average pressure equal to or less than 200 kPa.

40. The method of claim 39, wherein the average pressure is equal to or less than 175 kPa.

41. The method of claim 39, wherein the average pressure is equal to or less than 150 kPa.

42. A folded three-dimensional (3D) molded packaging product (30) for cushioning and / or thermal insulation of goods, wherein the folded three-dimensional (3D) molded packaging product (30) is folded at at least one crease (22A, 22B, 22C, 22D, 22E) in a three-dimensional (3D) molded product (20) formed by hot pressing an air-laid preform (10), the air-laid preform (10) comprising at least 70% by weight of natural fibers and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform (10).

43. The foldable three-dimensional (3D) shaped packaging product according to claim 42, comprising: At least two sidewalls (36A, 36B); and The intermediate section (34), wherein at least two sidewalls (36A, 36B) are angled relative to the intermediate section (34) at corresponding angles, the corresponding angles being independently selected in the range of 10° to 170°.

44. The foldable three-dimensional (3D) shaped packaging product according to claim 43, wherein the respective angle is independently selected in the range of 45° to up to 135°.

45. The foldable three-dimensional (3D) shaped packaging product according to claim 43, wherein the respective angle is independently selected in the range of 80° to up to 100°.

46. ​​The foldable three-dimensional (3D) shaped packaging product according to claim 43, wherein the corresponding angle is 90°.

47. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 46, wherein the density of the folded three-dimensional (3D) shaped packaging product (30) is equal to or less than four times the density of the air-laid preform (10).

48. The folded three-dimensional (3D) shaped packaging product according to claim 47, wherein the density of the folded three-dimensional (3D) shaped packaging product (30) is equal to or less than three times the density of the air-laid preform (10).

49. The folded three-dimensional (3D) shaped packaging product according to claim 47, wherein the density of the folded three-dimensional (3D) shaped packaging product (30) is equal to or less than twice the density of the air-laid preform (10).

50. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 49, wherein the density of the folded three-dimensional (3D) shaped packaging product (30) is selected within the interval of 15 to 240 kg / m3. 3 of 15 to 240 kg / m3.

51. The foldable three-dimensional (3D) shaped packaging product according to claim 50, wherein the density of the foldable three-dimensional (3D) shaped packaging product (30) is between 15 and 200 kg / m³. 3 Choose within the specified range.

52. The foldable three-dimensional (3D) shaped packaging product according to claim 50, wherein the density of the foldable three-dimensional (3D) shaped packaging product (30) is between 15 and 150 kg / m³. 3 Choose within the specified range.

53. The foldable three-dimensional (3D) shaped packaging product according to claim 50, wherein the density of the foldable three-dimensional (3D) shaped packaging product (30) is between 15 and 100 kg / m³. 3 Choose within the specified range.

54. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 53, wherein the natural fiber is wood fiber.

55. The folded three-dimensional (3D) shaped packaging product according to claim 54, wherein the natural fiber is cellulose and / or lignocellulose fiber.

56. The foldable three-dimensional (3D) shaped packaging product according to claim 54, wherein the natural fiber is cellulose and / or lignocellulose pulp fiber produced by chemical, mechanical and / or chemimechanical pulping of softwood and / or hardwood.

57. The folded three-dimensional (3D) shaped packaging product according to claim 54, wherein the natural fiber is selected from cellulose and / or lignocellulose pulp fibers in the form of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fibers (MDF-fibers) intended for use in medium-density fiberboard, chemi-thermomechanical pulp (CTMP), high-temperature chemi-thermomechanical pulp (HTCTMP), or combinations thereof.

58. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 57, wherein the thermoplastic polymer adhesive or at least a portion thereof has a softening point not exceeding the degradation temperature of the natural fiber.

59. The foldable three-dimensional (3D) molded packaging product according to any one of claims 42 to 58, wherein the thermoplastic polymer adhesive comprises a two-component polymer fiber, the two-component polymer fiber comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

60. The foldable three-dimensional (3D) shaped packaging product according to any one of claims 42 to 58, wherein the thermoplastic polymer adhesive is a two-component polymer fiber, the two-component polymer fiber comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

61. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60, wherein the thermoplastic polymer adhesive comprises a single-component and / or a two-component thermoplastic polymer fiber, said single-component and / or a two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

62. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60, wherein the thermoplastic polymer adhesive is a one-component and / or two-component thermoplastic polymer fiber, said one-component and / or two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

63. The folded three-dimensional (3D) molded packaging product according to any one of claims 42 to 60, wherein at least a portion of the thermoplastic polymer adhesive is water-soluble at the resizing temperature selected for resizing the folded three-dimensional (3D) molded packaging product (30).

64. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60 and 63, wherein the thermoplastic polymer adhesive comprises a single-component and / or a two-component thermoplastic polymer fiber, said single-component and / or a two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

65. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60 and 63, wherein the thermoplastic polymer adhesive is a one-component and / or two-component thermoplastic polymer fiber, said one-component and / or two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

66. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60 and 63 to 65, wherein the thermoplastic polymer adhesive comprises a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

67. The folded three-dimensional (3D) shaped packaging product according to any one of claims 42 to 60 and 63 to 65, wherein the thermoplastic polymer binder is a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

68. Three-dimensional (3D) molded products (20), of which The three-dimensional (3D) molded product (20) is formed by hot pressing an air-laid preform (10) comprising at least 70% natural fibers by weight of the air-laid preform (10) and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform (10); and The three-dimensional (3D) shaped product (20) includes at least one crease (22A, 22B, 22C, 22D, 22E) which forms a folding line for folding the three-dimensional (3D) shaped product (20) into a folded three-dimensional (3D) shaped package product (30) for cushioning and / or thermal insulation of goods.

69. The three-dimensional (3D) formed product according to claim 68, wherein the density of the three-dimensional (3D) formed product (20) is equal to or less than four times the density of the air-laid preform (10).

70. The three-dimensional (3D) formed product according to claim 69, wherein the density of the three-dimensional (3D) formed product (20) is equal to or less than three times the density of the air-laid preform (10).

71. The three-dimensional (3D) formed product according to claim 69, wherein the density of the three-dimensional (3D) formed product (20) is equal to or less than twice the density of the air-laid preform (10).

72. The three-dimensional (3D) molded product according to any one of claims 68 to 71, wherein the density of the three-dimensional (3D) molded product (20) is between 15 and 240 kg / m³. 3 Choose within the specified range.

73. The three-dimensional (3D) molded product according to claim 72, wherein the density of the three-dimensional (3D) molded product (20) is between 15 and 200 kg / m³. 3 Choose within the specified range.

74. The three-dimensional (3D) molded product according to claim 72, wherein the density of the three-dimensional (3D) molded product (20) is between 15 and 150 kg / m³. 3 Choose within the specified range.

75. The three-dimensional (3D) molded product according to claim 72, wherein the density of the three-dimensional (3D) molded product (20) is between 15 and 100 kg / m³. 3 Choose within the specified range.

76. The three-dimensional (3D) molded product according to any one of claims 68 to 75, wherein the natural fiber is wood fiber.

77. The three-dimensional (3D) shaped product according to claim 76, wherein the natural fiber is cellulose and / or lignocellulose fiber.

78. The three-dimensional (3D) molded product according to claim 76, wherein the natural fiber is cellulose and / or lignocellulose pulp fiber produced by chemical, mechanical and / or chemimechanical pulping of softwood and / or hardwood.

79. The three-dimensional (3D) shaped product according to claim 76, wherein the natural fiber is selected from cellulose and / or lignocellulose pulp fibers in the form of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fibers (MDF-fibers) intended for use in medium-density fiberboard, chemi-thermomechanical pulp (CTMP), high-temperature chemi-thermomechanical pulp (HTCTMP), or combinations thereof.

80. The three-dimensional (3D) molded product according to any one of claims 68 to 79, wherein the thermoplastic polymer adhesive or at least a portion thereof has a softening point not exceeding the degradation temperature of the natural fiber.

81. The three-dimensional (3D) molded product according to any one of claims 68 to 80, wherein the thermoplastic polymer binder comprises a two-component polymer fiber, the two-component polymer fiber comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

82. The three-dimensional (3D) molded product according to any one of claims 68 to 80, wherein the thermoplastic polymer binder is a two-component polymer fiber, the two-component polymer fiber comprising: The core component is made of a material whose melting temperature is higher than the temperature at which the air-laid preform (10) is heated during hot pressing; and The sheath component is made of a material with a melting temperature lower than the temperature at which the air-laid blank (10) is heated during hot pressing.

83. The three-dimensional (3D) molded product according to any one of claims 68 to 82, wherein the thermoplastic polymer adhesive comprises a single-component and / or a two-component thermoplastic polymer fiber, said single-component and / or a two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

84. The three-dimensional (3D) molded product according to any one of claims 68 to 82, wherein the thermoplastic polymer binder is a one-component and / or two-component thermoplastic polymer fiber, said one-component and / or two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

85. The three-dimensional (3D) molded product according to any one of claims 68 to 82, wherein at least a portion of the thermoplastic polymer adhesive is water-soluble at the resizing temperature selected for resizing the folded three-dimensional (3D) molded packaging product (30).

86. The three-dimensional (3D) molded product according to any one of claims 68 to 82 and 85, wherein the thermoplastic polymer binder comprises a single-component and / or a two-component thermoplastic polymer fiber, said single-component and / or two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

87. The three-dimensional (3D) molded product according to any one of claims 68 to 82 and 85, wherein the thermoplastic polymer binder is a one-component and / or two-component thermoplastic polymer fiber, said one-component and / or two-component thermoplastic polymer fiber being made of: i) one or more materials selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

88. The three-dimensional (3D) molded product according to any one of claims 68 to 82 and 85 to 87, wherein the thermoplastic polymer binder comprises a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

89. The three-dimensional (3D) molded product according to any one of claims 68 to 82 and 85 to 87, wherein the thermoplastic polymer binder is a two-component thermoplastic polymer fiber, the two-component thermoplastic polymer fiber comprising: The core component is made from: i) a material selected from polyethylene (PE), ethylene-acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof, or mixtures thereof; and ii) optionally one or more additives; and The sheath component is made from: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, or mixtures thereof, and ii) optionally one or more additives.

90. A method for manufacturing a three-dimensional (3D) molded product (20), the method comprising: A male mold tool (60) is hot-pressed (S30) into an air-laid preform (10), the air-laid preform (10) comprising at least 70% natural fibers by weight of the air-laid preform (10) and a thermoplastic polymer binder selected in the range of 4% to 30% by weight of the air-laid preform (10) to form the three-dimensional (3D) molded product (20) having a three-dimensional (3D) shape at least partially defined by the male mold tool (60). and While the male mold tool (60) is hot-pressed (S30), at least one rod (64) is pressed (S31) into the air-laid blank (10) to form at least one crease (22A, 22B, 22C, 22D, 22E), which constitutes a folding line for folding the three-dimensional (3D) shaped product (20) into a folded three-dimensional (3D) shaped packaged product (30) for cushioning and / or thermal insulation of goods.

91. The method according to claim 90, wherein pressing (S31) the at least one rod (64) comprises pressing the male mold tool (60) containing the at least one rod (64) into the air-laid blank (10) while hot-pressing (S30) the male mold tool (60) into the air-laid blank (10).

92. The method according to claim 90 or 91, wherein the hot pressing (S30) of the male mold tool (60) comprises hot pressing (S30) the heated male mold tool (60) into the air-laid blank (10).

93. The method according to claim 92, wherein the heated male mold tool (60) is heated to a temperature selected in the range of 120°C to up to 210°C.

94. The method according to claim 92, wherein the hot pressing (S30) of the heated male mold tool (60) comprises hot pressing (S30) the heated male mold tool (60) into the air-laid blank (10) positioned on a base plate (50) at a temperature equal to or lower than the ambient temperature.

95. The method according to any one of claims 90 to 94, wherein hot pressing (S21, S23, S30) comprises hot pressing (S21, S23, S30) the male mold tool (60) into the air-laid blank (10) at an average pressure equal to or less than 200 kPa.

96. The method of claim 95, wherein the average pressure is equal to or less than 175 kPa.

97. The method of claim 95, wherein the average pressure is equal to or less than 150 kPa.

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