Protective packaging insert

Abstract

A protective packaging insert comprising a substrate and a solid cellulose foam sheet; wherein the substrate comprises at least two areas and at least one fold line separating the at least two areas, and the at least one fold line is arranged to allow the insert to be folded into a folded state; the solid cellulose foam board comprises two or more parts; wherein a first portion of the solid cellulose foam sheet comprises at least one through hole, and wherein at least one second portion of the solid cellulose foam sheet has a shape corresponding to a shape of the at least one through hole; wherein a bottom surface of the first portion of the solid cellulose foam sheet is fixedly arranged on a top surface of the first region of the substrate and an upper surface of the at least one second portion of the solid cellulose foam sheet is fixedly arranged on a top surface of the second region of the substrate.

Description

Technical Field

[0001] The present invention relates to the field of cellulose foam for packaging, and more particularly to a protective packaging insert comprising a substrate and a solid cellulose foam sheet.

[0002] The present invention further relates to methods of making protective packaging inserts and methods of protecting products by embedding the products in protective packaging inserts. Background Art

[0003] In a society striving to reduce plastic use and waste and move towards renewable materials, plastic packaging materials such as fossil-based foams appear increasingly out of place. With regulators now pushing for policies that trend towards restricting or banning fossil-based foam materials in packaging, new solutions are needed.

[0004] There are many challenges in finding foams from renewable resources. Many bio-based foams have higher production costs and lower mechanical properties, as well as poor stability in water or high temperatures compared to long-established foams from oil-based sources. Bio-based and recyclable protective materials need to have the same excellent properties and performance as petroleum-based protective materials to be preferred over petroleum-based materials.

[0005] The low weight and good shock absorption of bio-based foams are examples of critically important properties. Furthermore, the ability to tailor the shape and form of the bio-based foam to the shape and form of the goods to be shielded by the protective material is extremely important. As the most abundant renewable natural polymer on earth, cellulose has been shown to have particular potential due to its crystalline structure and the availability of methods for its preparation in large quantities on an industrial scale.

[0006] Several bio-based foams containing cellulose have been described. WO20200011587A1 describes a porous material prepared by aerating a paste containing cellulose fibers and gluten and depositing the aerated paste in a mold where the paste is dried. WO2015036659A1 describes a molded cellulosic product prepared by foaming an aqueous suspension of natural fibers combined with synthetic fibers and a surfactant, feeding the cellulosic foam into a mold where the cellulosic foam is dried to produce a dry cellulosic product.

[0007] Goods to be shielded may often have protruding parts that require additional protection by packaging materials during storage and transportation. In addition, goods may be made of susceptible materials (e.g., glass, porcelain) that require protection due to their fragility. When products are subjected to constant corner or edge impacts during the delivery cycle, bio-based foams on the market do not provide the necessary protection.

[0008] Therefore, there still exists a need for a solid cellulose foam that can be customized around goods of any shape and protect every part of the goods. The goods must be well shielded so that any impact generated during storage and transportation will be absorbed by the surrounding cellulose foam and, thus, will not damage the goods.

[0009] Furthermore, solid cellulose foams need to be renewable, biodegradable, and fully recyclable in the stream of regular paper and board, allowing them to become part of the circular material stream in the existing packaging waste management system. To be a competitive option, the production cost of producing the foams and customizing their shape into any product shape must be modest.

[0010] In order to save raw materials, there is also a need to reduce the amount of material in protective packaging inserts and to minimize waste material.

[0011] Furthermore, there is a need for protective packaging materials that can be easily transported to where the goods are to be packaged in the protective packaging materials, provide three-dimensional customized protection for the goods, and take up as little space as possible during transportation to the packaging location. Summary of the invention

[0012] It is an object of the present invention to obviate at least some of the disadvantages of the prior art and to provide a protective packaging insert comprising a substrate and a solid cellulose foam sheet and a method of making the protective packaging insert.

[0013] Thanks to the invention as defined in claim 1, a protective packaging insert is provided which is flat when not in use. An advantage of a flat insert is that it takes up very little space when stored or during transport to the place of use. All parts of the insert are fixedly arranged, which means that there are no loose parts which risk falling off or being lost.

[0014] Furthermore, the insert is easy to open / unfold, and when the insert is opened, the protective components are already in place, ready to receive the product to be protected by the insert.

[0015] All parts of the solid cellulose foam board are fixedly arranged on a substrate with low air permeability, so that the protective packaging insert can be used for vacuum suction and automation, making the assembly of the packaged product more convenient and less time-consuming.

[0016] Another advantage is that the cushioning and masking material of the insert (ie the solid cellulose foam board) can be easily customized to any shape of the product to be protected and has a low cost.

[0017] By a combination of through cuts and incomplete cuts in the solid cellulose foam sheet, portions of the solid cellulose foam sheet are provided which can be customized around a product.

[0018] The area of ​​the substrate can be folded towards the product so that the cut-out portion of the solid cellulose foam sheet comes into direct contact with the product. The very good cushioning capacity of the solid cellulose foam sheet effectively shields the product; the cut-out portion fixedly arranged on the substrate helps to position the product during embedding and gives additional protection.

[0019] As a result of compressing well defined portions of the solid cellulose foam board into a higher density compressed material, the stiffness and resilience of the solid cellulose foam board is increased in those portions.This provides a means for holding the product in place within the protective packaging insert.

[0020] Yet another advantage is that no waste material is formed during the manufacturing process of the insert. Instead, all the material and all the parts of the solid cellulose foam board are used through the customization of the board to the product shape.

[0021] The through cuts form through holes, the volume of which contributes to a housing for surrounding the product, whereas the incomplete cuts define a surface which is then pressed, thereby forming a pressed zone. The volume of the pressed zone also contributes to the housing. Thus, the arrangement of the housing in the solid cellulose foam board does not result in waste material.

[0022] The incomplete cuts allow the product to be perfectly positioned and add vital extra protection in the packaging. The pressed details of the solid cellulose foam board ensure proper positioning of the heaviest and / or most fragile parts of the product and ensure they remain in place.

[0023] Another advantage is that the production process of the present invention can be easily carried out in large-scale plants.

[0024] Further aspects and embodiments are defined in the appended claims, which are specifically incorporated herein by reference. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] The foregoing aspects of the present invention and many of the attendant advantages will become more readily appreciated as the same becomes better understood by reference to the following detailed description when used in conjunction with the accompanying drawings, in which:

[0026] The present invention will be described in more detail with reference to the accompanying drawings, in which:

[0027] Figure 1is an oblique side view from above of a protective packaging insert that has not yet been fully completed.

[0028] Figure 2a-2c showing different side views of a fully manufactured protective packaging insert in an unfolded state, and

[0029] Figure 3 An oblique view from above is shown of a folded protective packaging insert. DETAILED DESCRIPTION

[0030] Before the present invention is disclosed and described in detail, it should be understood that the present invention is not limited to the specific compounds, configurations, method steps, substrates, and materials disclosed herein, because such compounds, configurations, method steps, substrates, and materials may vary slightly. It should also be understood that the terminology employed herein is only for the purpose of describing specific embodiments and is not intended to be limiting, because the scope of the present invention is limited only by the appended claims and their equivalents.

[0031] It must be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise.

[0032] Unless otherwise defined, any terms and scientific terms used herein are intended to have the meaning commonly understood by one of ordinary skill in the art to which this invention belongs.

[0033] The term "about" used in conjunction with numerical values ​​throughout the specification and claims indicates an interval of accuracy familiar and acceptable to those skilled in the art. The interval is ±10%.

[0034] As used herein, the expression “fixedly arranged” means arranging one object to another object so that the objects are fixed to each other in an undetachable manner.

[0035] As used herein, the expression "a fold line separates..." means that a fold line divides a flat surface into two parts, whereby the two parts can be easily folded relative to each other so that they form an angle relative to each other. The parts separated by the fold line are still connected to each other and are the same as they were before the fold line was arranged. The fold line merely facilitates folding, and the folding occurs at the desired position.

[0036] As used herein, the expression "flat" means an object having a height, a width and a length. The width and the length define two surfaces, and the height defines at least one side wall. The height is so small relative to the length and the width that the object is considered to be a flat object. Examples of flat objects are boards, tabletops, wall mirrors, door panels, glass panes, solar panels. The expression "flat" refers to an object having a horizontal surface without any protrusions or depressions. Thus, when in the folded state, the top and bottom surfaces of the protective packaging insert of the present invention are flat, so that the packaging insert has no protruding parts.

[0037] The expressions "at least one removably arranged portion of the solid cellulose foam sheet" and "at least one second portion of the solid cellulose foam sheet" are used interchangeably hereinafter and refer to the same portion of the solid cellulose foam sheet.

[0038] The expressions "the remainder of the solid cellulose foam board" and "the first portion of the solid cellulose foam board" are used interchangeably hereinafter and refer to the same portion of the solid cellulose foam board.

[0039] As used herein, the term "foam" refers to a substance made by trapping air or gas bubbles inside a solid or liquid. Typically, the volume of the gas is much larger than the volume of the liquid or solid, with a thin film separating the gas pockets. In order to form a foam, three requirements must be met. Mechanical work is required to increase the surface area. This can occur by stirring, dispersing a large amount of gas into the liquid, or injecting the gas into the liquid. The second requirement is that a foam former (typically an amphiphilic substance), a surfactant, or a surface-active component must be present to reduce surface tension. Finally, the foam must form more quickly than the foam bursts.

[0040] As used herein, the term "cellulose foam" refers to a foam comprising cellulose and other components such as thickeners, surfactants and additives. The main component of the cellulose foam is cellulose, such that cellulose constitutes at least 70 wt % of the dry content of the cellulose foam. Cellulose has the form of fibers, and therefore, the foam may also be defined as a cellulosic foam or a cellulose fiber foam. The cellulose foam may be wet or solid.

[0041] As used herein, the term "wet foam" or "wet cellulose foam" refers to a wet foam comprising cellulose and other components such as thickeners, surfactants, and additives. Gas bubbles are present within the wet foam. The wet foam is free-standing and behaves as a viscoelastic solid. This means that the wet foam has both viscosity and elasticity. The wet foam will behave as a solid, and therefore free-standing, unless a force large enough is applied to cause it to begin to flow and behave instead as a viscous material. Depending on the magnitude and time scale of any applied shear stress, the wet foam may exhibit predominantly viscous or elastic behavior.

[0042] As used herein, the term "solid cellulose foam" or "dried cellulose foam" refers to a dry porous cellulose material that has been formed from a wet cellulose foam (i.e., a foam-forming material). During the drying process, the closed-cell wet cellulose foam is converted into an open-cell solid cellulose foam. During the drying process, the network of cellulose fibers is prevented from collapsing. Therefore, the solid cellulose foam will have a shape that corresponds to the shape of the wet cellulose foam to a large extent. The dry content of the solid cellulose foam may be at least 95 wt%, calculated based on the total weight of the solid cellulose foam. The shape and density of the solid cellulose foam are also maintained in an unrestricted state. The solid cellulose foam has an open-cell structure that allows air to occupy the pores within the foam. The solid cellulose foam may also be described as a porous material or a low-density material.

[0043] The following detailed description and the examples contained therein are provided only for the purpose of describing and illustrating certain embodiments of the present invention and are not intended to limit the scope of the present invention in any way.

[0044] In a first aspect, the present invention provides a protective packaging insert.

[0045] In a second aspect, the present invention is directed to a method of making a protective packaging insert comprising a substrate and a solid cellulosic foam material.

[0046] In a third aspect, the invention is directed to a method of protecting a product by embedding the product in a protective packaging insert.

[0047] The solid cellulose foam board may preferably be prepared from a cellulose foam composition comprising:

[0048] a) 71-95 wt% of cellulose fibers, calculated on the total weight of the solid content of the composition,

[0049] b) 4 to 24 wt% of a water-soluble thickener, calculated on the total weight of the solid content of the composition, and

[0050] c) at least two surfactants.

[0051] Cellulosic fibers suitable for use in the present invention may be derived from wood (e.g., softwood or hardwood), from leaves, or from fiber crops (including cotton, flax, and hemp). Cellulosic fibers suitable for use in the present invention may also be derived from regenerated cellulose, such as rayon and Lyocell. Cellulosic fibers suitable for use in the present invention may include lignin or hemicellulose or both, or the cellulose fibers may be free of lignin and hemicellulose. Preferably, the cellulose fibers are derived from wood, and more preferably, the cellulose fibers are pulp fibers obtained by a pulping process in which the fibers are released from a wood matrix. The pulp fibers may be released as follows: by mechanical pulping to obtain mechanical pulp, such as thermomechanical pulp (TMP) or chemical thermomechanical pulp (CTMP); or, by chemical pulping, such as kraft pulp or pulp obtained by sulfite process, soda process, or organic solvent pulping process. More preferably, the cellulose fibers are pulp fibers released by a chemical pulping process. The different characteristics of each cellulose fiber will affect the properties of the final cellulose foam. Compared to the width of the cellulose fibers, it is significantly longer. The cellulose fibers may have an average width of 0.01-0.05 mm. The fiber length of softwood can be 2.5-4.5mm, while hardwood can have a fiber length of 0.7-1.6mm, and eucalyptus is 0.7-1.5mm. However, the fiber length can vary considerably with different growing locations, etc. The cellulose fibers in the cellulose foam disclosed herein can have a length of 0.1mm-65mm, or 0.1mm-10mm, or 0.5mm-65mm, or 0.5mm-10mm, or 0.5mm-7mm. The fiber length can provide different mechanical properties for the foam. Due to the length of the fibers, they can entangle with each other and give the mutual combination of fibers to fibers (which brings strength to the foam). The aspect ratio (i.e., the ratio of fiber length to fiber width) of the cellulose fibers in the cellulose foam according to the present invention can be at least 10, at least 25, at least 50, at least 75, or at least 100, which provides the retention and stability of the foam structure during the drying procedure, making it possible to dry the wet cellulose foam in a retained shape. The aspect ratio can be up to 6500, or preferably up to 2000.

[0052] The cellulose fibers may be modified to provide different properties to the final cellulose foam. For example, phosphorylated fibers or periodate-oxidized fibers may also be used when producing cellulose foams according to the present invention.

[0053] The cellulosic fibers of the cellulosic foam composition may be selected from: wood pulp; regenerated cellulose fibers; and plant fibers, such as fibers from bamboo, cotton, hemp, flax, and jute.

[0054] Preferably, the cellulosic fibers are selected from: wood pulp, such as softwood pulp, hardwood pulp, chemithermomechanical pulp; and dissolving pulp; or a combination of one or more of these.

[0055] More preferably, the cellulosic pulp fibers are selected from softwood pulp, chemithermomechanical pulp, or dissolving pulp.

[0056] Most preferably, the cellulosic pulp fibers are selected from softwood pulps, such as softwood kraft bleached pulp.

[0057] The water-soluble thickener can be present in an amount of 4-24wt% or 5-20wt%, calculated by the total weight of the solid content of the foam. The thickener can have a molecular weight of 80000-250000g / mol or 83000-197000g / mol. Exemplary water-soluble thickeners are selected from carboxymethyl cellulose (CMC), methyl cellulose (MC), hydroxyethyl cellulose (HEC), ethyl hydroxyethyl cellulose (EHEC), methyl hydroxypropyl cellulose (MHPC), starch, xanthan gum, guar gum, and xyloglucan, or mixtures thereof.

[0058] The foam preferably comprises a mixture of at least two surfactants. One of the at least two surfactants is preferably a fast-acting surfactant that settles rapidly at the air-water interface during mechanical stirring during the preparation of the foam, which helps to form a foam with high density and high viscosity and is therefore able to become a self-standing foam. Suitable surfactants for this purpose are anionic surfactants, preferably low molecular weight anionic surfactants. Low molecular weight anionic surfactants can be selected from: sodium dodecyl sulfate (SDS); potassium dodecyl sulfate, sodium laureth sulfate (SLES); sodium dodecylbenzene sulfonate; sodium cocoyl sarcosinate; sodium lauroyl sarcosinate. Low molecular weight anionic surfactants are preferably selected from: sodium dodecyl sulfate (SDS); sodium p-n-dodecylbenzene sulfonate; sodium cocoyl sarcosinate; and sodium lauroyl sarcosinate. More preferably, the low molecular weight anionic surfactant is sodium cocoyl sarcosinate. The anionic surfactant may be biodegradable.

[0059] The other of the at least two surfactants is preferably a cosurfactant. The cosurfactant may be selected from: high pKa fatty acids, such as raw materials of plant origin, such as myristic acid, sodium oleate, lauric acid, palmitic acid, and stearic acid; glucose-based cosurfactants with aliphatic carbon tails, such as alkyl glycosides, alkyl polyglucosides, alkyl thioglycosides, and alkyl maltosides; amphoteric betaines, such as cocamidopropyl betaine (CAPB), and sodium cocoimidodipropionate (CADP); polyethylene glycol sorbitan monolaurate, i.e. (For example 20. 80 and 85); and polyoxyethylene lauryl ethers, such as polyethylene glycol lauryl ether, pentaethylene glycol monododecyl ether and octaethylene glycol monododecyl ether.

[0060] The foam composition can preferably be prepared by a method comprising the following steps:

[0061] a) decomposing cellulose fibers in water to obtain a slurry of cellulose fibers;

[0062] b) adding a thickener to the slurry obtained in a) to obtain a mixture of thickener and cellulose fibers in water;

[0063] c) adding the at least two surfactants to the mixture obtained in b) to obtain a fiber suspension;

[0064] d) aerating the suspension obtained in c) to obtain a wet foam,

[0065] The wet foam comprises 10-38 wt% of cellulose fibers, 0.5-10 wt% of a water-soluble thickener, and 0.1-2 wt% of a surfactant, calculated based on the total weight of the wet foam, and the wet foam has a density of 140-500 kg / m 3 Density and yield stress of 40-400Pa;

[0066] e) drying the wet foam obtained in d) to obtain a dry cellulose foam.

[0067] The wet foam can be dried without the use of a mold, ie, the wet foam is free-standing and retains its shape during drying without the need for a mold.

[0068] Due to the small bubble size (typically below 100 μm) obtained when the mixture of cellulose fibers, thickeners and surfactants is aerated, the wet foam is homogeneous and has good stability. The wet foam does not flocculate during processing. During any subsequent processing or drying step, the average bubble size remains unchanged to a large extent, and the cellulose fibers remain well dispersed. The resulting solid cellulose foam obtained by drying the wet foam will be uniform, firm, have good mechanical properties, smooth surface and no defects in structure. Since the foam has a smooth surface, it can be easily connected to, for example, a substrate. In contrast, the wet cellulose foam with low stability has a larger average bubble size (i.e., typically higher than 100 μm), and the bubbles will merge faster during processing and drying, so that larger bubbles are formed. In addition, the cellulose fibers will form clusters during processing and drying. This causes the wet foam to collapse during drying. The resulting solid cellulose foam will not have a uniform structure and will also contain such defects, which have the form of cavities produced by the merged bubbles in the wet foam. Due to the defects, such solid cellulose foam is not firm and has a rough surface.

[0069] The dried cellulose foam obtained in step e) can be used as a solid cellulose foam board.

[0070] The dried cellulose foam obtained in step e) may be obtained by a process comprising:

[0071] depositing discrete cells of foam on a surface to obtain a first foam deposition,

[0072] depositing wet foam between the discrete cells to obtain subsequent foam deposition, and,

[0073] The wet foam is dried to obtain a solid foam in which discrete cells of foam are embedded in a foam matrix. The solid foam can then be used as a solid cellulose foam board as claimed in claim 1 and its dependent claims.

[0074] However, without departing from the scope of the present invention, the solid cellulose foam board may be prepared by other methods than those described above. For example, the solid cellulose foam board may be prepared by a single deposition of wet foam into any desired shape. Optionally, any suitable confinement means may be used, such as a mold or a frame.

[0075] The solid cellulose foam board can be prepared, for example, by depositing the foam composition on the forming section of a conventional papermaking machine for forming foam webs or on a papermaking machine suitably adapted for this purpose.

[0076] The solid cellulose foam is preferably not a memory foam that returns to its original shape, but rather the foam remains in its compressed shape because the open cell structure of the body of the foam deforms during compression.

[0077] Examples of dimensions that may be considered are solid cellulose foam boards having a thickness in the range of 1-20 cm, or 1-10 cm, or 1-5 cm, or 4-6 cm. A preferred thickness is about 5 cm. The at least one base portion may be cut from such a board, and the thickness of the board may preferably correspond to the width of the rear surface 23 of the at least one base portion.

[0078] The dimensions described serve as examples only and should not be considered to limit the products of the present invention to the described dimensions.

[0079] The production of solid cellulose foam comprises different production steps, one of which is a drying step. During the drying step, the outer surfaces of the foam (top surface, bottom surface, side surfaces) will acquire an outer layer having different properties from the body part of the foam, which comprises a more uniform and open-celled porous fiber network. The outer layer has a higher density than the density of the body part, because the fibers are more densely packed and partly oriented differently. The outer layer is called a "densification layer". The densification layer will provide the foam with improved mechanical stability and improved strength.

[0080] Since the densified layer has improved mechanical stability and provides strength to the foam, it is preferred to orient the surface comprising the densified layer towards a direction where additional impact absorption may be required. The improved properties of the densified layer are used in various locations of the product where they can contribute to the protective properties of the product.

[0081] Despite the higher density, the densified layer is still highly porous and breathable.

[0082] The first aspect, the protective packaging insert, will now be described in detail.

[0083] exist Figure 1 , the protective packaging insert 1 comprising a substrate 2 and a solid cellulose foam board 3 is shown.

[0084] The substrate 2 is a flat substrate including a top surface 21 , a bottom surface 22 , and a width w2 (ie, the length of the short side of the substrate 2 ).

[0085] The substrate 2 includes: at least two regions 23, 25; and at least one folding line FL3 separating the at least two regions 23, 25, wherein the at least one folding line FL3 is arranged to allow the substrate 2 to be folded into a folded state.

[0086] exist Figure 1 In the embodiment, the substrate 2 comprises three regions 23, 24, 25 separated by two folding lines FL2, FL3. The three regions are a first region 25, a second region 23 and a third region 24.

[0087] The second region 23 includes three parts, namely, a first part 23a, a second part 23b, and a third part 23c.

[0088] The first portion 23a of the second region 23 includes a surface 231a.

[0089] The second portion 23b of the second region 23 includes a surface 231b.

[0090] The third portion 23c of the second region 23 includes a surface 231c.

[0091] The surfaces 231 a , 231 b , 231 c of the three portions 23 a , 23 b , 23 c are parts of the top surface 21 of the substrate 2 .

[0092] A folding line FL4 divides the second region into the first portion 23a and the second portion 23b, and another folding line FL5 further divides the second region into the second portion 23b and the third portion 23c.

[0093] The hole 20 is arranged on the folding line FL5 separating the second portion 23b and the third portion 23c and is centered on the folding line FL5.

[0094] The third region 24 includes two parts, namely a first part 24a and a second part 24b.

[0095] The first portion 24a of the third region 24 includes a surface 241a.

[0096] The second portion 24b of the third region 24 includes a surface 241b.

[0097] The surfaces 431 a , 241 b of the two portions 24 a , 24 b are parts of the top surface 21 of the substrate 2 .

[0098] The folding line FL1 divides the third region 24 into the first portion 24a and the second portion 24b.

[0099] The total length of the substrate is the sum of the sub-lengths of the regions and parts of the regions, i.e., the sum of l23c, l23b, l23a, l22, l24a and l24b (see Figure 2c ).

[0100] like Figure 1 As shown in FIG. 1 , the top surface 21 of the substrate 2 is arranged with the solid cellulose foam board 3 .

[0101] The solid cellulose foam board 3 comprises an upper surface 31 , a bottom surface 32 , two long side surfaces 33 having a length l3 , and two short side surfaces 34 having a width w3 .

[0102] The upper surface 31 and the bottom surface 32 are flat surfaces.

[0103] The bottom surface 32 of the plate 3 is arranged on the top surface 21 of the substrate 2 .

[0104] The width w3 of the short side surface 34 of the plate 3 corresponds to the width w2 of the substrate 2 .

[0105] The length l22 of the first region 25 of the substrate 2 (in Figure 2c ) corresponds to the length l3 of the long side surface 33 of the plate 3.

[0106] The long side surface 33 has a height h3 . The height h3 corresponds to the thickness x3 of the plate 3 .

[0107] The upper surface 31 of the plate 3 comprises at least one cutting line 4 having a predetermined cutting depth DC (see Figure 2a ).

[0108] The at least one cutting line 4 is arranged on the upper surface 31 of the solid cellulose foam board 3, thereby defining a first portion 36 and at least one second portion 35 of the solid cellulose foam board 3 (see Figure 2a-2c ).

[0109] The at least one cutting line 4 defines at least one pattern 6 on the upper surface 31 of the plate 3 .

[0110] The at least one pattern 6 defines the at least one second portion 35 including an upper surface 351 and the first portion 36 including an upper surface 361 .

[0111] The at least one second portion 35 of the plate 3 is arranged as at least one removably arranged portion 35 having an upper surface 351 .

[0112] exist Figure 1, it is shown that the at least one second portion 35 of the plate 3 (i.e. the at least one removably arranged portion 35 of the plate 3) includes four second portions 35a, 35b, 35c, 35d. Each of the four second portions 35a, 35b, 35c, 35d includes an upper surface 351a, 351b, 351c, 351d, respectively.

[0113] The two second parts of the at least one second part 35 form a first pair of removably arranged parts 35a, 35b and the two further second parts of the at least one second part 35 form a second pair of removably arranged parts 35c, 35d.

[0114] It should be understood that said first portion 36 is the remaining portion 36 of said plate 3 after cutting away said at least one second portion 35 .

[0115] Figure 2a-2c is a side view of the protective packaging insert 1, which will now be described in detail.

[0116] The bottom surface of the first portion 36 of the solid cellulose foam board 3 is fixedly arranged on the top surface 251 of the first region 25 of the substrate 2 .

[0117] According to the present invention, the upper surface 351 of the at least one second portion 35 of the solid cellulose foam board 3 is fixedly arranged on the top surface 231 b , 241 b of the at least one second area 23 , 24 of the substrate 2 .

[0118] The upper surfaces 351a, 351b of the first pair 35a, 35b of the at least one removably arranged portion 35 of the solid cellulose foam sheet 3 are fixedly arranged on the top surface 241b of the second portion 24b of the third area 24 of the substrate 2.

[0119] The upper surfaces 351c , 351d of the second pair 35c , 35d of the at least one removably arranged portion 35 of the solid cellulose foam sheet 3 are fixedly arranged on the top surface 231b of the second portion 23b of the second area 23 of the substrate 2 .

[0120] The first portion 36 of the solid cellulose foam sheet 3 comprises at least one through hole 38 .

[0121] exist Figure 2a-2c , it is shown that the first portion 36 includes two through holes 381 and 382 (a first through hole 381 and a second through hole 382 of the first portion 36 ).

[0122] The through holes 381 and 382 expose a portion of the top surface 251 of the first region 25 of the substrate 2 .

[0123] The at least one second portion 35 arranged as the at least one removably arranged portion 35 has a shape corresponding to the shape of the at least one through-hole 38. The corresponding shapes of the at least one removably arranged portion 35 and the at least one through-hole 38 are of course due to the fact that the at least one second portion 35 is a cut-out portion of the plate 3, resulting in the at least one through-hole 38.

[0124] The first pair of removably arranged portions 35 a , 35 b and the second pair of removably arranged portions 35 c , 35 d both have shapes that fit into the through holes 381 , 382 .

[0125] Two second parts 35 a and 35 c of the four second parts are fitted into the first through hole 381 , and the other two second parts 35 b and 35 d are fitted into the second through hole 382 .

[0126] exist Figure 2a-2c In FIG. 1 , it is further shown that the protective packaging insert 1 comprises at least one receiving chamber 5 , which is arranged to receive the product to be protected.

[0127] Contained in said solid cellulose foam sheet 3 is said at least one receiving chamber 5 arranged to receive the product to be protected.

[0128] The at least one receiving chamber 5 included in the plate 3 is preferably formed by: the at least one through-hole 38; and, at least one compressed area 37 included in the first portion 36 of the plate 3. By forming the receiving chamber 5 by the at least one through-hole 38 and the at least one compressed area 37, fewer cutouts are required in the plate 3. This enables a stronger protective packaging insert. Furthermore, material waste is reduced, as no material is cut out and discarded to form the receiving chamber.

[0129] By means of a receiving chamber 5 comprising at least one compression zone 37, the strength of the receiving chamber 5 is increased due to the increased density of the compression zone 37. This is particularly important when heavy objects are to be protected.

[0130] The at least one accommodation chamber of the first portion 36 comprises a depth and is arranged in the upper surface 31 of the first portion and in a direction from the upper surface 31 towards the bottom surface of the first portion 36 of the plate 3. The depth may be smaller than the thickness x3 of the plate.

[0131] The at least one receiving chamber 5 further comprises a depth equal to the thickness x3 of the plate 3 and corresponding to the at least one through hole 38. Preferably, at least one portion of the at least one receiving chamber 5 is arranged as follows: by pressing a pressing tool into the surface of at least one pattern 6 on the upper surface 31 of the first portion 36; and / or, by pressing the product to be protected by the protective packaging insert into the surface of at least one pattern 6 on the upper surface 31 of the first portion 36.

[0132] The at least one compression zone 37 will now be described.

[0133] exist Figure 2a-2c In FIG. 1 , two compression zones 37, 37' are shown. Figure 2a , said two compression zones 37 , 37 ′ are contained in said plate 3 and more specifically in said first portion 36 of said plate 3 .

[0134] It should be understood that the compression zone 37, 37' is arranged after the at least one removably arranged portion 35a-35d is moved out and away from the plate 3. The removal of the at least one removably arranged portion 35a-35d is performed in the direction from the bottom surface 32 of the plate 3 towards the upper surface 31 of the plate 3.

[0135] The compression zones 37 , 37 ′ are arranged by compressing the surface of the first portion 36 of the plate 3 .

[0136] However, before said compression, at least one cutting line 4 with a predetermined cutting depth (DC) is first arranged on the surface of said board 3. Said at least one cutting line is arranged on and into the upper surface 31 of said first portion 36 of said solid cellulose foam board 3. Said at least one cutting line 4 thus defines said at least one pattern 6 on said upper surface 31 of said first portion 36.

[0137] The at least one cutting line 4 is further arranged to partially cut through the thickness of the cellulose foam board 3 such that the predetermined cutting depth DC is smaller than the thickness x3 of the cellulose foam board 3 .

[0138] The predetermined cutting depth DC of the at least one cutting line 4 is 90% or less, preferably 70% or less, and more preferably 60% or less of the thickness x3 of the cellulose foam board 3 .

[0139] Then, the compression is performed by pressing at least one pressing tool into the at least one pattern 6 of the upper surface 31 of the cellulose foam board 3 , thereby forming the compressed areas 37 , 37 ′, so that the compressed areas 37 , 37 ′ form the at least one receiving chamber 5 .

[0140] In some embodiments, the product to be protected by the protective packaging insert may be the pressing tool. In such embodiments, no pre-pressing is required. Thus, a more efficient process is achieved since a separate pressing step can be omitted.

[0141] In other embodiments, the pressing may be performed by a pressing tool that compresses the upper surface 31 of the cellulose foam board 3 to a certain depth, followed by further pressing by the product to be protected while the product is embedded in the compressed areas 37, 37'.

[0142] The first compression zone 37 includes a compressed material 372 having a compressed thickness x372 and an upper surface 371 .

[0143] The second compression zone 37' comprises a compressed material 372' having a compressed thickness x372' and an upper surface 371'.

[0144] The thicknesses x372, x372' of the compressed materials 372, 372' may be the same or different. Figure 2a-2c , it is shown that the thickness x372 of the compressed material 372 of the first compressed zone 37 is greater than the thickness x372' of the compressed material 372' of the second compressed zone 37'.

[0145] It should be understood that different thicknesses correspond to different densities.

[0146] A smaller thickness corresponds to a higher density, which means that the density of the compressed material 372 ′ of the second compressed area 37 ′ is higher than the density of the compressed material 372 of the first compressed area 37 .

[0147] It is further shown that the shape of the upper surface 371 of the first compression zone 371 is different from the shape of the upper surface 371 ′ of the second compression zone 37′.

[0148] The density of the compressed material 372, 372' is preferably 10-90% higher than the density of the solid cellulose foam board 3, more preferably 20-90% higher and most preferably 40-90% higher.

[0149] The protective packaging insert 1 may be in a folded state or in an unfolded state.

[0150] When the protective packaging insert 1 is in the folded state, the insert 1 has a flat shape with a minimum volume.

[0151] The state of the substrate 2 determines the state of the insert 1 .

[0152] When the substrate 2 is folded around the plate 3, the insert 1 is in a folded state FS.

[0153] In the folded state of the substrate 1 , the at least one second portion 35 of the solid cellulose foam sheet 3 is arranged in the at least one through hole 38 of the first portion 36 of the solid cellulose foam sheet 3 .

[0154] The at least one fold line facilitates the folding and unfolding.

[0155] exist Figure 3 , the folded state FS of the insert 1 is shown. The four removably arranged parts (ie the four second parts) 35a-35d are arranged in the respective through holes 381, 382. In the folded state, the insert 1 is flat.

[0156] Two second parts 35 a and 35 c of the four second parts are arranged in the first through hole 381 , and the other two second parts 35 b and 35 d are arranged in the second through hole 382 .

[0157] The substrate 2 is in close relationship with the plate 3 in the folded state. Each area 23, 24, 25 of the substrate 2 is in contact with a corresponding surface of the plate 3.

[0158] The top surface 251 of the first area 25 of the substrate 2 is fixedly arranged to the bottom surface of the first portion 36 of the plate 3 .

[0159] The top surface 241 a of the first portion 24 a of the second region 24 is in contact with one of the short side surfaces 34 of the plate 6 .

[0160] The top surface 231 a of the first portion 23 a of the second region 23 is in contact with the other of the short side surfaces 34 of the plate 6 .

[0161] The top surface 241 b of the second portion 24 b of the second region 24 is in contact with the upper surface 31 of the plate 6 .

[0162] The top surface 231 b of the second portion 23 b of the second region 23 is in contact with the upper surface 31 of the plate 6 .

[0163] The third portion 23 c of the third region 23 overlaps the second portion 24 b of the second region 24 such that the top surface 231 c of the third portion 23 c contacts the bottom surface of the second portion 24 b of the second region 24 .

[0164] Said hole 20 arranged on said folding line FL5 separating said second portion 23b and said third portion 23c provides a handle for easily opening the folded insert.

[0165] The bottom surfaces of the four second portions 35 a - 35 d are in contact with the top surface 251 of the first region 25 .

[0166] exist Figure 3 In the embodiment shown in , the step of pressing into the surface of the at least one pattern 6 has not yet been carried out. Instead, in this embodiment, the product itself will be the pressing tool. The surface of the product is positioned so that it faces the surface of the at least one pattern 6. The product is then pressed into the surface of the at least one pattern 6 and into the plate 3, thereby compressing the plate at the same time and creating at least one compressed zone 37, 37'.

[0167] Since the surface of the pattern 6 has not been pressed into the plate 6 , the top surface 231b of the second portion 23b of the second region 23 and the top surface 241b of the second portion 24b of the third region 24 further contact the upper surface 361 of the first portion 36 of the plate 3 .

[0168] Figure 2a-2c The protective packaging insert is shown in the unfolded state ready for insertion into a product to be protected.

[0169] The insert 1 is arranged to accommodate a first part of a product to be protected in the at least one accommodation chamber 5 of the first portion 36 of the solid cellulose foam sheet 3, wherein the at least one second portion 35 of the solid cellulose foam sheet 3 is arranged to hold the second part of the product in position in the insert 1 and protect the second part of the product when the at least one second area is folded towards the product and the at least one second portion 35 of the solid cellulose foam sheet 3 is arranged to surround the second part of the product. The entire product is now protected by the insert 1.

[0170] It will be appreciated that when the product is arranged inside the insert 1 and the at least one second region is folded against the product, the insert 1 is arranged to have a shape corresponding to the shape of the product.

[0171] This second aspect: the method for producing the protective packaging insert 1 comprising a substrate 2 and a solid cellulose foam material 3 will now be described.

[0172] The method for producing the protective packaging insert 1 comprises the following steps:

[0173] a) providing a solid cellulose foam board 3;

[0174] b) arranging at least one portion 35 of the solid cellulose foam board 3 into at least one removably arranged portion 35 of the solid cellulose foam board 3, thereby dividing the cellulose foam board 3 provided in step a) into a remaining portion 36 (also referred to as the first portion of the solid cellulose board 3 in the description of the first aspect of the present invention) and the at least one removably arranged portion 35 (also referred to as the second portion in the description of the first aspect of the present invention);

[0175] c) providing a substrate 2 comprising at least two regions 23, 24, 25 and at least one folding line FL1-FL5;

[0176] d) fixedly arranging the bottom surface 362 of the remaining portion 36 of the solid cellulose foam board 3 on the top surface 251 of the first area 25 of the substrate 2 by fixing means, and

[0177] e) fixedly arranging the upper surface 351 of the at least one removably arranged portion 35 of the solid cellulose foam board 3 to the top surface 231b, 241b of the second area 23b, 24b of the at least two areas of the substrate 2 by the fixing means.

[0178] The method further includes folding the second region 23, 24 of the at least two regions 23, 24, 25 of the substrate 2 around the at least one folding line FL1-FL4 so that the top surface 231b, 241b of the second region 23, 24 reaches a position adjacent to the upper surface 351 of the at least one removably arranged portion 35 of the solid cellulose foam board 3 before the upper surface 351 of the at least one removably arranged portion 35 is fixedly arranged to the top surface 231b, 241b of the second region 23, 24.

[0179] The preferred embodiment will now be described. The preferred embodiment is as described above and with reference to Figure 1-3 A method for producing the protective packaging insert 1.

[0180] In step a) the solid cellulose foam board 3 is provided. The board 3 is flat and the dimensions of the board 3 are selected based on the dimensions of the product to be enclosed and protected.

[0181] Step b) comprises arranging the four parts 35 of the solid cellulose foam board 3 into four removably arranged parts 35a-35d of the solid cellulose foam board 3, thereby dividing the cellulose foam board 3 provided in step a) into the remaining part 36 and the four removably arranged parts 35a-35d.

[0182] In step c), the substrate 2 is provided. The substrate comprises three regions 23, 24, 25 and at least two folding lines separating the three regions 23, 24, 25. The folding line FL2 separates the first region 25 and the third region 24, and the folding line FL3 separates the first region 25 and the second region 23.

[0183] In the preferred embodiment, up to five folding lines FL1 - FL5 are arranged and as disclosed in relation to the first aspect of the invention.

[0184] Step d) comprises fixedly arranging the bottom surface of the remaining part 36 of the solid cellulose foam board 3 on the top surface 251 of the first area 25 of the substrate 2 by fixing means.

[0185] Step e) comprises fixedly arranging the upper surfaces 351a-351d of the four removably arranged portions 35a-35d of the solid cellulose foam board 3 to the top surface 231b, 241b of the second area 23b, 24b of the at least two areas of the substrate 2 by the fixing means.

[0186] The fixing means may be a glue, preferably a bio-based glue.

[0187] The four removably arranged parts 35a - 35d of the solid cellulose foam sheet 3 are arranged to be removable from the upper surface 31 of the solid cellulose foam sheet 3 .

[0188] The method further comprises providing at least one cutting line 4 having a predetermined cutting depth DC into the surface of the solid cellulose foam board 3 , whereby the at least one cutting line 4 defines at least one pattern 6 on the surface of the solid cellulose foam board 3 .

[0189] exist Figure 1 In FIG. 4 , it is shown that the at least one cutting line 4 comprises several cutting lines 4. The several cutting lines 4 preferably have different predetermined cutting depths DC.

[0190] The cutting lines 4 are provided in the upper surface 31 of the solid cellulose foam board 3 .

[0191] At least one cutting line 4 is arranged to cut through the thickness of the cellulose foam board 3 so that the predetermined cutting depth DC is equal to the thickness x3 of the cellulose foam board 3, thereby arranging the four parts of the solid cellulose foam board 3 into the four removably arranged parts of the solid cellulose foam board 3.

[0192] At least one cutting line 4 is arranged to partially cut through the thickness x3 of the cellulose foam board 3 such that the predetermined cutting depth DC is smaller than the thickness of the cellulose foam board 3 .

[0193] For the at least one cutting line 4 arranged to partially cut through the thickness x3 of the board 3, the predetermined cutting depth DC of the at least one cutting line is 90% or less, preferably 70% or less, and more preferably 60% or less of the thickness x3 of the cellulose foam board 3.

[0194] The method further comprises a pressing step. At least one pressing tool is pressed into the at least one pattern 6 of the upper surface 31 of the cellulose foam board 3 and / or by pressing the product to be protected by the protective packaging insert.

[0195] The at least one pressing tool preferably has a pressing area corresponding to or smaller than the area of ​​the at least one pattern 6 of the upper surface 31 of the cellulose foam board 3 .

[0196] The pressing is preferably performed without heating the at least one pressing tool and the cellulose foam sheet.

[0197] Two compression regions 37 , 37 ′ are thus formed; the two compression regions 37 , 37 ′ form the at least one receiving chamber 5 .

[0198] The depth of the at least one receiving chamber 5 is smaller than the thickness x3 of the solid cellulose foam board 3 .

[0199] The method further includes folding the first part 23a and the second part 23b of the second area 23 of the substrate 2 around folding lines FL3, FL4 and folding the first part 24a and the second part 24b of the third area 24 around folding lines FL1, FL2, so that the top surfaces 231b, 241b of the corresponding second and third areas 23, 24 reach the position of the upper surfaces 351a-351d of the four removably arranged parts 35 adjacent to the solid cellulose foam board 3, and then fixing the upper surfaces 351a-351d of the four removably arranged parts 35 to the top surfaces 231b, 241b of the corresponding second and third areas 23, 24.

[0200] The upper surfaces 351a , 351b of the first pair 35a , 35b of the four removably arranged portions 35 of the solid cellulose foam board 3 are fixedly arranged on the top surface 241b of the second portion 24b of the third area 24 of the substrate 2 .

[0201] The upper surfaces 351c , 351d of the second pair 35c , 35d of the at least one removably arranged portion 35 of the solid cellulose foam sheet 3 are fixedly arranged on the top surface 231b of the second portion 23b of the second area 23 of the substrate 2 .

[0202] The at least one removably arranged portion 35 (the four removably arranged portions 35 a - 35 d of the preferred embodiment) are fixedly arranged on the top surface 21 of the substrate 2 .

[0203] The at least one removably arranged portion 35 (the four removably arranged portions 35a-35d in the preferred embodiment) is further arranged to be removable from the at least one through hole 38 (the two through holes 381, 382 in the preferred embodiment) of the remaining portion 36 of the plate 3 (i.e., the first portion 36 of the plate 3).

[0204] The at least one removably arranged portion 35 is arranged to be removed from and reintroduced into the at least one through-going hole 38 .

[0205] The at least one removably arranged portion 35 is further fixedly arranged to the top surface 21 of the substrate 2 .

[0206] When the at least one removably arranged portion 35 is arranged in the at least one through-going hole 38, the substrate 2 tightly surrounds the plate 3. The insert 1 is in its folded state FS and has the flat shape.

[0207] The protective packaging insert 1 has now been produced by the method described.

[0208] The protective packaging insert 1 is ready to be sent to the producer of the product for protectively packaging the product in the protective packaging insert 1 .

[0209] The third aspect of the invention (ie, a method of protecting a product by embedding the product in a protective packaging insert) will now be described.

[0210] The method comprises the following steps:

[0211] a) providing said protective packaging insert 1 , preferably in said folded state FS;

[0212] b) unfolding said second region 23, 24 of said substrate 2 of said protective packaging insert 1 from a folded state to an open state, thereby exposing said first portion 36 of said solid cellulose foam sheet 3 and said at least one second portion 35 of said solid cellulose foam sheet 3;

[0213] c) embedding the product to be protected in the at least one receiving chamber 5 included in the first part 36; whereby the at least one receiving chamber 5 surrounds a first portion of the product;

[0214] d) folding the second area 23, 24 towards the product so that the at least one second portion 23, 24 of the solid cellulose foam sheet 3 surrounds a second portion of the product; thereby protecting the entire product and preferably subsequently

[0215] e) inserting said protective packaging insert containing said protected product in a closed package.

[0216] In a preferred embodiment of the method for protecting a product, the method further comprises:

[0217] Grab the handle arranged on the insert 1. In a preferred embodiment, the hole 20 is arranged as the handle. However, it is conceivable to arrange the handle in other ways without departing from the scope of the present invention.

[0218] By grasping the hole 20, the second region 23 of the substrate 2 can be moved from the tight enclosure of the plate 3. When the second region 23 is moved, the second pair of removably arranged portions 35c, 35d are moved out of the through holes 381, 382. The second portion 23b of the second region 23 is unfolded around the folding line FL4 and the first portion 23a of the second region 23 is unfolded around the folding line FL3.

[0219] The next step is to grasp the third area 24. This area may also be provided with some kind of handle, such as a hole. The second portion 24b of the third area 24 moves from the tight surrounding of it by the plate 3. When the third area 24 moves, the first pair of removably arranged portions 35a, 35b moves out of the through holes 381, 382. The second portion 24b of the second area 24 is unfolded around the folding line FL1 and the first portion 24a of the second area 24 is unfolded around the folding line FL2.

[0220] Both the first pair 35a, 35b and the second pair 35c, 35d are moved out of the through holes 381, 382. The insert 1 is now in its unfolded state and is ready to receive the product to be protected.

[0221] The product to be protected is inserted into the insert 1 so that the surface of the product is placed in the at least one receiving chamber 5 of the remaining (first) portion 36 .

[0222] exist Figure 3 In the embodiment shown in , there is no accommodation chamber 5. The plate 3 comprises at least one cutting line 4 having a predetermined cutting depth DC less than the thickness x3 of the plate 3. The surface of the product is positioned so that the surface of the product contacts the surface of the pattern 6 defined by the at least one cutting line 4. Pressure is applied to the product, causing the surface of the product to be pressed into the core of the plate, thereby creating the compression zones 37, 37′ and the accommodation chambers 5.

[0223] After the product is positioned in and surrounded by the at least one receiving chamber 5, the third area 24 is folded towards the product about its folding lines FL1, FL2. The first pairing 35a, 35b comes into direct contact with a portion of the second portion of the product. The portion of the second portion of the product will be securely held in place by the first pairing 35a, 35b of the removably arranged portion 35 of the solid cellulose foam board 3. The first pairing further protects the portion of the second portion due to the cushioning properties of the cellulose foam material of the board 3.

[0224] The folding of the third region 24 is followed by the folding of the second region 23 .

[0225] The second area 23 is folded towards the product around its folding lines FL3, FL4. The second pairing 35c, 35d comes into direct contact with another part of the second portion of the product. The other part of the second portion of the product will be firmly held in place by the second pairing 35c, 35d of the removably arranged portion 35 of the solid cellulose foam board 3. Due to the cushioning properties of the cellulose foam material of the board 3, the second pairing further protects the other part of the second portion.

[0226] The entirety of the product is protected by the protective packaging insert 1 .

[0227] Preferably, the protective packaging insert containing the protected product is embedded in an enclosed packaging (preferably comprising cellulose fibers), such as a cardboard box.

[0228] Materials and material properties

[0229] The substrate 2 is preferably made of a material including at least one of cardboard, fiberboard, corrugated fiberboard, paper and paperboard.

[0230] The substrate comprises a pulp selected from wood pulp, non-wood pulp, unbleached or bleached chemical pulp, defibrated fibrous material, bagasse, straw, hemp, bamboo, spruce CTMP, eucalyptus CTMP, spruce HT CTMP, kraft pulp, sulfite pulp, PGW, GW, DIP, recycled paper and paperboard, shredded paper, RMP, TMP, CMP, CSP NSSC nanopulp, dissolving pulp, and recycled fibers or mixtures thereof.

[0231] The solid cellulose foam board 3 comprises:

[0232] a) 71-95 wt% of cellulose fibers, calculated based on the total weight of the solid content of the foam sheet 3,

[0233] b) 4-24 wt% of a water-soluble thickener, calculated based on the total weight of the solid content of the foam sheet 3, and

[0234] c) at least two surfactants.

[0235] The cellulose fibers contained in the solid cellulose foam board 3 are selected from wood pulp, regenerated cellulose fibers, and plant fibers; preferably selected from softwood pulp, bleached kraft pulp, chemical thermomechanical pulp (CTMP) and dissolving pulp or a combination thereof.

[0236] The density of the solid cellulose foam board 3 is between 10-80 kg / m 3 , preferably 20-50kg / m 3 And more preferably 20-50kg / m 3 within the range.

[0237] The density of the at least one compressed zone 37, 37' is greater than the density of the solid cellulose foam board 3 provided in step a).

[0238] The density of the at least one compressed zone is preferably 10-90%, more preferably 20-90% and most preferably 40-90% higher than the density of the solid cellulose foam board provided in step a).

[0239] The solid cellulose foam board comprises at least one densified outer layer. All outer surfaces of the solid cellulose foam board may comprise a densified outer layer, or the upper surface 31 and the bottom surface 32 of the solid cellulose foam board 3 may comprise a densified outer layer. Preferably, at least the upper surface 31 of the solid cellulose foam board 3 comprises a densified outer layer.

[0240] As will be appreciated by those skilled in the art, many changes and modifications may be made to the above described embodiments and other embodiments of the present invention without departing from the scope of the present invention as defined by the appended claims. For example, in some embodiments, the folding line FL5 passing through the hole 20 may be excluded.

[0241] It is conceivable to first arrange the plate 3 to the top surface 21 of the substrate 2 and thereafter arrange parts of the plate as removably arranged parts.

[0242] Parts of the plate 3 may be fixedly arranged to the plate 3 before other parts of the plate are arranged as removably arranged parts.

[0243] Example

[0244] Example 1

[0245] Protective packaging inserts for steam irons (similar to Figure 1-3 The protective packaging insert shown in FIG. 1 is constructed from a solid cellulose foam board having a thickness of 5 cm. The cellulose foam is dry and has a density of 32-35 kg / m 3 and contains 83-88 wt % cellulose fibers (softwood bleached kraft pulp), 10-15 wt % thickener (CMC) and about 2 wt % surfactant (a mixture of myristic acid and sodium cocoyl sarcosinate).

[0246] Four sections of foam are cut out using a cutting table, thereby forming two through-holes in the plate. The remaining section of the foam plate is shaped corresponding to the base of the steam iron by pre-cutting and pressing.

[0247] Put the four parts back into the board. Apply glue to the bottom side of the foam board and to the top side of the four parts. Then, put the foam board including the four parts on the cardboard (made of virgin pulp fibers, the thickness of the cardboard is 1.5 mm). The cardboard has Figure 1 Fold the side areas of the cardboard so that the four parts are connected to them.

[0248] The foam sheet and the cardboard can be stored in a folded state. When the steam iron is to be inserted, the cardboard is unfolded so that the four parts are removed from the foam sheet. The steam iron is placed in the shaped foam sheet and the cardboard is folded again so that it is wrapped around the steam iron. After folding, the four parts are in contact with the steam iron. The side areas of the cardboard are connected to each other.

[0249] The packaging insert is placed in a box. A drop test is performed and the protective packaging insert protects the steam iron during the drop. These four parts help to hold the steam iron in place in the packaging insert and also provide cushioning properties. Without these four parts, the steam iron does not hold in place in the packaging insert.

[0250] It should be noted that the above described aspects may be the subject of their own protection in a separate divisional application. Therefore, it is foreseeable that this aspect of the invention may require its own protection, for example, because it may also be applicable to other concepts than those defined by the independent claims of the present application.

Claims

1. A protective packaging insert (1) comprising a substrate (2) and a solid cellulose foam sheet (3): - the substrate comprises at least two regions (23, 24, 25) and at least one folding line (FL1-FL5) separating the at least two regions (23, 24, 25), wherein the at least one folding line (FL1-FL5) is arranged to allow the insert (1) to be folded into a folded state; - the solid cellulose foam sheet (3) comprises two or more parts (35, 36); wherein a first part (36) of the solid cellulose foam sheet (3) comprises at least one through hole (38), and wherein at least one second part (35) of the solid cellulose foam sheet (3) has a shape corresponding to the shape of the at least one through hole (38); -Wherein, the bottom surface (362) of the first part (36) of the solid cellulose foam board (3) is fixedly arranged on the top surface (251) of the first area (25) of the substrate, and the upper surface (351) of at least one second part (35) of the solid cellulose foam board (3) is fixedly arranged on the top surface (231b, 241b) of the second area (23, 24) of the substrate (2).

2. The protective packaging insert of claim 1, wherein: When the substrate is in a folded state, the at least one second portion (35) of the solid cellulose foam sheet (3) is arranged within the at least one through hole (38) of the first portion (36) of the solid cellulose foam sheet (3).

3. The protective packaging insert according to claim 1 or 2 comprises at least one cutting line (4) having a predetermined cutting depth (DC), wherein the at least one cutting line (4) is arranged on the upper surface (31) of the solid cellulose foam board (3); the at least one cutting line (4) defines at least one pattern (6) on the upper surface (31) of the solid cellulose foam board (3); preferably, the at least one cutting line (4) is arranged on the upper surface (361) of the first part (36) of the solid cellulose foam board (3).

4. The protective packaging insert according to any of the preceding claims, wherein the first portion (36) of the solid cellulose foam board (3) further comprises at least one receiving chamber (5), the at least one receiving chamber (5) being arranged to receive a product to be protected.

5. The protective packaging insert according to claim 4, wherein the receiving chamber (5) of the first portion (36) and the at least one through-going hole (38) of the first portion (36) together receive the product to be protected.

6. A protective packaging insert according to claim 4 or 5, wherein the upper surface (361) of the first portion (36) of the solid cellulose foam board (3) is arranged for the product to be inserted into the receiving chamber (5).

7. A protective packaging insert according to any one of claims 4-6, wherein the at least one receiving chamber (5) is arranged by: pressing a pressing tool into the surface of at least one pattern (6) on the upper surface (361) of the first portion (36) of the solid cellulose foam board (3); and / or, pressing the product to be protected by the protective packaging insert into the surface of at least one pattern on the upper surface (361) of the first portion (36) of the solid cellulose foam board (3).

8. The protective packaging insert (1) according to any one of the preceding claims, wherein: When the at least one second portion (35) of the solid cellulose foam board (3) is arranged in the at least one through hole (38) of the first portion (36) of the solid cellulose foam board (3), the insert (1) is in a folded state (FS) and is a flat insert (1).

9. A protective packaging insert according to any one of claims 4-8, wherein the insert (1) is arranged to accommodate a first portion of a product in the at least one receiving chamber (5) of the first portion of the solid cellulose foam board (3), wherein the at least one second portion of the solid cellulose foam board (3) is arranged to hold the second portion of the product in position in the insert (1) and to protect the second portion of the product when the second area is folded toward the product, and further, the at least one second portion of the solid cellulose foam board (3) is arranged to surround the second portion of the product; wherein the entire product is protected by the insert (1).

10. The protective packaging insert of any one of the preceding claims, wherein: When the product is arranged inside the insert (1) and the second area is folded against the product, the insert (1) conforms to the shape of the product.

11. The protective packaging insert according to any one of the preceding claims, wherein the substrate (2) is preferably made of a material comprising at least one of cardboard, fiberboard, corrugated fiberboard, paper and paperboard.

12. A protective packaging insert according to any of the preceding claims, wherein the cellulose fibers contained in the solid cellulose foam board (3) are selected from wood pulp, regenerated cellulose fibers, and plant fibers; preferably selected from softwood pulp, bleached kraft pulp, chemical thermomechanical pulp (CTMP) and dissolving pulp or a combination thereof.

13. The protective packaging insert according to any one of the preceding claims, wherein the solid cellulose foam board (3) comprises: a) 71-95 wt% of cellulose fibers, calculated based on the total weight of the solid content of the foam sheet (3), b) 4-24 wt% of a water-soluble thickener, calculated on the basis of the total weight of the solid content of the foam sheet (3), and c) at least two surfactants.

14. A method for producing a protective packaging insert (1), said method comprising the steps of: a) providing a solid cellulose foam sheet (3); b) arranging at least one portion (35) of the solid cellulose foam sheet (3) into at least one removably arranged portion (35) of the solid cellulose foam sheet (3), thereby dividing the cellulose foam sheet (3) provided in step a) into a remaining portion (36) and the at least one removably arranged portion (35); c) providing a substrate (2) comprising at least two regions (23, 24, 25) and at least one folding line (FL1-FL5); d) fixedly arranging the bottom surface (362) of the remaining part (36) of the solid cellulose foam board (3) on the top surface (251) of the first area (25) of the substrate (2) by fixing means, and e) fixedly arranging the upper surface (351) of the at least one removably arranged portion (35) of the solid cellulose foam board (3) to the top surface (231b, 241b) of the second area (23b, 24b) of the at least two areas of the substrate (2) by the fixing means.

15. The method according to claim 14, wherein the density of the solid cellulose foam board (3) is between 10 and 80 kg / m 3 , preferably 10-60kg / m 3 And more preferably 20-50kg / m 3 within the range.

16. Method according to any one of claims 14 or 15, wherein the method comprises arranging the at least one removably arranged portion (35) of the solid cellulose foam board (3) to be removable from an upper surface (31) of the solid cellulose foam board (3).

17. A method according to any one of claims 14-16, wherein the method further comprises providing at least one cutting line (4) having a predetermined cutting depth (DC) into the upper surface (31) of the solid cellulose foam board (3), whereby the at least one cutting line (4) defines at least one pattern (6) on the surface (31) of the solid cellulose foam board (3).

18. Method according to claim 17, wherein the at least one cutting line is provided into an upper surface (361) of the remaining part (36) of the solid cellulose foam board (3).

19. A method according to any one of claims 17 or 18, wherein the method further comprises arranging the at least one cutting line (4) to cut through the thickness of the cellulose foam board (3) so that the predetermined cutting depth (DC) is equal to the thickness (x3) of the cellulose foam board (3), thereby arranging the at least one portion of the solid cellulose foam board (3) into the at least one removably arranged portion of the solid cellulose foam board (3).

20. The method according to any one of claims 17-19, wherein the method further comprises arranging the at least one cutting line (4) to partially cut through the thickness of the cellulose foam board (3) so that the predetermined cutting depth (DC) is less than the thickness of the cellulose foam board (3).

21. The method according to any one of claims 17 to 20, wherein the method further comprises: At least one pressing tool is pressed into the at least one pattern (6) of the upper surface (31) of the cellulose foam board (3), and / or, by pressing the product to be protected by the protective packaging insert, at least one compression zone (37, 37') is formed, and the at least one compression zone (37, 37') forms at least one receiving chamber (5).

22. Method according to any one of claims 21, wherein the density of the at least one compressed zone (37, 37') is greater than the density of the solid cellulose foam board (3) provided in step a).

23. A method according to any one of claims 14-22, wherein the method further comprises folding the second region (23, 24) of the at least two regions (23, 24, 25) of the substrate (2) around the at least one folding line (FL1-FL4) so ​​that the top surface (231b, 241b) of the second region (23, 24) reaches a position adjacent to the upper surface (351) of the at least one removably arranged portion (35) of the solid cellulose foam board (3) before the upper surface (351) of the at least one removably arranged portion (35) is fixedly arranged to the top surface (231b, 241b) of the second region (23, 24).

24. The method according to any one of claims 14 to 23, wherein the substrate (2) is a flat substrate (2) comprising at least three areas (23, 24, 25) separated by at least two folding lines (FL1-FL5).

25. The method according to any one of claims 14-24, wherein the fixing means is a glue, preferably a bio-based glue.

26. The method according to any one of claims 14 to 25, wherein the substrate (2) is preferably made of a material comprising at least one of cardboard, fiberboard, corrugated fiberboard, paper and paperboard.

27. The method according to any one of claims 14 to 26, wherein the solid cellulose foam board (3) comprises: a) 71-95 wt% of cellulose fibers, calculated based on the total weight of the solid content of the foam sheet (3), b) 4-24 wt% of a water-soluble thickener, calculated on the basis of the total weight of the solid content of the foam sheet (3), and c) at least two surfactants.

28. The method of any one of claims 14-27, wherein the solid cellulose foam comprises pulp selected from wood pulp, regenerated cellulose fibers, and plant fibers; preferably selected from softwood pulp, bleached kraft pulp, chemithermomechanical pulp (CTMP), and dissolving pulp or a combination thereof.

29. A method of protecting a product by embedding the product in a protective packaging insert, the method comprising the steps of: a) providing a folded flat protective packaging insert (1) as defined in claims 1 to 13; b) unfolding the second region (23, 24) of the substrate (2) of the protective packaging insert (1) from a folded state to an open state, thereby exposing the first portion (36) of the solid cellulose foam sheet (3) and the at least one second portion (35) of the solid cellulose foam sheet (3); c) embedding a product to be protected in the at least one receiving chamber (5) contained in the first part (36); whereby the at least one receiving chamber (5) surrounds a first portion of the product; d) folding the second area (23, 24) towards the product so that the at least one second portion (23, 24) of the solid cellulose foam sheet (3) surrounds a second portion of the product; thereby protecting the entire product, and preferably subsequently e) inserting said protective packaging insert containing said protected product in a closed package.

Images