Collapsible packaging insert comprising plurality of cellulose-based airlaid or solid foam substrates

Abstract

A packaging insert (10) comprises a plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) having respective first and second major sides (22, 22A, 22B, 22C, 24, 24A, 24B, 24C). The packaging insert (10) also includes a first paper-based sheet (30) attached to the first major side (22, 22A, 22B, 22C) and a second paper-based sheet (40) attached to the second major side (24, 24A, 24B, 24C). The edges (26, 26A, 26B, 28, 28B, 28C) of continuous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) facing each other are beveled edges (26, 26A, 26B, 28, 28B, 28C) and form an angle (alpha) between each other of less than 90 DEG. At least one hinge section (50, 50A, 50B) is interposed between the beveled edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid or solid foam substrate (20, 20A, 20B, 20C). The package insert (10) is foldable in the hinge section (50, 50A, 50B) and positionable within the package (80) to protect the articles of the package. The invention also relates to a method for producing a packaging insert (10).

Description

Technical Field

[0001] The present invention relates generally to packaging inserts, and in particular to such packaging inserts suitable for protecting packaged items from shock impact and / or for thermal insulation of the packaged items. Background Art

[0002] With the growth of awareness of environmental and human-induced climate change, the use of plastic insulation and / or cushioning products is increasingly questioned. However, despite this concern, the use of these products has grown significantly with new trends in lifestyle and consumer habits in the past decade. One reason for this is that more and more items are transported globally, and these items need protection from impact or shock and / or extreme temperatures. A common way to protect items is to include cushioning and / or insulation products, such as inserts in the packaging in a suitable form. These can be made of different materials, but typically made of foamed polymers, of which expanded polystyrene (EPS) is by far the cheapest and most common. In some cases, the entire package can be made of EPS. However, EPS is one of the most questioned plastic materials, and many brand owners are looking for more sustainable solutions for these packaging applications.

[0003] US10,787,303 discloses a packaging insulation for insertion into a packaging container, comprising an air-laid natural cellulosic batt having a foldable paper sheet material adhered to both sides of the batt. US2021 / 0061542 discloses an insulation packaging assembly comprising a box defining a box cavity, the box cavity comprising an insulation liner. The disclosed insulation liner is made of polyethylene terephthalate (PET), polyethylene, polyurethane or polypropylene. The biodegradable insulation liner can be made of recycled cotton.

[0004] US 10,625,918 discloses a foldable and biodegradable cushioning sheet, which comprises a flexible base film and a plurality of cushioning objects located on the top surface of the flexible base film. The cushioning sheet can be folded in one direction to provide a strong inner corner.

[0005] A disadvantage of prior art inserts is that, due to the thickness of the insulating material of the inserts, they do not easily collapse when placed within a box or container. Accordingly, there is a need for an improved packaging insert that can be easily collapsed to fit into a box or container and used therein to protect articles from impact shock and / or for thermal insulation of the packaged articles. Summary of the invention

[0006] A general object is to provide a packaging insert for protecting articles from shock, impact, shock and / or for thermal insulation of the packaged articles.

[0007] A particular object is to provide a foldable packaging insert.

[0008] These and other objects are met by the embodiments disclosed herein.

[0009] The invention is defined in the independent claim. Further embodiments of the invention are defined in the dependent claims.

[0010] One aspect of the present invention relates to a packaging insert comprising a plurality of cellulose-based airlaid or solid foam substrates having a respective first main side and a second main side opposite the first main side. The packaging insert further comprises a first paper-based sheet attached to the first main side of the plurality of cellulose-based airlaid or solid foam substrates and a second paper-based sheet attached to the second main side of the plurality of cellulose-based airlaid or solid foam substrates. The edges of the continuous cellulose-based airlaid or solid foam substrates of the plurality of cellulose-based airlaid or solid foam substrates facing each other are beveled edges and form an angle of less than 90° with each other. At least one hinged section is interposed between the beveled edges of the continuous cellulose-based airlaid or solid foam substrates. The packaging insert is foldable in the at least one hinged section.

[0011] Another aspect of the invention relates to a packaging assembly comprising a package comprising a bottom and a plurality of side walls defining a cavity. The packaging assembly also comprises a packaging insert according to the above positioned within the cavity.

[0012] Another aspect of the present invention relates to a method for producing a packaging insert. The method comprises cutting a cellulose-based airlaid or solid foam substrate blank at an angle of less than 45° relative to a normal to a major side of the cellulose-based airlaid or solid foam substrate blank and at a second angle equal to the first angle but opposite in sign to obtain at least a first cellulose-based airlaid or solid foam substrate comprising a beveled edge, a second cellulose-based airlaid or solid foam substrate comprising two beveled edges, and a third cellulose-based airlaid or solid foam substrate comprising a beveled edge. The method further comprises turning the second cellulose-based airlaid or solid foam substrate upside down so that the beveled edge of the first cellulose-based airlaid or solid foam substrate faces the first beveled edge of the second cellulose-based airlaid or solid foam substrate, and the beveled edge of the third cellulose-based airlaid or solid foam substrate faces the second beveled edge of the second cellulose-based airlaid or solid foam substrate. The beveled edge of the first cellulose-based airlaid or solid foam substrate and the first beveled edge of the second cellulose-based airlaid or solid foam substrate form an angle of less than 90° with each other. The beveled edge of the third cellulose-based airlaid or solid foam substrate and the second beveled edge of the second cellulose-based airlaid or solid foam substrate form an angle of less than 90° with each other. The method also includes attaching a first paper-based sheet to the first major side of the at least first, second and third cellulose-based airlaid or solid foam substrates, and attaching a second paper-based sheet to the second major side of the at least first, second and third cellulose-based airlaid or solid foam substrates to form a packaging insert. The packaging insert includes a first hinged section inserted between the beveled edge of the first cellulose-based airlaid or solid foam substrate and the first beveled edge of the second cellulose-based airlaid or solid foam substrate. The packaging insert also includes a second hinged section inserted between the second beveled edge of the second cellulose-based airlaid or solid foam substrate and the beveled edge of the third cellulose-based airlaid or solid foam substrate.

[0013] The packaging insert is designed to be foldable, but still effectively protect the article from impact shock and / or for thermal insulation. The packaging insert can be folded so as to fit well into various packages, boxes and containers, but without causing any significant damage to the cushioning or thermal insulation capabilities of the packaging insert at the fold. This is possible by providing continuous or adjacent cellulose-based airlaid or solid foam substrates with beveled edges forming an angle of less than 90°. The beveled edges facing each other constitute a hinge section. The packaging insert is then easily folded at the hinge section and is designed so that when folded at the hinge section, the continuous cellulose-based airlaid or solid foam substrates can be positioned next to or adjacent to each other and also provide cushioning and insulation at the fold. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The embodiments and further objects and advantages thereof may best be understood by reference to the following description taken in conjunction with the accompanying drawings, in which:

[0015] Figure 1 is a cross-sectional view of a packaging insert according to one embodiment;

[0016] Figure 2 is a cross-sectional view of a packaging insert according to another embodiment;

[0017] Figure 3 is a cross-sectional view of a packaging insert according to another embodiment;

[0018] Figures 4A to 4D An embodiment of producing a packaging insert is schematically shown.

[0019] Figure 5 shows a packaging assembly including a packaging insert according to one embodiment;

[0020] Figure 6 shows a packaging assembly including a packaging insert according to one embodiment;

[0021] Figure 7 yes Figure 6 A close-up of a portion of the packaging assembly shown in FIG.

[0022] Figure 8 is a flow chart illustrating a method of producing a packaging insert according to one embodiment; and

[0023] Fig. 9 yes Figure 3 0026] Figure 2 is a top view of a packaging insert shown in cross-section. DETAILED DESCRIPTION

[0024] The present invention relates generally to packaging inserts, and in particular to such packaging inserts suitable for protecting packaged items from impact shock and / or for thermal insulation of the packaged items.

[0025] The packaging insert of the present embodiment can be used as an environmentally more friendly alternative to corresponding packaging inserts made of or from foamed polymers such as expanded polystyrene (EPS). There are packaging inserts made of environmentally friendly materials such as recycled cotton disclosed in US10,787,303 and US2021 / 0061542. These packaging inserts are said to be foldable, however, the thickness of the packaging inserts means that they are not easily folded to fit into the corners of various packages, boxes and containers without significantly compressing the packaging insert at the fold. This compression at the fold, in turn, means that the packaging insert is less effective in protecting the article from impact shocks at the compressed fold. Furthermore, if the packaging insert is intended to provide insulation for tempered or cold articles, the compressed folds constitute vulnerable sections in which the insulating capacity of the packaging insert is lower.

[0026] The packaging insert of the present embodiment is designed to be foldable, but still effectively protect articles from impact shock and / or for thermal insulation. This means that the packaging insert can be folded so as to fit well into various packages, boxes and containers, but without causing any significant damage to the cushioning or thermal insulation capabilities of the packaging insert at the fold. This is possible by providing the continuous cellulose-based air-laid or solid foam substrate with beveled edges that form an angle of less than 90° between each other. The hinge section is inserted between the beveled edges facing each other. The packaging insert is then easily folded at the hinge section and is designed so that when folded at the hinge section, the continuous cellulose-based air-laid or solid foam substrates will be adjacent or adjacent to each other and also provide cushioning and insulation at the fold.

[0027] Figure 1 A packaging insert 10 according to one embodiment is shown. The packaging insert 10 includes a plurality of (i.e., at least two) cellulose-based airlaid or solid foam substrates 20 having respective first main sides 22 and second main sides 24 opposite the first main sides 22. The packaging insert 10 also includes a first paper-based sheet 30 attached to the first main sides 22 of the plurality of cellulose-based airlaid or solid foam substrates 20 and a second paper-based sheet 40 attached to the second main sides 24 of the plurality of cellulose-based airlaid or solid foam substrates 20. The edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrates 20 of the plurality of cellulose-based airlaid or solid foam substrates 20 facing each other are beveled edges 26, 28. These beveled edges 26, 28 form an angle of less than 90° between each other. The packaging insert 10 includes at least one hinged section 50 interposed between the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrates 20. Packaging insert 10 is then foldable in the at least one hinge section 50 .

[0028] like Figure 1 As shown, the plurality of cellulose-based airlaid or solid foam substrates 20 are sandwiched between the first paper-based sheet 30 and the second paper-based sheet 40, thereby forming a plurality of sandwich sections 52. The packaging insert 10 further comprises at least one hinge section 50 interposed between adjacent sandwich sections 52 of the plurality of sandwich sections 52. Thus, a corresponding hinge section 50 is provided between two consecutive sandwich sections 52. Then, the packaging insert 10 can be easily folded in or at the at least one hinge section 50.

[0029] The packaging insert 10 includes a plurality of individual cellulose-based air-laid or solid foam substrates 20, also referred to herein as panels. These multiple cellulose-based air-laid or solid foam substrates 20 are separated from each other to form individual substrates or panels 20. The multiple cellulose-based air-laid or solid foam substrates 20 are arranged one after another along a longitudinal axis A passing through the multiple cellulose-based air-laid or solid foam substrates 20. The multiple cellulose-based air-laid or solid foam substrates 20 are held together by a first paper-based sheet 30 and a second paper-based sheet 40 attached to a first main side or surface 22 and a second main side or surface 24 of the multiple cellulose-based air-laid or solid foam substrates 20. Therefore, the packaging insert 10 will include a so-called sandwich section 52, at which the multiple cellulose-based air-laid or solid foam substrates 20 are sandwiched between the first paper-based sheet 30 and the second paper-based sheet 40. Thus, each such sandwich section 52 comprises a cellulose-based airlaid or solid foam substrate 20 interposed between two paper-based sheets 30, 40. Successive sandwich sections 52 in packaging insert 10 are separated from one another by respective hinge sections 50. Figure 1 The hatching in FIG. 5 separates the sandwich section 52 and the hinge section 50 .

[0030] like Figure 1 As shown, the plurality of cellulose-based airlaid or solid foam substrates 20 are relatively thicker compared to the two paper-based sheets 30, 40. Therefore, the cellulose-based airlaid or solid foam substrates 20 provide cushioning and / or insulation capabilities of the packaging insert 10. This relatively large thickness of the cellulose-based airlaid or solid foam substrates 20 means that they are not easily folded without causing significant compression of the cellulose-based airlaid or solid foam substrates 20. However, the relatively thin paper-based sheets 30, 40 are easily foldable. This means that the packaging insert 10 can be easily folded at the one or more hinge sections 50 to be packaged in the package 80, see Figures 5 to 7, without any significant compression of the cellulose-based airlaid or solid foam substrate 20, even at the corners 12A, 12B of the package 80.

[0031] In one embodiment, the average thickness of each of the plurality of cellulose-based airlaid or solid foam substrates 20 is preferably at least 10 times greater than the average thickness of each of the two paper-based sheets 30, 40, preferably at least 15 times greater than the average thickness of the two paper-based sheets 30, 40, for example at least 20 times greater, at least 25 times greater, or at least 30 times greater. In a specific embodiment, the average thickness of each of the plurality of cellulose-based airlaid or solid foam substrates 20 is preferably at least 50 times greater than the average thickness of each of the two paper-based sheets 30, 40.

[0032] The at least one hinge section 50 is interposed between two consecutive or adjacent beveled edges 26, 28. When the plurality of cellulose-based airlaid or solid foam substrates 20 are arranged one after another along the longitudinal axis A of the packaging insert 10, the two beveled edges 26, 28 face each other, thereby forming an angle α together. This angle α formed by the two beveled edges 26, 28 facing each other is in a cross-sectional plane of the packaging insert 10 taken along the longitudinal axis A, and further as shown in FIG. Figure 1 The beveled edges 26, 28 are edges of the cellulose-based airlaid or solid foam substrate 20 that are not perpendicular to the major sides 22, 24 of the cellulose-based airlaid or solid foam substrate 20. The beveled edges 26, 28 are thus cut at an angle β of less than 90°, see Figure 2 In fact, the sum of the angles β at which the two facing beveled edges are cut forms an angle α, which is less than 90°. If the two facing beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20 are cut at the same angle β but of opposite sign, the angle α formed by the two facing beveled edges 26, 28 is equal to 2×β, i.e., α=2×β.

[0033] like Figure 1 As shown, when facing each other and when the continuous cellulose-based airlaid or solid foam substrates 20 are arranged one after another along the axis A, the two beveled edges 26, 28 form a wedge-shaped channel or gap 51 between the first paper-based sheet 30 and the second paper-based sheet 40, and in particular between the portion 34 of the first paper-based sheet 30 and the portion 44 of the second paper-based sheet 40 within the at least one hinge section 50. Figure 1In the embodiment, the base of the wedge-shaped channel 51 is located at the portion 34 of the first paper-based sheet 30 within the hinge section 50, the tip is located at the portion 44 of the second paper-based sheet 40 within the hinge section 50, and the sides are along the oblique edges 26, 28 of the continuous cellulose-based air-laid or solid foam substrate 20. In this case, the tip of the wedge-shaped channel 51 extends along the second paper-based sheet 40 and has an angle α.

[0034] Thus, in one embodiment, the at least one hinge section 50 comprises a wedge-shaped channel 51 defined by the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20 and the first and second paper-based sheets 30, 40. In particular, the at least one hinge section 50 comprises a channel or gap 51 that is wedge-shaped when the plurality of cellulose-based airlaid or solid foam substrates 20 are arranged one after another along the longitudinal axis A of the packaging insert 10.

[0035] like Figure 1 As shown, the portions 25 , 27 of the beveled edges 26 , 28 adjacent to the second paper-based sheet 40 , i.e. the portions 25 , 27 of the beveled edges 26 , 28 forming the tip of the wedge-shaped channel 51 , are preferably arranged close to each other and may even meet at the tip of the wedge-shaped channel 51 .

[0036] like Figure 2 As shown and mentioned further above, the beveled edges 26A, 28B, 26B, 28C (see Figure 2 ) is cut at an angle β of less than 45° relative to a normal 1 to the first and second major sides 22A, 22B, 22C, 24A, 24B, 24C of the plurality of cellulose-based airlaid or solid foam substrates 20A, 20B, 20C.

[0037] In one embodiment, each beveled edge 26A, 28B, 26B, 28C of the continuous cellulose-based airlaid or solid foam substrate 20A, 20B, 20C is cut at the same angle β less than 45° relative to the normal 1. However, embodiments are not limited to cutting the beveled edges 26A, 28B, 26B, 28C at the same angle. In embodiments, facing beveled edges 26A, 28B, 26B, 28C may be cut at different angles β relative to the normal 1. For example, Figure 2The beveled edge 26A of the first cellulose-based air-laid or solid foam substrate 20A in the package may be cut at an angle β1 relative to the normal 1, while the beveled edge 28B of the second cellulose-based air-laid or solid foam substrate 20B may be cut at an angle β2 relative to the normal 1. Then, both angles β1 and β2 are less than 45°, but may be different. In such an embodiment, the angle α formed by the two beveled edges 26A, 28B is β1+β2. Therefore, the facing beveled edges 26A, 28B, 26B, 28C may be cut at angles β1 and β2, respectively, which together form an angle α. For a pair of facing beveled edges 26A, 28B, 26B, 28C, these angles β1 and β2 may be the same or different. In addition, if the packaging insert 10 includes multiple hinged sections 50A, 50B, the angles β1 and β2 may be the same or different for different pairs of beveled edges 26A, 28B, 26B, 28C.

[0038] In one embodiment, the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20 form an angle α selected within the range of 45° up to 90°, but not including 90°. In a preferred embodiment, the angle α is selected within the range of 45° up to 85°, and more preferably within the range of 45° up to 80°.

[0039] In one embodiment, the at least one hinge section 50 comprises a portion 34 of the first paper-based sheet 30 that is not attached to any cellulose-based airlaid or solid foam substrate 20 or the second paper-based sheet 40, and a portion 44 of the second paper-based sheet 40 that is not attached to any cellulose-based airlaid or solid foam substrate 20 or the first paper-based sheet 30. These respective portions 34, 44 of the first paper-based sheet 30 and the second paper-based sheet 40 in the hinge section 50 correspond to the portions 34, 44 of the first paper-based sheet 30 or the second paper-based sheet 40 that are located between the continuous interlayer sections 52. Thus, the first paper-based sheet 30 includes sheet portions or segments 31 within the interlayer section 52, wherein each such sheet portion or segment 31 is attached to a respective first major side 22 of the cellulose-based airlaid or solid foam substrate 20, and a respective intermediate sheet portion or segment 34 within the at least one hinge section 50, wherein each such intermediate sheet portion or segment 34 is not attached to any cellulose-based airlaid or solid foam substrate 20 or the second paper-based sheet 40. Each intermediate sheet portion or segment 34 is positioned between consecutive sheet portions or segments 31 of consecutive interlayer sections 52. Accordingly, the second paper-based sheet 40 includes sheet portions or segments 41 within the interlayer section 52, wherein each such sheet portion or segment 41 is attached to a respective second major side 24 of the cellulose-based airlaid or solid foam substrate 20, and a respective intermediate sheet portion or segment 44 within the at least one hinge section 50. However, each such intermediate sheet portion or section 44 of the second paper-based sheet 40 is not attached to any cellulose-based airlaid or solid foam substrate 20 or the first paper-based sheet 30. Each intermediate sheet portion or section 44 is positioned between the continuous sheet portions or sections 41 of the continuous interlayer section 52.

[0040] In one embodiment, packaging insert 10 comprises two sandwich sections 52 with an intermediate hinge section 50, such as Figure 1 Such packaging insert 10 may then be folded at hinge section 50 to form an L-shaped packaging insert 10 when inserted into packaging 80 .

[0041] In other embodiments, packaging insert 10 includes more than two interlayer sections 52A, 52B, 52C, and thus more than one hinge section 50A, 50B, see Figure 2 and Figure 3 In such Figure 2 and Figure 3In the illustrated embodiment, the packaging insert 10 comprises at least a first cellulose-based airlaid or solid foam substrate 20A, a second cellulose-based airlaid or solid foam substrate 20B, and a third cellulose-based airlaid or solid foam substrate 20C. In such an embodiment, the edges 26A, 28B of the first and second cellulose-based airlaid or solid foam substrates 20A, 20B that face each other are beveled edges 26A, 26B and form an angle α of less than 90° with each other. Correspondingly, the edges 26B, 28C of the second and third cellulose-based airlaid or solid foam substrates 20B, 20C that face each other are beveled edges 26B, 26A and form an angle α of less than 90° with each other.

[0042] In this embodiment, the packaging insert 10 thus comprises three sandwich sections 52A, 52B, 52C and two hinge sections 50A, 50B, wherein the first hinge section 50A is inserted between the first sandwich section 52A and the second sandwich section 52B, and the second hinge section 50B is inserted between the second sandwich section 52B and the third sandwich section 52C. Such a packaging insert 10 can be folded twice because it has two hinge sections 50A, 50B. Then, the packaging insert 10 folded in this way forms a U-shaped packaging insert 10 when inserted into the package 80, as shown in FIG. Figure 5 and Figure 6 shown.

[0043] However, embodiments are not limited to packaging inserts 10 consisting of two or three sandwich sections 52, 52A, 52B, 52C and one or two hinge sections 50, 50A, 50B. Figures 1 to 3 Thus, packaging insert 10 may include more than three interlayer sections 52, 52A, 52B, 52C, with respective hinge sections 50, 50A, 50B interposed between consecutive interlayer sections 52, 52A, 52B, 52C.

[0044] The angle α formed by the oblique edges 26A, 28B of the first and second cellulose-based air-laid or solid foam substrates 20A, 20B may be the same as the angle α formed by the oblique edges 26B, 28C of the second and third cellulose-based air-laid or solid foam substrates 20B, 20C. However, the embodiment is not limited to this. For example, the oblique edges 26A, 28B of the first and second cellulose-based air-laid or solid foam substrates 20A, 20B may form an angle α1, and the oblique edges 26B, 28C of the second and third cellulose-based air-laid or solid foam substrates 20B, 20C form an angle α2. In such an example, both angles α1, α2 are less than 90°, but do not need to be the same, that is, α1≠α2.

[0045] In one embodiment, the first cellulose-based airlaid or solid foam substrate 20A comprises a straight edge 28A and a beveled edge 26A, the second cellulose-based airlaid or solid foam substrate 20B comprises two beveled edges 26B, 28B, and the third cellulose-based airlaid or solid foam substrate 20C comprises a straight edge 26C and a beveled edge 28C, see Figure 2 . Therefore, in a preferred embodiment, when arranged one after another along the longitudinal axis A, only the edges of the multiple cellulose-based air-laid or solid foam substrates 20A, 20B, 20C facing another cellulose-based air-laid or solid foam substrate 20A, 20B, 20C are beveled edges 26A, 26B, 28B, 28C. However, the first or front edge 28A of the first or front cellulose-based air-laid or solid foam substrate 20A and the packaging insert 10 therefrom and the last edge 26C of the third or last cellulose-based air-laid or solid foam substrate 20C and the packaging insert 10 therefrom are straight edges 28A, 26C, i.e. cut at an angle equal to 90°. The straight edges 28A, 26C are perpendicular to the main sides 22, 24 of the multiple cellulose-based air-laid or solid foam substrates 20A, 20B, 20C.

[0046] The multiple cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C preferably have the same dimensions, namely, average thickness, average length and average width. However, the embodiment is not limited thereto. Preferably, the multiple cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C have the same or substantially the same thickness and width, but may not necessarily have the same length. For example, if the packaging insert 10 is to be positioned in the cavity 85 of a rectangular package 80 having side walls 86 that are longer than the front wall 88 (and the rear wall), the lengths of the first and third cellulose-based air-laid or solid foam substrates 20A, 20C are preferably substantially the same but longer than the length of the second cellulose-based air-laid or solid foam substrate 20B, so as to obtain a U-shaped packaging insert 10 extending along the side walls 86 and the front wall 88, such as Figure 5 The cellulose-based airlaid or solid foam substrate 20, 20A, 20C, 20C of the packaging insert 10 may also have different thicknesses (but the same length and width), different widths (but the same thickness and width), different lengths (but the same thickness and width), or indeed different thicknesses and widths (but the same length), different thicknesses and lengths (but the same width), different widths and lengths (but the same thickness), or different thicknesses, lengths, and widths.

[0047] The length of the first paper-based sheet 30 and the second paper-based sheet 40 is preferably equal to or longer than the combined length of the plurality of interlayer sections 52, 52A, 52B, 52C (and thus the plurality of cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C) and the at least one hinge section 50, 50A, 50B. The width of the first paper-based sheet 30 and the second paper-based sheet 40 is preferably substantially equal to the width of the plurality of cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C, or, if the plurality of cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C have different widths, preferably a width selected within the interval equal to the minimum width and the maximum width of the plurality of cellulose-based air-laid or solid foam substrates 20, 20A, 20B, 20C. In a preferred embodiment, the first paper-based sheet 30 has a size and general shape covering the first major side 22 of the plurality of cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, and the second paper-based sheet 40 correspondingly has a size and general shape covering the second major side 24 of the plurality of cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, such as Fig. 9 shown.

[0048] In one embodiment, see Figure 3 The end portion 38 of the first paper-based sheet 30 extends beyond the last cellulose-based air-laid or solid foam substrate 20C of the plurality of cellulose-based air-laid or solid foam substrates 20A, 20B, 20C, that is, Figure 3 The third cellulose-based airlaid or solid foam substrate 20C of the plurality of cellulose-based airlaid or solid foam substrates 20A, 20B, 20C is preferably attached to the first paper-based sheet 30 and the second paper-based sheet 40. Accordingly, the end portion 48 of the second paper-based sheet 40 extends beyond the last cellulose-based airlaid or solid foam substrate 20C of the plurality of cellulose-based airlaid or solid foam substrates 20A, 20B, 20C. In this case, the end portions 38, 48 of the first paper-based sheet 30 and the second paper-based sheet 40 are preferably attached to each other.

[0049] In another embodiment, the front portion 36 of the first paper-based sheet 30 extends beyond the front cellulose-based airlaid or solid foam substrate 20A of the plurality of cellulose-based airlaid or solid foam substrates 20A, 20B, 20C, i.e. Figure 34. The front portion 46 of the second paper-based sheet 40 extends beyond the front cellulose-based air-laid or solid foam substrate 20A of the plurality of cellulose-based air-laid or solid foam substrates 20A, 20B, 20C. In this case, the front portions 36, 46 of the first paper-based sheet 30 and the second paper-based sheet 40 are preferably attached to each other.

[0050] You can also Figure 3 The two embodiments are shown in combination, wherein the leading portions 36, 46 of the first and second paper-based sheets 30, 40 are attached to each other, and the end portions 38, 48 of the first and second paper-based sheets 30, 40 are attached to each other.

[0051] The front portions 36, 46 may be attached to each other and / or the end portions 38, 48 may be attached to each other using an adhesive. The adhesive is preferably the same adhesive used to attach the first paper-based sheet 30 and the second paper-based sheet 40 to the plurality of cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, as will be further described herein.

[0052] The attachment of the front and / or end portions 36, 46, 38, 48 of the first and second paper-based sheets 30, 40 to each other means that the end sides of the front and / or last cellulose-based airlaid or solid foam substrates 20A, 20C will be protected by the paper-based sheets 30, 40. This reduces the risk of cellulose-based particles or fibers falling off the packaging insert 10 when the packaging insert 10 is inserted into the packaging 80. In such a process, the end sides of the front and / or last cellulose-based airlaid or solid foam substrates 20A, 20C may engage another packaging insert 10 that has been inserted into the cavity 85 of the packaging 80 or the walls 86, 88 of the packaging 80. Such contact between the unprotected end sides of the front and / or last cellulose-based airlaid or solid foam substrates 20A, 20C and another packaging insert 10 of the walls 86, 88 may cause cellulose-based particles or fibers to fall off from the end sides and fall into the cavity 85 of the packaging 80. Furthermore, the paper-based sheets 30, 40 generally have a smoother surface than the cellulose-based airlaid or solid foam substrates 20A, 20B, 20C, which can more easily slide along the walls 86, 88 of the package and along the paper-based sheets 30, 40 of another packaging insert 10. Figure 2 Compared to the embodiment of the packaging insert 10 shown with the free front and end portions of the first paper-based sheet 30 and the second paper-based sheet 40, when the packaging insert 10 is inserted into the cavity 85 of the package 80, as shown in FIG. Figure 3The embodiment shown having an attached front portion 36, 46 and / or an attached end portion 38, 48 is generally easier to handle.

[0053] The front portion 36, 46 and the end portions 48, 48 may be attached to each other anywhere along the end sides of the front and last cellulose-based airlaid or solid foam substrates 20A, 20C. Figure 3 An embodiment is shown in which the front portion 36, 46 and the end portion 48, 48 are attached to each other closer to one of the major sides of the front and last cellulose-based airlaid or solid foam substrate 20A, 20C rather than in the middle of the end side of the front and last cellulose-based airlaid or solid foam substrate 20A, 20C. In such an embodiment, the attached front portion 36, 46 and the end portion 48, 48 can be as shown. Figure 6 80 or another packaging insert 10 inserted into the package 80.

[0054] Furthermore, attached front portions 36, 46 and end portions 38, 48 constitute protruding structures that a user may easily grasp when removing folded packaging insert 10 from cavity 85 of packaging 80. Thus, these attached front portions 36, 38 and end portions 46, 48 may serve as retaining members when handling packaging insert 10.

[0055] In one embodiment, the first paper-based sheet 30 comprises an adhesive 60, see Figure 1 , the adhesive 60 is provided or applied (e.g., coated or sprayed) to at least a portion of the major side 32 of the first paper-based sheet 30 and attached to the first major side 22 of the plurality of cellulose-based airlaid or solid foam substrates 20, wherein the major side 32 of the first paper-based sheet 30 faces the first major side 22 of the plurality of cellulose-based airlaid or solid foam substrates 20. Accordingly, the second paper-based sheet 40 preferably includes the adhesive 60, which is provided to at least a portion of the major side 42 of the second paper-based sheet 40 and attached to the second major side 24 of the plurality of cellulose-based airlaid or solid foam substrates 20, wherein the major side 42 of the second paper-based sheet 40 faces the second major side 24 of the plurality of cellulose-based airlaid or solid foam substrates 20.

[0056] The same adhesive 60 may be applied to both the first paper-based sheet 30 and the second paper-based sheet 40 , or different adhesives 60 may be applied to both the first paper-based sheet 30 and the second paper-based sheet 40 .

[0057] The adhesive 60 may then be provided or applied (such as coated or sprayed) onto the entire portions 31, 41, 44 of the major sides 32, 42 of the first and second paper-based sheets 30, 40. Alternatively, the adhesive 60 may be provided onto only a portion of the major sides 32, 42 in the interlayer section 52 and in the at least one hinge section 50 for the major side 42 of the second paper-based sheet 40. For example, the adhesive 60 may be applied along a frame in connection with the circumference of the portions 31, 41, 44 of the major sides 32, 42 of the first and second paper-based sheets 30, 40. The adhesive 60 may also be applied at a plurality of separate locations on the major sides 32, 42 of the first and second paper-based sheets 30, 40.

[0058] Alternatively or in addition, in order to provide adhesive 60 to at least a portion 31, 41, 44 of the main sides 32, 42 of the first paper-based sheet 30 and the second paper-based sheet 40, the adhesive 60 can be applied to at least a portion of the first main side 22 and / or at least a portion of the second main side 42 of the plurality of cellulose-based air-laid or solid foam substrates 20.

[0059] In one embodiment, adhesive is selected from pressure-sensitive adhesive, solvent-based adhesive, polymer dispersion adhesive, contact adhesive and hot melt adhesive. Pressure-sensitive adhesive forms bonding by applying slight pressure so that adhesive is combined with adherend. Solvent-based adhesive is a mixture of polymer components dissolved in a solvent. As the solvent evaporates, the adhesive hardens. Accordingly, polymer dispersion adhesive, also referred to as emulsion adhesive, is a milky dispersion usually based on polyvinyl acetate (PVAc). Contact adhesive needs to be applied to paper-based sheet 30,40 and the multiple cellulose-based air-laid or solid foam substrate 20 and before paper-based sheet 30,40 is attached to cellulose-based air-laid or solid foam substrate 20, allow a period of time to dry. Hot melt adhesive is a thermoplastic polymer applied in molten form, which solidifies to form a strong bond when cooled.

[0060] Currently preferred adhesives include pressure-sensitive adhesives, solvent-based adhesives, polymer dispersion adhesives and hot melt adhesives because they can provide a strong bond between the first paper-based sheet 30 and the second paper-based sheet 40 and the multiple cellulose-based air-laid or solid foam substrates 20, but only need to be applied to the major sides 32, 42 of the paper-based sheets 30, 40 or the major sides 22, 24 of the multiple cellulose-based air-laid or solid foam substrates 20.

[0061] Illustrative but non-limiting examples of adhesives that can be used to attach the paper-based sheets 30, 40 to the cellulose-based airlaid or solid foam substrate 20 include low density polyethylene (LDPE) as an example of a hot melt adhesive. Other non-limiting examples include wood glues or adhesives, such as polyvinyl acetate-based wood glues or adhesives, and wallpaper glues or adhesives, such as starch-based wallpaper glues or adhesives.

[0062] The first paper-based sheet 30 and the second paper-based sheet 40 may be any paper-based sheet 30, 40 that can be attached to the plurality of cellulose-based airlaid or solid foam substrates 20 and is flexible enough to be folded at the at least one hinge section 50. In one embodiment, the first paper-based sheet 30 and the second paper-based sheet 40 are selected from paper sheets, paperboard sheets, tissue paper sheets, and nonwoven paper sheets.

[0063] As an example, the first paper-based sheet 30 and the second paper-based sheet 40 can be selected from kraft paper sheets, cardboard sheets, boxboard sheets and corrugated paperboard sheets. Generally, kraft paper sheets are thinner and more flexible than cardboard sheets, boxboard sheets and corrugated paperboard sheets. Illustrative examples of kraft paper sheets that can be used for packaging inserts include kraft paper sheets with a grammage of 15 g / m 2 Up to 135g / m 2 , preferably with a grammage of 20 g / m 2 Up to 60g / m 2 , and more preferably the grammage is 30g / m 2 Up to 50g / m 2 Sheets of kraft paper.

[0064] The first paper-based sheet 30 and the second paper-based sheet 40 are generally made of the same type of paper-based material, such as the same type of kraft paper sheet. However, different types of paper-based materials can be used for the first paper-based sheet 30 and the second paper-based sheet 40, such as different types of kraft paper sheets.

[0065] The outer major side of the first paper-based sheet 30 and / or the second paper-based sheet 40 facing away from the cellulose-based airlaid or solid foam substrate 20 may optionally be coated, for example, to provide a waterproof coating or barrier, a grease repellent coating or barrier, a pigmented coating, and / or a structured coating. The first paper-based sheet 30 and / or the second paper-based sheet 40 may comprise one or more layers of paper-based material. Thus, the first paper-based sheet 30 and / or the second paper-based sheet 40 may be a paper-based multi-layer or laminated sheet.

[0066] The first paper-based sheet 30 and the second paper-based sheet 40 not only hold the plurality of cellulose-based air-laid or solid foam substrates 20 together, but also form at least one hinge section 50. The first paper-based sheet 30 and the second paper-based sheet 40 also constitute the surface covering of the first major side 22 and the second major side 24 of the plurality of cellulose-based air-laid or solid foam substrates 20, and optionally also constitute the surface covering of the end sides, such as Figure 3 The surface covering alleviates the need for any surface treatment of the plurality of cellulose-based airlaid or solid foam substrates 20 to reduce dust from cellulose-based particles or fibers of the plurality of cellulose-based airlaid or solid foam substrates 20. In addition, the first paper-based sheet 30 and the second paper-based sheet 40 can protect the plurality of cellulose-based airlaid or solid foam substrates 20 and any items protected by the packaging insert 10 from moisture, grease, or other liquids that might otherwise penetrate through the cellulose-based airlaid or solid foam substrates 20.

[0067] The airlaid or solid foam substrate 20 is cellulose-based if the airlaid or solid foam substrate 20 comprises a cellulosic and / or lignocellulosic material as a major portion or component. Various such cellulosic and / or lignocellulosic materials may be included in the cellulose-based airlaid or solid foam substrate 20, including, but not limited to, cellulosic and / or lignocellulosic fibers, cellulosic and / or lignocellulosic particles, and / or cellulosic and / or lignocellulosic fibrils.

[0068] In one embodiment, the plurality of cellulose-based airlaid or solid foam substrates 20 comprise cellulose and / or lignocellulose fibers. Lignocellulose as used herein is a mixture of cellulose and lignin. Cellulose and / or lignocellulose fibers may additionally contain hemicellulose. In a particular embodiment, cellulose and / or lignocellulose fibers are cellulose and / or lignocellulose pulp fibers produced by chemical, mechanical and / or chemimechanical pulping of softwood and / or hardwood. For example, the form of cellulose and / or lignocellulose pulp fibers is selected from sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical fibers intended for medium density fiberboard (MDF-fibers), chemical thermomechanical pulp (CTMP), high temperature chemical thermomechanical pulp (HTCTMP) and combinations thereof.

[0069] The cellulosic and / or lignocellulosic pulp fibers may be bleached or unbleached.

[0070] Cellulosic and / or lignocellulosic fibers may also be produced by other pulping methods and / or from other cellulosic or lignocellulosic raw materials besides wood, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw or rice husks. Natural fibers may also be used, which are mixtures of fibers from different raw materials, such as a mixture of wood and any of the above materials.

[0071] In addition to the cellulosic and / or lignocellulosic materials, the plurality of cellulose-based airlaid or solid foam substrates 20 may also include one or more additives. Illustrative but non-limiting examples of such additives include foam formers (also known in the art as blowing agents), thickeners, conductive or semiconductive fillers, coupling agents, flame retardants, dyes, impact modifiers, and the like.

[0072] In one embodiment, the average density of the plurality of cellulose-based airlaid or solid foam substrates 20 is preferably in the range of 10 to 60 kg / m 3 In a particular embodiment, the average density of the plurality of cellulose-based air-laid or solid foam substrates 20 is in the range of 15 to 60 kg / m 3 More preferably, it is in the range of 15 to 50 kg / m 3 within the range.

[0073] In one embodiment, the plurality of cellulose-based airlaid or solid foam substrates 20 are a plurality of cellulose-based airlaid substrates 20. Airlaid substrates (also referred to as airlaid panels) are formed by airlaid materials through a process called airlaying, in which cellulose and / or lignocellulose fibers and polymer binders are mixed with air to form a porous fiber mixture that is deposited on a carrier and consolidated or bonded by heating. The airlaid substrate is characterized in that it is porous, has the characteristics of open-cell foam, and is produced in a so-called dry forming method, i.e., usually without adding water. The airlaid process was originally described in U.S. Patent No. 3,575,749. Therefore, the airlaid substrate can be formed by airlaid blanks, dry-laid blanks, airlaid pads, dry-laid blanks, airlaid webs or dry-laid webs.

[0074] In one embodiment, each cellulose-based air-laid substrate 20 comprises cellulose and / or lignocellulosic fibers at a concentration of at least 70% by weight of the cellulose-based air-laid substrate 20, and a polymer binder at a concentration selected from the range of 2.5 to up to 30% by weight of the cellulose-based air-laid substrate 20.

[0075] In a preferred embodiment, each cellulose-based airlaid substrate 20 comprises cellulose and / or lignocellulosic fibers at a concentration of at least 72.5% by weight, more preferably at least 75% by weight, such as at least 77.5% by weight, at least 80% by weight, at least 82.5% by weight, at least 85% by weight of the cellulose-based airlaid substrate 20. In some applications, even higher concentrations of cellulose and / or lignocellulosic fibers, such as at least 87.5% by weight, or at least 90% by weight, at least 92.5% by weight, at least 95% by weight, or at least 97.5% by weight of the cellulose-based airlaid substrate 20, may be used.

[0076] In some embodiments, the concentration of the polymer binder contained in each cellulose-based air-laid substrate 20 is selected from the range of 5 to up to 30 weight % of the cellulose-based air-laid substrate 20, preferably selected from the range of 10 to up to 25 weight % of the cellulose-based air-laid substrate 20, for example, selected from the range of 12.5 to up to 22.5 weight % of the cellulose-based air-laid substrate 20, or selected from the range of 15 to up to 20 weight % of the cellulose-based air-laid substrate 20.

[0077] The plurality of cellulose-based airlaid substrates 20 may also include a small portion of synthetic materials or fibers mixed with cellulose and / or lignocellulosic fibers. Such synthetic materials or fibers that may be mixed with cellulose and / or lignocellulosic fibers include, for example, glass or mineral wool, and / or carbon fibers. Any such synthetic material or fiber may be added in an amount not exceeding 10% (w / w) of the cellulose-based airlaid substrate 20, preferably not exceeding 8% (w / w) of the cellulose-based airlaid substrate 20, for example not exceeding 6% (w / w), or preferably not exceeding 4% (w / w).

[0078] The plurality of cellulose-based airlaid substrates 20 may also include a small portion of synthetic materials or fibers mixed with cellulose and / or lignocellulosic fibers. Such synthetic materials or fibers that may be mixed with cellulose and / or lignocellulosic fibers include, for example, glass or mineral wool, and / or carbon fibers. Any such synthetic material or fiber may be added in an amount not exceeding 10% (w / w) of the cellulose-based airlaid substrate 20, preferably not exceeding 8% (w / w) of the cellulose-based airlaid substrate 20, for example not exceeding 6% (w / w), or preferably not exceeding 4% (w / w).

[0079] The length of fibers (e.g., cellulose and / or lignocellulosic fibers), as referred to herein, is the length-weighted average fiber length. 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, as described in, for example, ISO 16065-1 or ISO 16065-2.

[0080] In one embodiment, the cellulosic and / or lignocellulosic fibers have a length-weighted average fiber length of up to 10 mm, preferably up to 8 mm, more preferably up to 6 mm, and most preferably up to 5 mm. In a particular embodiment, the cellulosic and / or lignocellulosic fibers have a length-weighted average fiber length selected in the interval of 1 mm to up to 10 mm, preferably a length-weighted average fiber length selected in the interval of 1 mm to up to 8 mm, more preferably a length-weighted average fiber length selected in the interval of 1 mm to up to 6 mm, and most preferably a length-weighted average fiber length selected in the interval of 1 mm to up to 5 mm.

[0081] A small proportion of longer fibers having a length-weighted average fiber length of 10 mm or more may also be included.

[0082] Polymer binder is included in the multiple cellulose-based airlaid substrates 20 to bond the multiple cellulose-based airlaid substrates 20 together and to maintain their form and structure during use, handling and storage. In one embodiment, polymer binder can also contribute to the foamed structure of the multiple cellulose-based airlaid substrates 20. In such an embodiment, polymer binder is mixed (intermingle) with cellulose and / or lignocellulosic fibers during the production of the multiple cellulose-based airlaid substrates 20. Polymer binder can be added in the form of powder, but more usually in the form of polymer fibers mixed with cellulose and / or lignocellulosic fibers during production. Alternatively or additionally, polymer binder can be added to cellulose and / or lignocellulosic fibers and cellulose and / or lignocellulosic fibers as solution, emulsion or dispersion during the production process.

[0083] In a particular embodiment, the polymer binder is selected from the group consisting of polymer powders, polymer fibers, and combinations thereof.

[0084] The polymer binder may be a natural or synthetic polymer binder, or a mixture of natural polymer binders, a mixture of synthetic polymer binders, or a mixture of natural and synthetic polymer binders, but is preferably a thermoplastic polymer binder.

[0085] In one embodiment, the polymer binder is made of: i) a material selected from the group consisting of polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene vinyl acetate (EVA), polypropylene (PP), polystyrene (PS) (e.g., styrene-butadiene rubber (SBR) or styrene acrylate copolymer), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl acetate (PVAc), polyurethane (PU), copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0086] In another embodiment, the polymer binder is a polymer binder that is water soluble at the repulping temperature of the repulping process. Such a water soluble polymer binder means that the packaging insert 10 can be recycled in the repulping process. In such an embodiment, the polymer binder is made of: i) a material selected from polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly (2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinyl pyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof and mixtures thereof, and ii) optionally one or more additives.

[0087] Therefore, in one embodiment, the polymer binder is made of a material selected from the above group. In another embodiment, the polymer binder is made of a material selected from the above group and one or more additives.

[0088] In one embodiment, the polymer binder is or comprises, for example, consists of, monocomponent and / or bicomponent polymer fibers. Bicomponent polymer fibers, also referred to as bico fibers, comprise a first polymer, copolymer and / or polymer blend and a second, different polymer, copolymer and / or polymer blend. Most commonly, the bicomponent polymer fiber comprises a core made of a first polymer, copolymer and / or polymer blend and a sheath made of a second polymer, copolymer and / or polymer blend, although other combinations of two or even more polymers, copolymers and / or polymer blends are also possible.

[0089] In a particular embodiment, the polymer binder is or comprises, for example consists of, a monocomponent polymer fiber made of: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives. In another particular embodiment, the polymer binder is or comprises, such as consists of, a bicomponent polymer fiber having a first material, which is a core, for example, made from: i) a first material, which is selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives, and a second material, which is a sheath, for example, made from: i) a second material, typically a different material, which is selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives. In another embodiment, the polymer binder is or comprises a combination or mixture of monocomponent polymer fibers and bicomponent polymer fibers, such as consisting of a combination or mixture of monocomponent polymer fibers, wherein the monocomponent polymer fibers are made of: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, and ii) optionally one or more additives, and the bicomponent polymer fibers have i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof and mixtures thereof, such as materials for the core and / or sheath, and ii) optionally one or more additives.

[0090] The polymer binder may be made of a single type of polymer fiber, i.e., made of the same material in the case of monocomponent polymer fibers, or made of the same material in the case of bicomponent polymer fibers. However, it is also possible to use a polymer binder made of one or more (i.e., two or more) different monocomponent polymer fibers made of different materials and / or one or more different bicomponent polymer fibers made of different materials.

[0091] In one embodiment, the polymer binder is a polymer powder made from: i) a material selected from PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0092] In addition to the natural fibers and polymer binders as described above, the plurality of cellulose-based airlaid substrates 20 may also include one or more additives. One or more additives may be added to the polymer binder and / or added when the polymer binder is produced. Alternatively or additionally, one or more additives may be added to cellulose and / or lignocellulosic fibers. Alternatively or additionally, one or more additives may be added to cellulose and / or lignocellulosic fibers and polymer binders.

[0093] In a particular embodiment, the polymer binder is a natural polymer selected from starch, agar, guar gum, locust bean gum, carrageenan and cellulose, such as fibrillar, microfibrillar or nanofibrillar cellulose.

[0094] In one embodiment, the polymeric binder may be in the form of a water-based (aqueous) solution, emulsion, suspension, or dispersion of the polymeric binder.

[0095] In another embodiment, the plurality of cellulose-based airlaid or solid foam substrates 20 are a plurality of cellulose-based solid foam substrates 20. Such cellulose-based solid form substrates 20 can be formed by cellulose and / or lignocellulose particles, cellulose and / or lignocellulose fibrils and / or cellulose and / or lignocellulose fibers. Cellulose-based solid foam substrates 20 comprising cellulose and / or lignocellulose fibers are also referred to herein as cellulose-based fibrous foam substrates 20.

[0096] Examples of cellulosic and / or lignocellulosic fibers that may be used for the cellulosic solid foam substrate 20 are described previously.

[0097] Cellulose and / or lignocellulose fibrils can be prepared by longitudinal fibrillation of cellulose and / or lignocellulose fibers. Such cellulose and / or lignocellulose fibrils can be in the form of so-called microfibrillated cellulose (MFC). MFC means cellulose particles, fibers or fibrils having a width or diameter of 20 nm to 1000 nm.

[0098] There are various methods for making MFC, such as single-pass or multi-pass refining, pre-hydrolysis followed by refining or high shear disintegration or release of fibrils. In order to make MFC manufacturing both energy-saving and sustainable, one or more pretreatment steps are generally required. Therefore, the cellulose fibers of the pulp used when producing MFC can be natural or enzymatic or chemically pretreated, for example to reduce the amount of hemicellulose and / or lignin. Cellulose fibers can be chemically modified before fibrillation, wherein the cellulose molecules contain (or more) functional groups in addition to the functional groups found in the original cellulose. Such groups especially include carboxymethyl (CM), aldehydes and / or carboxyl (cellulose obtained by oxidation mediated by N-oxyl, such as "TEMPO") or quaternary ammonium (cationic cellulose). After modification or oxidation in one of the above methods, it is easier to disintegrate the fibers into MFC.

[0099] MFC can be produced from wood cellulose fibers (both hardwood fibers and softwood fibers). It can also be made from microbial sources, agricultural fibers such as straw pulp, bamboo, bagasse or other non-wood fiber sources. It can be made from pulp, including pulp from virgin fibers, such as mechanical, chemical and / or thermomechanical pulp. It can also be made from waste paper or recycled paper.

[0100] Cellulosic and / or lignocellulosic particles can be produced by grinding cellulose and / or lignocellulosic fibers and / or fibrils into particles.Such cellulose and / or lignocellulosic particles typically have a size in the micrometer or nanometer range.

[0101] The term "foam" as used herein refers to a substance made by trapping air or gas bubbles within a solid or liquid. Typically, the volume of the gas is much greater than the volume of the liquid or solid, with a thin film separating the gas pockets. Mechanical work is used to increase the surface area during foam formation. This can occur by stirring, dispersing large amounts of gas into a liquid, or injecting gas into a liquid. A foam former is present, typically an amphiphilic substance, a surfactant, or a surface-active component to reduce surface tension. The foam can typically be a liquid foam or a solid foam. The cellulose-based solid foam substrate 20 of the packaging insert 10 is a solid foam.

[0102] As used herein with respect to foams, the term "solid" refers to a foam that is not liquid or fluid, but is firm and stable in shape. A solid is a sample of matter that retains its shape and density when not restrained. A solid may be rigid, or susceptible to plastic and / or elastic deformation. The adjective solid describes the state or condition of a substance having such properties. Cellulose-based solid foam substrates are porous.

[0103] refer to Figure 5 and Figure 6 The present invention also relates to a packaging assembly 70 comprising a package 80 comprising a bottom 82 and a plurality of side walls 86, 88 defining a cavity 85. The packaging assembly 70 also comprises a packaging insert 10 according to the present invention and as described herein positioned within the cavity 85.

[0104] Package 80 can be made of various materials. In one embodiment, package 80 comprises or consists of a paper-based material, i.e., package 80 is made of a paper-based material. An illustrative but non-limiting example of such a paper-based material is corrugated cardboard. The paper-based material can optionally be coated with a barrier coating, for example, to limit the ingress of moisture or grease.

[0105] The packaging insert 10 of the embodiment can be used for protecting various articles in different types of packaging, including but not limited to boxes and containers. The bottom 82 in the packaging 80 is preferably a square or rectangular bottom 82. In this case, the packaging 80 comprises four sidewalls 86, 88 connected to the bottom 82. The packaging 80 may also include a lid 84. However, the embodiment is not limited thereto. The packaging 80 may include less than four sidewalls 86, 88, for example, three sidewalls 86, 88 with a triangular bottom 82, or may include more than four sidewalls 86, 88, for example, five, six, seven, eight or even more sidewalls 86, 88 with a pentagon, hexagon, heptagon or octagon bottom 82.

[0106] In one embodiment, packaging insert 10 is folded at at least one hinge section 50A, 50B to form at least one corner 12A, 12B. The at least one corner 12A, 12B is preferably a 90° angle.

[0107] In this case, the packaging insert 10 is preferably folded at the at least one hinge section 50A, 50B so that the top portion 26A', 26B', 28B', 28C' (see Figure 2 ) are adjacent or proximate to each other, and preferably in contact with each other, see Figure 7These top portions 26A′, 26B′, 28B′, 28C′ of the beveled edges 26A, 26B, 28B, 28C are adjacent to or adjacent to the first paper-based sheet 30 .

[0108] Thus, by cutting the beveled edges 26A, 26B, 28B, 28C at an angle β < 45°, so that the beveled edges 26A, 26B, 28B, 28C facing each other form an angle α < 90°, the second paper-based sheet 40 facing the walls 86, 88 and / or the bottom 82 of the package 80 will be too short, and the first paper-based sheet 30 facing the cavity 85 of the package 80 will be tacked into the gaps between the consecutive beveled edges 26A, 26B, 28B, 28C in the corners 12A, 12B. This in turn means that the force F1 acts on the top portions 26A', 26B', 28B', 28C' of the beveled edges 26A, 26B, 28B, 28C, as shown in FIG. Figure 7 As shown, a force F2 extending along the length of the continuous cellulose-based air-laid or solid foam substrate 20A, 20B, 20C acts on the opposite bottom portion of the beveled edge 26A, 26B, 28B, 28C to push the top portion 26A', 26B', 28B', 28C toward each other. This in turn ensures that the continuous cellulose-based air-laid or solid foam substrates 20A, 20B, 20C are adjacent or adjacent to each other and minimize any gaps between the cellulose-based air-laid or solid foam substrates 20A, 20B, 20C. Therefore, by reducing any gaps between the cellulose-based air-laid or solid foam substrates 20A, 20B, 20C, the folded packaging insert 10 provides good insulation and protection, even at the fold of the packaging insert 10.

[0109] exist Figure 5 and Figure 6 In the illustrated embodiment, packaging insert 10 is folded at first hinge section 50A and second hinge section 50B to form a U-shaped packaging insert 10. Accordingly, as shown in FIG. Figure 1 Packaging insert 10 is shown folded to have a generally L-shape.

[0110] Package 80 may include a single packaging insert 10 in its cavity 85. However, it is generally preferred to include more than one packaging insert 10 in cavity 85 to protect any item from all sides, including the bottom and top. Figure 2 and Figure 3 The two packaging inserts 10 shown can be positioned in the package 80 to provide protection and insulation at all four side walls 86, 88, the bottom 82 and the lid 84. Different types of packaging inserts 10 can also be included in a single package 80, such as Figure 1 One or more packaging inserts 10 including two sandwich sections 52 as shown and as Figure 2 and 3 One or more packaging inserts 10 are shown including three sandwich sections 52A, 52B, 52C.

[0111] The packaging insert 10 of the present invention effectively protects items and articles from impacts and shocks. The packaging insert 10 also has good insulating properties and can therefore be used to provide thermal insulation, ie, to insulate heated items or cold items.

[0112] Another aspect of the present invention relates to a method for producing a packaging insert 10, see FIG. 4A to FIG. 4D and Figure 8 The method comprises cutting the cellulose-based airlaid or solid foam substrate blank 20' at a first angle β of less than 45° relative to a normal 1' to a main side 22' of the cellulose-based airlaid or solid foam substrate blank 20' and at a second angle β equal to the first angle β but opposite in sign to obtain at least a first cellulose-based airlaid or solid foam substrate 20A comprising a beveled edge 26A, a second cellulose-based airlaid or solid foam substrate 20B comprising two beveled edges 26B, 28B, and a third cellulose-based airlaid or solid foam substrate 20C comprising a beveled edge 28C, as in step S1. Figure 4B The method then includes inverting the second cellulose-based airlaid or solid foam substrate 20B so that the beveled edge 26A of the first cellulose-based airlaid or solid foam substrate 20A faces the first beveled edge 28B of the second cellulose-based airlaid or solid foam substrate, and the beveled edge 28C of the third cellulose-based airlaid or solid foam substrate 20C faces the second beveled edge 26B of the second cellulose-based airlaid or solid foam substrate 20B, as shown. Figure 4C As shown. The beveled edge 26A of the first cellulose-based air-laid or solid foam substrate 20A and the first beveled edge 28B of the second cellulose-based air-laid or solid foam substrate 20B form an angle α of less than 90° between the beveled edges 26A, 26B. Correspondingly, the beveled edge 28C of the third cellulose-based air-laid or solid foam substrate 20B and the second beveled edge 26B of the second cellulose-based air-laid or solid foam substrate 20B form an angle α of less than 90° between the beveled edges 26B, 28C. The next step S3 includes attaching the first paper base 30 to the first main sides 22A, 22B, 22C of at least the first, second and third cellulose-based air-laid or solid foam substrates 20A, 20B, 20C, and attaching the second paper base sheet 40 to the second main sides 24A, 24B, 24C of at least the first, second and third cellulose-based air-laid or solid foam substrates 20A, 20B, 20C to form a packaging insert 10. See. Figure 2, packaging insert 10 includes a first hinge section 50A interposed between an oblique edge 26A of a first cellulose-based airlaid or solid foam substrate 20A and a first oblique edge 28B of a second cellulose-based airlaid or solid foam substrate 20B. Packaging insert 10 also includes a second hinge section 50B interposed between a second oblique edge 26B of the second cellulose-based airlaid or solid foam substrate 20B and an oblique edge 28C of a third cellulose-based airlaid or solid foam substrate 20C.

[0113] In one embodiment, the first hinge section 50A comprises a wedge-shaped channel 51 defined by the beveled edge 26A of the first cellulose-based airlaid or solid foam substrate 20A and the first beveled edge 28B of the second cellulose-based airlaid or solid foam substrate 20B, and the first paper-based sheet 30 and the second paper-based sheet 40. In this embodiment, the second hinge section 50B comprises a wedge-shaped channel 51 defined by the second beveled edge 26B of the second cellulose-based airlaid or solid foam substrate 20B and the beveled edge 28C of the third cellulose-based airlaid or solid foam substrate 20C, and the first paper-based sheet 30 and the second paper-based sheet 40.

[0114] In one embodiment, the method further comprises attaching an end portion 38 of the first paper-based sheet 30 extending beyond the third cellulose-based airlaid or solid foam substrate 20C to an end portion 48 of the second paper-based sheet 40 extending beyond the third cellulose-based airlaid or solid foam substrate 20C.

[0115] In one embodiment, the method further comprises attaching a leading portion 36 of the first paper-based sheet 30 extending beyond the first cellulose-based airlaid or solid foam substrate 20A to a leading portion 46 of the second paper-based sheet 40 extending beyond the first cellulose-based airlaid or solid foam substrate 20A.

[0116] The above embodiments should be understood as several illustrative examples of the present invention. Those skilled in the art will appreciate that various modifications, combinations and changes may be made to the embodiments without departing from the scope of the present invention. In particular, different partial solutions in different embodiments may be combined in other configurations where technically possible.

Claims

1. A packaging insert (10) comprising: a plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) having respective first major sides (22, 22A, 22B, 22C) and second major sides (24, 24A, 24B, 24C) opposite the first major sides (22, 22A, 22B, 22C); a first paper-based sheet (30) attached to a first major side (22, 22A, 22B, 22C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); and a second paper-based sheet (40) attached to a second major side (24, 24A, 24B, 24C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C), wherein: The edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) facing each other are beveled edges (26, 26A, 26B, 28, 28B, 28C) and form an angle (α) of less than 90° with each other; and At least one hinge section (50, 50A, 50B) is interposed between the beveled edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid or solid foam substrate (20, 20A, 20B, 20C), wherein the packaging insert (10) is foldable in the at least one hinge section (50, 50A, 50B).

2. A packaging insert according to claim 1, wherein the at least one hinged section (50, 50A, 50B) comprises a wedge-shaped channel (51), which is defined by the oblique edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based air-laid or solid foam substrate (20, 20A, 20B, 20C) and the first paper-based sheet and the second paper sheet (30, 40).

3. The packaging insert of claim 1 or 2, wherein: When the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) are arranged one after another along the longitudinal axis (A) of the packaging insert (10), the beveled edges (26, 26A, 26B, 28, 28B, 28C) form an angle (α) of less than 90° between each other.

4. A packaging insert according to any one of claims 1 to 3, wherein the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) are sandwiched between the first paper-based sheet and the second paper-based sheet (30, 40).

5. A packaging insert according to any one of claims 1 to 4, wherein the edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based air-laid or solid foam substrate (20, 20A, 20B, 20C) are cut at an angle (β) less than 45° relative to a normal (1) to the first main side and the second main side (22, 22A, 22B, 22C, 24, 24A, 24B, 24C).

6. A packaging insert according to any one of claims 1 to 5, wherein the beveled edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based air-laid or solid foam substrate (20, 20A, 20B, 20C) form an angle (α), the angle (α) being selected in the range of 45° to up to but not including 90°, preferably 45° to up to 85°, and more preferably 45° to up to 80°.

7. The packaging insert according to any one of claims 1 to 6, wherein the packaging insert (10) comprises: At least a first cellulose-based airlaid or solid foam substrate (20A), a second cellulose-based airlaid or solid foam substrate (20B) and a third cellulose-based airlaid or solid foam substrate (20C), wherein The edges (26A, 28B) of the first and second cellulose-based airlaid or solid foam substrates (20A, 20B) that face each other are beveled edges (26A, 28B) and form an angle (α) that is less than 90°; and The edges (26B, 28C) of the second and third cellulose-based airlaid or solid foam substrates (20B, 20C) that face each other are beveled edges (26B, 28C) and form an angle (α) that is less than 90°.

8. The packaging insert of claim 7, wherein The first cellulose-based airlaid or solid foam substrate (20A) comprises straight edges (28A) and beveled edges (26A); The second cellulose-based airlaid or solid foam substrate (20B) comprises two beveled edges (26B, 28B); and The third cellulose-based airlaid or solid foam substrate (20C) comprises straight edges (26C) and beveled edges (28C).

9. The packaging insert according to any one of claims 1 to 8, wherein The end portion (38) of the first paper-based sheet (30) extends beyond the last cellulose-based airlaid or solid foam substrate (20C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); The end portion (48) of the second paper-based sheet (40) extends beyond the last cellulose-based airlaid or solid foam substrate (20C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); and End portions (38, 48) of the first paper-based sheet and the second paper-based sheet (30, 40) are attached to each other.

10. The packaging insert of any one of claims 1 to 9, wherein A front portion (36) of the first paper-based sheet (30) extends beyond a front cellulose-based airlaid or solid foam substrate (20A) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); A front portion (46) of the second paper-based sheet (40) extends beyond a front cellulose-based airlaid or solid foam substrate (20A) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); and Front portions (36, 46) of the first and second paper-based sheets (30, 40) are attached to each other.

11. The packaging insert of any one of claims 1 to 10, wherein The first paper-based sheet (30) comprises an adhesive (60) applied to at least a portion of a major side (32) of the first paper-based sheet (30) and attached to a first major side (22, 22A, 22B, 22C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C), wherein the major side (32) of the first paper-based sheet (30) faces the first major side (22, 22A, 22B, 22C) of the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C); and The second paper-based sheet (40) comprises an adhesive applied to at least a portion of a major side (42) of the second paper-based sheet (40) and attached to second major sides (24, 24A, 24B, 24C) of the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C), wherein the major side (42) of the second paper-based sheet (40) faces the second major sides (24, 24A, 24B, 24C) of the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C).

12. The packaging insert according to any one of claims 1 to 11, wherein the first and second paper-based sheets (30, 40) are selected from paper sheets, paperboard sheets, tissue paper sheets and non-woven paper sheets.

13. The packaging insert according to any one of claims 1 to 12, wherein the first paper sheet substrate and the second paper-based sheet (30, 40) are selected from the group consisting of kraft paper sheets, cardboard sheets, boxboard sheets and corrugated board sheets.

14. A packaging insert according to any one of claims 1 to 13, wherein the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) comprise cellulose and / or lignocellulosic fibers, preferably cellulose and / or lignocellulosic pulp fibers produced by chemical, mechanical and / or chemimechanical pulping of softwood and / or hardwood.

15. A packaging insert according to claim 14, wherein the cellulose and / or lignocellulosic fibers are cellulose and / or lignocellulosic pulp fibers in the form of kraft pulp, sulfite pulp, dissolving pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical fibers intended for medium density fiberboard (MDF-fibers), chemothermomechanical pulp (CTMP), high temperature chemothermomechanical pulp (HTCTMP) and combinations thereof.

16. A packaging insert according to any one of claims 1 to 15, wherein the plurality of cellulose-based air-laid or solid foam substrates (20, 20A, 20B, 20C) are a plurality of cellulose-based air-laid substrates (20, 20A, 20B, 20C).

17. The packaging insert of claim 16, wherein the plurality of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) comprise a polymer binder, preferably a thermoplastic polymer binder.

18. A packaging assembly (70), comprising: A package (80) comprising a bottom (82) and a plurality of side walls (86, 88) defining a cavity (85); and A packaging insert (10) as claimed in any one of claims 1 to 17, positioned within the cavity (85).

19. The packaging assembly according to claim 18, wherein the packaging insert (10) is folded at the at least one hinge section (50, 50A, 50B) to form at least one angle (12A, 12B), preferably at least one 90° angle (12A, 12B).

20. A packaging assembly according to claim 18 or 19, wherein the top portions (26A', 26B', 28B', 28C') of the beveled edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based air-laid or solid foam substrate (20, 20A, 20B, 20C) are in contact with each other, wherein the top portions (26A', 26B', 28B', 28C') of the beveled edges (26, 26A, 26B, 28, 28B, 28C) are adjacent to the first paper-based sheet (30).

21. A packaging assembly according to any one of claims 18 to 20, wherein The packaging assembly (70) comprises a packaging insert (10) according to claim 6 or 7 positioned within the cavity (85); and The packaging insert (10) is folded at the first hinge section (50A) and the second hinge section (50B) to form a U-shaped packaging insert (10).

22. A method for producing a packaging insert (10), comprising: Cutting (S1) a cellulose-based airlaid or solid foam substrate blank (20') at a first angle (β) less than 45° relative to a normal (1') to a main side (22') of the cellulose-based airlaid or solid foam substrate blank (20') and at a second angle (β) equal to the first angle (β) but with an opposite sign to obtain at least a first cellulose-based airlaid or solid foam substrate (20A) comprising an oblique edge (26A), a second cellulose-based airlaid or solid foam substrate (20B) comprising two oblique edges (26B, 28B), and a third cellulose-based airlaid or solid foam substrate (20C) comprising an oblique edge (28C); The second cellulose-based airlaid or solid foam substrate (20B) is inverted (S2) so that the oblique edge (26A) of the first cellulose-based airlaid or solid foam substrate (20A) faces the first oblique edge (28B) of the second cellulose-based airlaid or solid foam substrate (20B), and the oblique edge (28C) of the third cellulose-based airlaid or solid foam substrate (20B) faces the second oblique edge (26B) of the second cellulose-based airlaid or solid foam substrate (20B), wherein: The beveled edge (26A) of the first cellulose-based airlaid or solid foam substrate (20A) and the first beveled edge (28B) of the second cellulose-based airlaid or solid foam substrate (20B) form an angle (α) of less than 90° between the beveled edges (26A, 28B); and The beveled edge (28C) of the third cellulose-based airlaid or solid foam substrate (20B) and the second beveled edge (26B) of the second cellulose-based airlaid or solid foam substrate (20B) form an angle (α) of less than 90° between the beveled edges (26B, 28C); and A first paper-based sheet (30) is attached (S3) to a first major side (22A, 22B, 22C) of at least a first, second and third cellulose-based airlaid or solid foam substrate (20A, 20B, 20C), and a second paper-based sheet (40) is attached (S3) to a second major side (24A, 24B, 24C) of at least a first, second and third cellulose-based airlaid or solid foam substrate (20A, 20B, 20C) to form the packaging insert (10), comprising: a first hinge section (50A) interposed between the beveled edge (26A) of the first cellulose-based airlaid or solid foam substrate (20A) and the first beveled edge (28B) of the second cellulose-based airlaid or solid foam substrate (20B); and A second hinged section (50B) is interposed between the second oblique edge (26B) of the second cellulose-based airlaid or solid foam substrate (20B) and the oblique edge (28C) of the third cellulose-based airlaid or solid foam substrate (20C).

23. The method according to claim 22, wherein The first hinged section (50A) comprises a wedge-shaped channel (51) defined by an angled edge (26A) of the first cellulose-based airlaid or solid foam substrate (20A) and a first angled edge (28B) of the second cellulose-based airlaid or solid foam substrate (20B) and the first and second paper-based sheets (30, 40); and The second hinged section (50B) comprises a wedge-shaped channel (51) defined by a second oblique edge (26B) of the second cellulose-based air-laid or solid foam substrate (20B) and an oblique edge (28C) of the third cellulose-based air-laid or solid foam substrate (20C) and the first paper-based sheet and the second paper-based sheet (30, 40).

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