Folding box, method for producing a folding box blank and a folding box body and device for carrying out the method

Abstract

The invention relates to a method for producing a folding box blank by means of dry fiber forming, the folding box body formed therefrom and a folding box produced by this method.

Description

[0001] The invention relates to a method for producing a folding box blank by means of dry fiber forming, the folding box body formed therefrom and a folding box produced by this method. Description and background

[0002] A "folding box" is a packaging structure made from a flat, usually fiber-based material. It is formed by folding, scoring, and joining (e.g., gluing or plugging) the base material, forming a substantially cuboid or prismatic hollow body with a base and lid, as well as side walls. The folding box is generally intended for the storage and protection of goods and is characterized by a flat delivery form (flat position), from which it can be converted into a ready-to-use three-dimensional state by simply erecting it.

[0003] A "folding carton blank" refers to a flat workpiece, typically made of cardboard, paper, or a similar material, with the necessary cut edges, creasing (fold lines), and slots to form a folding carton by folding and joining. The blank is manufactured from a flat starting material using suitable processes such as punching, creasing, and perforating and already has all the geometric features required for the formation of the side walls, base and lid surfaces, and connecting flaps.

[0004] The "folding box body" refers to the circumferential side wall area of ​​a folding box consisting of several wall sections, which defines the height and circumference of the hollow body after the folding box blank has been erected. The wall sections are connected by grooves or fold lines and are typically permanently joined along an adhesive flap or an adhesive surface, creating a closed, annular, rectangular, or polygonal cross-section. Alternatively, the wall sections can also be connected by mechanical connecting structures, such as tuck-in flaps or insert tongues, although this design is an exception. The "folding box body" is usually delivered folded flat and is erected during the packaging process.

[0005] The frame contributes significantly to the dimensional stability of the folding box and, together with the base and lid segments, enables the formation of an enclosed packaging volume.

[0006] The manufacturing process of a folding carton typically involves several consecutive steps, which can be performed both manually and mechanically. On an industrial scale, production is predominantly carried out using specialized machines, particularly folding carton gluers. The process is essentially divided into the following main steps: Providing the source material • Use of a flat material, preferably cardboard, paper or multi-layer composite materials. • The material (substrate) can be in flat, cut form (cardboard sheets) or as a roll • The material can be untreated or provided with functional layers (e.g. barrier coatings, varnishes). Printing the source material • Optional printing of the substrate using digital, flexographic, gravure or offset printing, usually combined with subsequent protective and decorative coatings. Producing the folding box blank • Cutting and punching: The material sheet is cut into the desired shape, whereby the cut includes all later elements of the folding box (side walls, base and lid surfaces, adhesive flaps, insert flaps). • Creasing and perforating: Applying fold lines (creases) to facilitate later erection and shaping. • Optional installation of window openings or other functional openings. Preparation for frame formation • Applying an adhesive film to the designated adhesive flap (usually dispersion adhesive or hot melt). • Alternatively, mechanical connecting elements can be provided (plug-in tabs, plug-in tongues), although this design is less common. Shapes of the folding box body • Fold the side walls along the grooves so that they form a closed circumference. • Connect the adhesive flap to the opposite side edge under pressure in order to permanently close the frame of the folding box. • The result is usually a flat box body (flat position) that is optimized for transport and storage. Final assembly and erection • If necessary, the flat box body is erected automatically or manually in the next process step. • Forming the base (e.g. by folding in base flaps or activating an automatic base). • Forming the lid or upper closure unit. Filling and closing • The folding box is then filled and closed, whereby different types of closure are possible depending on the box construction (tuck-in flap closure, adhesive closure, automatic lid).

[0007] The substrate production for paper-based packaging, such as board, has remained essentially the same for centuries. The starting point for such processes is typically the provision of a pulp, which is defined as an aqueous suspension of cellulosic fibers. The fibers are obtained from wood raw materials, grass fibers, or recycled material either by chemical processes, such as the sulfate kraft process to remove lignin, or by mechanical processes, such as refining or high-pressure treatments. During board production, the pulp is evenly distributed on an endless screen in a paper machine, usually according to the Fourdrinier principle. Subsequent dewatering using suction rolls and presses, as well as thermal drying, produces a coherent fiber web, which can then be compacted and smoothed.Optionally, the surface of the cardboard can be refined by applying microfibrillated cellulose, starch-containing layers or other functional coatings to achieve specific printing properties or barrier functions.

[0008] It is also known that the production of cardboard is associated with significant environmental impacts. These include, in particular, the high energy requirements during thermal drying, the water consumption for pulp preparation, and the emission of greenhouse gases, which, depending on the process and fiber source, can amount to approximately 0.61 to 1.98 tons of CO2 equivalent per ton of cardboard. In addition, wastewater containing dissolved organic and inorganic components is generated, which requires complex treatment.

[0009] From an economic perspective, manufacturing costs are significantly influenced by the price development of the raw materials used, the costs of energy and water, and the use of chemicals. While primary wood fibers require high investment in chemical pulping processes, secondary fibers from waste paper offer potential for cost savings but require intensive sorting and cleaning to avoid contamination. Refining processes to achieve a fine fiber structure represent another significant cost factor, especially in the production of cardboard substrates with high demands on smoothness and printability.

[0010] The substrate properties required for industrial use of cardboard as a packaging base include high mechanical strength, both in dry and wet conditions, defined creasing and folding properties, and a consistent surface finish. The basis weight typically ranges from 20 to 300 g / m². 2 , with values ​​between 30 and 75 g / m 2 are preferred. Further requirements concern porosity and opacity to enable both printing processes and barrier coatings. The pulp itself has a fiber length of preferably 0.2 to 0.4 mm and a hydrodynamic surface of at least 10 m 2 / g. While surface application can be carried out, the pulp consistency is typically 0.3 to 1.5% to ensure a uniform application with a basis weight of 3 to 5 g / m 2Furthermore, the substrate production of cardboard takes place on large paper machines, which do not allow for small quantities or constantly changing fiber compositions. The existing manufacturing processes for paper and cardboard require highly standardized input materials and high-volume production to operate efficiently and profitably.

[0011] The state of the art includes various processes for the recovery and recycling of paper-based products, which play a key role in the circular economy. These processes aim to remove contaminants, restore fiber quality, and reform the fiber matrix for the production of new paper or board products. Recycling typically begins with the collection and sorting of waste paper, in which different paper qualities (e.g., newspapers, cardboard, graphic papers) are classified. Subsequently, the material is shredded and suspended (pulped) in a pulper, a water-filled drum or container in which the paper-based material is mechanically torn and converted into a fibrous suspension.This step requires a high water input and considerable mechanical energy to break down the fiber structure and disperse foreign matter such as plastics, metals, coatings, or printing ink particles. Subsequent processes such as screening, centrifugal separation, and flotation are used to remove impurities of various sizes and densities from the pulp. Flotation is particularly useful for removing hydrophobic particles, such as printing inks (deinking), by introducing air bubbles into the suspension, to which the particles attach and are then skimmed off. After cleaning, the pulp is dewatered and reprocessed.

[0012] In terms of environmental impact, the pulping process in particular has significant ecological relevance. This step is characterized by: • high water consumption (up to 50 m 3 water per ton of waste paper), • increased energy requirements for pulper operation (up to 500 kWh / t) and • the formation of wastewater streams with dissolved organic and inorganic compounds (e.g. lignin, starches, synthetic adhesives, mineral oils from printing inks).

[0013] The wastewater contains elevated BOD (Biochemical Oxygen Demand) and COD (Chemical Oxygen Demand) values, necessitating complex wastewater treatment. This usually includes mechanical pretreatment, biological wastewater treatment, and, in some cases, chemical-physical processes to remove residues and heavy metals.

[0014] Furthermore, residues resulting from pulping processes, such as so-called "pulper rejects," consisting of plastics, metal staples, and other non-fibrous materials, must be considered. These are usually thermally recycled or landfilled, creating additional environmental pollution.

[0015] In summary, the environmental impacts of paper and board production, as well as the recycling of paper-based packaging and printed products, are significantly influenced by the processing methods used. In particular, the dissolving of the materials into a pulp, the subsequent water extraction, and other downstream processing steps, such as drying, are key factors and drivers of environmental impact.

[0016] An alternative to the state-of-the-art processes for producing packaging from paper and cardboard is the wet molding process, which is also referred to outside of the English-speaking world as the “Moulded Packaging Process” or, more precisely, as the “Wet Molded Packaging Process”.

[0017] The wet forming process begins with the preparation of the raw materials (“hydropulping”). Fiber materials, typically cardboard fibers or waste paper, are first shredded into small pieces approximately 2 to 3 cm in size and then soaked in water for approximately 12 hours to dissolve the fibers. The resulting mass is then mixed in a hydropulper to create a fiber suspension. The duration of the hydropulping process and the dilution of the suspension are crucial, as these parameters significantly influence the consistency and morphology of the fibers.

[0018] During the pulp preparation and additive addition phase, the suspension is diluted to a low consistency of 0.3% to 0.5%. Various additives can be added to achieve specific material properties. These additives include, for example, binders such as cationic starches or—in prototypes—white glue, which improve the wet and dry strength of the fibers. Foam control agents and pH regulators can also be added.

[0019] Molding is achieved by vacuum adsorption of the fiber suspension into a predetermined mold, where it is formed into a moist sheet. Different molding methods are available, depending on the desired end product and production requirements: • One-cast process (Plain Moulding / Thick-Wall): This involves creating a mold that is smooth on one side and rough on the other. The formed sheet is then placed on a conveyor belt for drying. This method is typically used for thick-walled recycled paper packaging, with wall thicknesses in the range of approximately 6 to 8 mm. • Transfer molding: After vacuum forming and initial dewatering, the formed sheet is transferred from the original mold to a transfer mold before being laid down for drying. This process is designed for high production volumes (over 20 tons per day) and produces products with a smoother interior and a silkscreen print on the exterior. The resulting wall thicknesses are typically between 3 and 5 mm. • Thermoforming (Precision Molding / Thin-Wall): This process eliminates the need for separate convection drying. Instead, hot pressing, curing, and drying are performed in a single step. This process is faster and allows for greater precision, but is associated with increased energy consumption and higher production costs. The resulting products have thin walls (0.4 to 1.5 mm) and a plastic-like appearance.

[0020] It should be noted that so-called "dry thermoforming" is a newer technology based on the use of dry fibers and is not classified as a wet forming process. Rather, this technology was developed as an alternative to significantly reduce water and energy consumption.

[0021] After forming, dewatering and drying represent a critical and time-consuming process step in the wet forming process. The porosity and permeability of the material play a particularly significant role. Drying is generally very energy-intensive and requires significantly higher energy input and a longer process time compared to other forming processes. Drying can be achieved using hot-air drying belts or pressure press drying. Hot pressing is also used to activate residual lignin and additives and to consolidate the fiber network. The precise drying conditions significantly influence the quality of the final product; for example, drying cycles of 3.5 hours at 80°C or stepwise drying with 6 hours at 80°C followed by 15 hours at 40°C were used for prototypes.

[0022] The wet forming process does offer the advantage of allowing smaller batches to be processed, allowing more flexible fiber handling, and requiring less equipment than traditional paper and board production. However, both manufacturing processes have in common that they work with pulp, i.e., an aqueous suspension with a high water and low fiber content. In both processes, it is first necessary to dewater the aqueous suspension and then subject it to a costly drying process, which, in addition to the high energy consumption, also causes a corresponding environmental impact.

[0023] The wet forming process also has the disadvantage that throughput times are longer due to the long drying phases, and the resulting output is comparatively low. For these reasons, the wet forming process is considered a relatively cost-intensive manufacturing process, especially when high demands are placed on the outer contour of the products.

[0024] The dry fiber forming process differs fundamentally from the wet molding process because it eliminates the need for process water to be added to the paper pulp. This makes the process more resource-efficient, as significantly less energy and time is required compared to the wet molding process, which requires considerably more energy and time for forming and completely drying the product. In particular, water consumption, drying time, and energy requirements are drastically reduced.

[0025] Although the underlying technology was already investigated at the end of the last century, it is still considered novel due to the lack of available products on the market.

[0026] For the production of packaging, especially in the food packaging sector, a variant of the dry forming process, known as dry thermoforming, is used. The process typically includes the following steps: 1. Fiber dispersion: The fibers are dispersed not in water but in air to create a loose fiber mat or fiber pile (“fluff”). 2. Material preparation: This involves using either defibrated cardboard or a hot-pressed fiberboard laminate as the starting material. The fiber source can be, for example, softwood kraft fluff pulp. However, the process offers a high degree of flexibility regarding the fiber sources used, so other fiber materials, such as bamboo, hemp, or other fibrous plant materials, can also be used as starting materials. 3. Optional moisture and additive application: The fiber mat can be sprayed with a food-grade, cellulose-compatible biopolymer, such as gelatin or guar gum. A small amount of water is also often applied, preferably by spraying, to increase the elasticity of the fibers and promote the formation of hydrogen bonds. 4. Layer formation: The sprayed fiber mat is optionally lined with thin tissue paper on the top and bottom sides to create a three-layer composite (“3-layer composite”). 5. Thermoforming: The resulting three-layer composite is then molded into the desired printing form, with hot pressing, curing, and drying taking place in a single process step. This process is faster and more precise than convection drying in the wet forming process. 6. Optional mechanical compaction: All-fiber boards can be subjected to mechanical, biaxial compaction using a rubber coating to increase the board's extensibility and reduce the anisotropy of the fiber network during thermoforming. This significantly improves the tensile strength, stiffness, and temperature and humidity stability of the final product.

[0027] The wet forming and dry forming processes produce three-dimensional packaging or packaging components that, after final trimming and, if necessary, further coating, can be used directly as packaging elements. Common applications include fruit trays, lids for coffee-to-go cups, and closures for beverage cartons.

[0028] In addition to the advantages of the dry forming process in packaging production due to the elimination of process water, the same applies to the dry fiberization of waste paper. This eliminates the complex water management typically required in the recycling process, including the associated energy consumption, water treatment, and the resulting environmental impact.

[0029] Typically, such packaging does not have sharp edges; rather, the edges are rounded as a result of the forming process, i.e., they have a defined rounding (radius). Deviations from this occur in molded packaging with a comparatively low fiber content of approximately 12% to 15% and a high proportion of non-fibrous components, such as starch.

[0030] Wet- or dry-formed packaging is also typically open on one side. To create a closed packaging unit, the packaging must be fitted with a lid. The final packaging therefore usually consists of two separately manufactured packaging components.

[0031] One advantage of wet and dry forming processes is that the substrate production process can be largely or entirely shifted to the packaging manufacturer's area of ​​responsibility. This reduces dependence on paper and board manufacturers. Furthermore, there are ecological benefits due to shorter transport routes.

[0032] There are several challenges when forming packaging using the dry-fibre process, which are mainly related to the low water content of the cellulose fibre network during the process.

[0033] The main challenges are: Complex stress state during forming: The stress state during the forming process is extremely complex. It includes multiaxial loading, extreme compaction, friction, large deformations, and the formation of fiber bonds. This complexity complicates the understanding and prediction of material behavior during forming.

[0034] Weaker fiber bonds due to low water content: In contrast to wet-formed materials, where water plays a crucial role in the formation of cohesive fiber bonds through capillary forces and fiber swelling, the low water content in the dry-fiber process leads to weaker fiber bonds in the final product. This directly impacts the mechanical properties of the formed packaging.

[0035] Lower mechanical properties compared to wet-formed materials: Dry-fibre materials generally exhibit lower tensile strength, stiffness and elongation than wet-formed counterparts, even at similar densities

[0036] This presents a challenge when specific performance requirements must be met for the packaging. For example, the tensile strength of dry-formed materials is significantly lower, while the shear modulus may be similar, but the shear strength is also lower.

[0037] Compromise between formability and final strength / stiffness: Loose fiber mats with low density are more formable due to fiber slip and rotation, but also weaker. As density increases during forming, fiber bonds form, increasing stiffness and strength but simultaneously reducing formability and making the material more brittle. Balancing these opposing properties during the forming process is challenging.

[0038] Heterogeneity and surface quality: Because heat is applied to the surface of the fiber mat during the pressing process, the formation of fiber bonds can be more pronounced near the surface than in the interior of the material. This can lead to heterogeneity in properties across the material thickness, with the central regions being less constrained and exhibiting greater extensibility, while the surface may be more prone to cracking. Furthermore, the surfaces of dry-fiber products can be less smooth and exhibit free-standing fibers, which impairs surface quality. Object of the invention

[0039] The invention is based on the object of providing a method for producing folding boxes that combines the positive properties of conventional folding boxes with the ecological and economic advantages of the dry fiber forming process. In particular, it should be possible to produce folding box blanks using a dry fiber forming process, whereby the resulting blanks exhibit high density and rigidity and are suitable for further processing into folding boxes.

[0040] Furthermore, the object is to avoid the disadvantages of the dry fiber forming process in the prior art, which occur in particular when forming complex three-dimensional structures by means of deep-drawing or vacuum processes, by forming only a flat folding box blank.

[0041] A further aspect of the object is to provide a device which is suitable for carrying out the method according to the invention and enables the production of such folding box blanks in reproducible quality. Solution to the task

[0042] This problem is solved by a method for producing a folding box blank, in which the blank is formed from a dry fiber dispersion using a dry fiber forming process. First, a dry fiber mat is produced from fibrous material, preferably from softwood kraft pulp, recycled paper fibers, or other plant fibers. Optionally, additives such as food-grade biopolymers or binders can be added to the fiber mat during or after forming to improve the mechanical and functional properties of the final product.

[0043] The formed blank is then compacted in a thermoforming step under the influence of heat and pressure, resulting in a flat, high-density, and rigid folding carton blank characterized by low porosity and high dimensional stability. By limiting the forming process to a flat geometry, the known problems of dry fiber forming in the production of complex three-dimensional shapes are avoided.

[0044] A folding box blank, as used herein, is a flat workpiece made of fibrous material that has been prepared by cutting, scoring, and optionally embossing to be further processed into a three-dimensional folding box by folding and gluing. The folding box blank typically comprises the following elements: • Panels: Surface sections that, after folding, form the side walls, base surfaces and lid of the folding box. • Score lines or crease lines: Lines along which the material is folded to create the desired three-dimensional geometry. • Flaps and glue flaps: Projecting material areas that serve to ensure the dimensional stability of the finished folding box by gluing or inserting. • Punchings or cut-outs: Optional openings or perforations for the formation of handles, viewing windows or ventilation slots.

[0045] In contrast to three-dimensionally formed packaging, which already achieves its final geometry during the manufacturing process and typically does not require further folding, the folding box blank is a flat intermediate product. The final shape is only achieved through a separate folding and gluing process during further processing.

[0046] Furthermore, the folding carton blank typically has flat, smooth surfaces without complex three-dimensional contours. Sharp edges and defined crease areas are characteristic due to the intended folding processes, whereas three-dimensionally shaped packaging typically has rounded transitions between surfaces resulting from the forming process.

[0047] In one embodiment, the outer contour of the folding box blank is cut out simultaneously during the forming process using a die or cutting blade. At the same time, creasing and / or folding lines are introduced into the material. The resulting intermediate product is a flat blank that only needs to be coated with a suitable adhesive at the designated bonding points, for example, along a longitudinal seam, and bonded to a corresponding counterpart to form a folding box body.

[0048] In an alternative embodiment, a sheet is first formed by pressing under the influence of pressure and heat, without any cracking of the outer contour. Creasing and / or folding lines can optionally be incorporated. In a subsequent process step, the outer contour of the formed sheet is trimmed using a cutting die to produce the final folding box blank.

[0049] The advantages of this method of producing a folding box blank using the inventive method and the dry-forming process are manifold. Firstly, the high energy costs incurred in the aqueous manufacturing processes of cardboard and paper production are avoided. This includes, in particular, the energy required for water treatment, dewatering of the fiber suspension, and subsequent drying. The process therefore represents a beneficial alternative from both an ecological and economic perspective. A further advantage is that, unlike conventional paper and cardboard production, the process can be flexibly adapted to different raw material sources at any time. The starting material ("fluff") does not necessarily have to consist of cellulose fibers from trees; alternative plant fibers such as straw, hemp, bamboo, or other lignocellulose-containing plants can also be used.

[0050] This opens up additional opportunities for the use of locally available, renewable raw materials and reduces transport and logistics costs. Compared to three-dimensionally shaped packaging, the process according to the invention also has the advantage of significantly reduced transport volume. While three-dimensional packaging can only be stacked inside each other and still requires a lot of space, the produced flat folding box blanks can be tightly packed and transported in a space-saving manner. This not only contributes to lower storage and transport costs but also reduces the CO2 footprint along the supply chain.

[0051] Another significant advantage is that the folding boxes formed with the folding box blanks produced according to the invention are compatible with the packaging machines widely used in the industry. No modification or conversion of the existing packaging infrastructure is required, so the transition to the inventive technology can be achieved with minimal investment. This facilitates integration into existing production lines and avoids production interruptions. Another advantage of the folding box produced according to the inventive steps is that no adaptation of the products and packaging inserts is required. This is due to the retained rectangular shape of the conventionally produced folding box.This assumption does not necessarily apply to three-dimensionally shaped packaging, as the shape, for example radii and uneven, outwardly extending side walls, could make this difficult or impossible.

[0052] From a technical and physical perspective, a three-dimensionally formed dry-fibre packaging differs fundamentally from the flat blank according to the invention and the folding box produced from it. During the three-dimensional forming process, a complex stress state develops in the material. This includes multiaxial loads, significant local compaction, friction effects on the tool surfaces, large plastic deformations, and the formation and partial destruction of fibre-to-fibre bonds. These extreme process conditions can lead to an inhomogeneous material structure and weaken the resulting fibre composites. Strength losses and increased porosity often occur, particularly in heavily deformed areas such as radii and transitions.According to the present invention, the degree of flatness of the folding box in the area of ​​the panels is defined by measuring the thickness of the blank between 0.2 mm and 2 mm, with a thickness of 0.2 to 0.8 mm being preferred.

[0053] In contrast, the stresses, deformations, and frictional forces in the inventive process, which only forms a flat folding box blank, are negligible. The critical problems of the three-dimensional forming process, such as fiber breakage, delamination, or uneven material thickness, do not occur here. Rather, a highly compacted substrate blank can be produced that exhibits high stiffness, strength, and density. Furthermore, the dimensional accuracy of the blank is improved, enabling precise further processing in automated folding and gluing processes.

[0054] The manufacturing process of the folding box blank is as follows: Step a.) The preparation of a fiber mat made from fluff. The fluff is formed by dispersing the separated fibers in air. In this process, the cellulose fibers are not dissolved in water, but dispersed in air. The result is a so-called "sparse fiber mat" or "fluff." This step is crucial for generating the starting material in this process. In the subsequent process step, the air-dispersed fibers are formed into pads of so-called "air-laid webs." In some cases, "softwood kraft fluff pulp" is used as the fiber source. This is fluff pulp obtained from softwood sulfate pulp. It is possible to replace the starting source with another pulp source, including recycled paper.The starting material can also be a mixture of different starting materials. In the first step of the process, the starting material is defibrinated. According to the present application, the term defibrination refers to a mechanical processing process in which fibrous starting material is broken down into its individual fibers or fiber bundles. The material processing process is usually carried out by mechanically crushing, tearing, or grinding the starting material in a dry or nearly dry environment, resulting in a loose, voluminous fiber mass (fluff). The production of the fluff usually takes place in a separate process step, which is carried out outside the forming machines.Another possibility would be to combine the processes of fluff production, compaction, and forming, along with any additional steps, thus implementing an inline process. The fiber mats are supplied in sheets or rolls. A sheet is a rectangular cut of fiber mat. Step b: Subsequently, it is possible to subject the fiber mat sheets or fiber mat rolls to further compaction, i.e., to a pre-compaction process. This is usually achieved by passing the fiber mats between corresponding rollers. Several pre-compaction stations can be installed in the conveying direction, enabling successive pre-compaction of the fiber mats in several stages. The compaction process involves a mechanical biaxial compaction process. A well-known problem in the processing of fiber-based board materials, particularly all-fiber boards made from lignocellulosic fibers, is the inherent anisotropy of the fiber network, which is due to the preferential orientation of the fibers during production.This anisotropy leads to different mechanical properties in the longitudinal and transverse directions and can significantly impair the processability of the sheets, especially in subsequent forming processes such as thermoforming.

[0055] In addition, conventionally manufactured all-fibreboards often have only limited extensibility in their initial state, which promotes the formation of cracks or local material weakening during thermal forming.

[0056] To overcome these disadvantages, a process was developed in which the all-fiber boards are subjected to mechanical biaxial compaction. In a first step, the board is compacted using a mechanical pressing force in a first direction (X direction). Subsequently, it is recompacted in a second orthogonal direction (Y direction). This biaxial compaction achieves a more uniform orientation of the fiber network, thereby reducing the anisotropy of the board and approximating its mechanical properties in both directions. This form of mechanical compaction or densification is preferably carried out using at least one roller provided with an elastic layer. The elastic layer can be made of rubber, silicone, or a functionally equivalent elastomeric material.This rubber coating ensures a more even pressure distribution across the plate surface and allows the fibers to reorient themselves within the matrix without structural damage. Furthermore, local stress peaks, such as those that can occur when using rigid rollers, are avoided.

[0057] The described process leads to an increase in the packing density of the fiber material as well as a significant improvement in the mechanical and thermomechanical properties of the panels. In particular, the following beneficial effects are observed: • Increased tensile strength due to denser fiber-to-fiber contacts and improved load transfer in the network. • Increase stiffness by reducing porosity and voids. • Improved temperature and humidity stability, as the denser structure effectively inhibits fiber swelling when moisture is absorbed and dimensional changes when temperatures change. • Increased extensibility of the sheets during thermal forming, which reduces the risk of cracking and enables more precise representation of complex geometries.

[0058] All variants listed in this step are subsumed under the term compaction.

[0059] Step c.) The process step c can be carried out in different ways. Step c can be performed before, during, or after step b. Examples include positioning between two compaction stations or the completion of step b, i.e., after the last pre-compaction station. Step c of the process can also be divided into different sub-stations, which in turn are integrated into various positions.

[0060] In step c, at least one coating agent is applied, preferably in a contactless manner, to the fiber mat. Contactless application is characterized by the absence of contact with the fiber web. Contact application carries the disadvantageous possibility of fibers being picked up and torn from the fiber web. Contactless application can be carried out by spraying, ultrasonic spraying or atomization, spin coating, or curtain coating. With dry agents, the agent can also be applied by trickle coating.

[0061] The coating agent can be water, which is applied to the fiber web without contact, so that the fiber web is moistened but not wet. The water is typically applied to the fiber mat by fine spraying or the emission of aerosols. The water serves to increase the moisture content of the fiber mat, thereby increasing the elasticity of the fibers and the fiber bonding. It is possible that additives have been added to the water to modify the pH value. It is possible that the water contains sticky substances or other additives, so-called wet strength materials. In this context, the term "moistened" is used to indicate that once the water has been absorbed into the fibers, no free water film remains. The moisture content is usually expressed as a mass percentage of water relative to the total mass.In the present case, the moisture content of the fiber mat after the moistening step should have a maximum value of 20%, with a value of less than 10% being preferred.

[0062] Possible coating agents include natural or synthetic resins, which can be applied to the fiber web in liquid solution or dry, using a trickle- or spin-coating process. The resins act as a crosslinking medium for the fibers and can also increase the moisture resistance of the compartment box substrate. Resins are characterized by a melting point. The temperature applied during the thermoforming process can be configured so that the resins reach a melting point and thus establish significant adhesion to the fibers.

[0063] The coating agent may be a biopolymer, such as gelatin, guar gum, or natural or modified starch, applied as an aqueous suspension or as a dry substance. These agents also act as crosslinking agents and, if necessary, as fillers.

[0064] The coating agent may also include synthetic, fossil-based or other tackifying substances, typically applied in an aqueous dispersion. Examples include the following polymers: polyvinyl acetate (PVAc), acrylate polymers and copolymers, ethyl vinyl acetate (EVA), or mixtures of synthetic materials.

[0065] The coating agent may contain a substance that serves to reduce surface tension. Examples include surfactants or alcohols. The surface tension of pure water at a temperature of 20 °C is approximately 72 mN / m. Wetting of the fibers therefore occurs primarily in droplets. As a result, wetting exhibits increased inhomogeneity. Only with the absorption of water into the fiber does a more even distribution of wetting occur. Cellulose fibers typically have a specific energy of 50-60 J / m 2The resulting contact angle between water and fiber is between 30° and 50°, indicating only moderate wetting. Experiments indicate that lowering the surface tension of water below 40 mN / m, preferably below 30 mN / m, leads to a contact angle close to 0°, which results in optimal wetting. The key advantage of this method is that more uniform wetting occurs and thus more uniform elasticity and formability of the fiber is achieved. Overall, less moisture can be used to achieve the desired effect. Surfactants specifically attach themselves to the water-air interface and displace water molecules. They also disrupt hydrogen bonds. It has been found that the cohesive forces at the surface are significantly reduced. The effect is concentration-dependent up to the CMC (critical micelle concentration).Alcohols also bind to the interface, but in a nonspecific manner. The OH group is capable of forming hydrogen bonds, but with less effectiveness and a more uniform effect.

[0066] At low concentrations, a significant reduction in surface tension was observed, while no micelle formation was observed.

[0067] The coating agent can contain fillers similar to those used in the paper industry. These include kaolin (China Clay), a fine aluminum silicate often used for smoothing and improved opacity; calcium carbonate (CaCO3), which serves as a natural or precipitated filler and increases brightness; and talc, which reduces friction and improves smoothness. Another option is titanium dioxide (TiO2), which provides very high opacity and whiteness. These fillers can be applied either as a single treatment or as a blend.

[0068] The coating agent may comprise sizing and binding agents, such as starch (corn, wheat or potato starch), which serves as a surface sizing and retention agent, or polyvinyl alcohol (PVOH), a water-soluble binder that increases strength and smoothness.

[0069] The substances used as binders include latex dispersions, resin sizes produced by combining aluminum sulfate and resin soaps, as well as alkyl ketene dimers (AKD) or alkyl succinic anhydrides (ASA).

[0070] The coating agent can comprise pigments and dyes, including, for example, water-soluble fiber dyes known as direct dyes, as well as anionic or cationic dyes. Optical brighteners (OBAs) can also be part of the coating agent.

[0071] The coating agent may comprise strengthening agents to increase wet strength, including polyamidoamine epichlorohydrin (PAE), melamine-formaldehyde resins and urea-formaldehyde resins.

[0072] The coating agent can comprise natural or synthetic substances as well as polymers suitable for improving the barrier effect of the substrate. These substances reduce, in particular, grease resistance, moisture absorption, water vapor permeability, or oxygen diffusion through the substrate. Suitable coating materials include: • Waxes, especially carnauba wax, beeswax or synthetic waxes, which primarily increase resistance to grease and moisture; • Polysaccharides such as starch, modified starch, chitosan, alginate or carrageenans, which have a barrier effect against moisture and gases; • Proteins, such as casein, gelatin, soy protein or wheat gluten, which can form oxygen and aroma barriers; • Shellac, which acts as a natural barrier against oil and moisture; • Polyolefins, in particular polyethylene (PE) and polypropylene (PP), which provide an effective barrier against moisture and grease; • Polyvinyl alcohol (PVOH), which provides an excellent oxygen barrier due to its hydrophilic properties but is water-soluble; • Ethyl vinyl alcohol copolymers (EVOH), known for their excellent oxygen barrier properties; • Polyethylene terephthalate (PET), which has a good barrier to oxygen and aromas; • Acrylate dispersions, especially polyacrylates, which can be used as a grease and moisture barrier; • Polyvinylidene chloride (PVDC), which has a very high barrier effect against oxygen and water vapor; • Polyurethanes (PU), which can form a flexible and water-repellent barrier; • Bio-based polymers, such as polylactide (PLA) or polyhydroxyalkanoates (PHA), which can be used as moisture and aroma barriers; • Nanocellulose, especially microfibrillated (MFC) or nanofibrillated cellulose (NFC), which significantly reduces oxygen permeability in dry environments; and • mineral particles such as kaolin, talc or bentonite, which can increase the grease and moisture resistance of the substrate.

[0073] The selection and combination of these coating agents depends on the specific requirements for the barrier properties of the substrate to be coated and the intended conditions of use of the packaging.

[0074] The coating agents can be applied individually or in the form of mixtures. In this paper, all coating agents that are not pure water and contain a functional component are referred to as functional coating agents. The previously listed classes of additives are referred to as "functional components." The term "substance" is to be understood broadly in this context and can also include polymers.

[0075] Step d.) Application of the coating agent can optionally be followed by a drying step. The purpose of drying is to remove excess water. Drying can be carried out using infrared, hot air convection, microwave drying, or a combination of these.

[0076] Step e) It is possible to apply a lining to one or both sides before, after or between different compaction steps. The lining is similar in nature to a side paper. It is possible to apply a thin printing paper to one or both sides of the fiber mat. The paper can be printed on the side facing away from the fiber mat. Alternatively, a film or paper with a barrier coating can be applied to create a barrier effect. The film and paper can also be laminated to the fiber mat web using an adhesive, although a starch adhesive is preferred. Alternatively, adhesion can also be achieved mechanically or via the moisture in the fiber mat. The final, firm bond is then created under high pressure during the thermopressing process according to the specified process.Film and paper can also be provided with a coating on the side facing the fiber mat, such as a rubber coating, which is activated under pressure and heat or the influence of moisture.

[0077] Step f.) The fiber mat is introduced into a heated printing form, where it, along with all its associated coatings, is compressed under the influence of pressure and heat until the substrate thickness is between 0.2 mm and 1 mm. This substrate forms the basic structure of the folding box blank. The base substrate is then fed to another processing station, where the folding lines are scored and the outer contour of the folding box blank is created. In the printing form, hot pressing, curing, and drying preferably take place in a single process step, eliminating the need for a subsequent drying step.

[0078] Preferably, the processing steps of compaction / densification and creasing as well as the production of the outer contour of the folded layer blank are carried out in one work step.

[0079] Step g.) The process optionally includes a decoration step. The term decoration refers to a variety of textual and pictorial representations that serve for advertising or information purposes. The decoration can be added to the forming process in combination with the fiber web. This can be achieved, for example, by laminating the fiber web or in combination with a printed paper web or sheet. Decoration is usually carried out by inserting a printed, precisely dimensioned inlet into the printing form. The connection to the fiber layer is then created under pressure and heat. It is possible to carry out the decoration using digital printing, whereby the formed blank of the folding box is printed digitally after the forming process, for example using injection printing. The digital printing process can be preceded by a priming step, which improves the printability of the substrate and increases print quality.The decoration process can consist of at least one printed label, which is applied to the erected body or to the folding box blank during the filling process. The decoration can take the form of a sleeve, which is applied to the folding box blank or to the erected body during the filling process. The sleeve can be bonded to the folding box material using either spot or surface adhesive bonding or purely mechanical clamping.

[0080] Step h.) Packing the folding box blanks and forwarding them to the next process station.

[0081] The folding box body is manufactured using a folding box gluing machine. This text defines a folding box gluing machine as one in which at least one folding process takes place along a folding groove so that the side walls (panels) form a closed perimeter or container. Bonding the glued flap to the opposite side edge with an adhesive, preferably under pressure, is necessary to permanently close the body of the folding box or to form the container. The adhesive bond can be achieved using a synthetic or natural-based aqueous dispersion glue. Alternatively, hot melt or gelatin adhesive can be used. Alternatively, the bond can also be achieved by heat sealing, by heating a coating on the substrate. Application methods include dot and bead application.The adhesive is ideally applied using adhesive application valves whose outlet openings are positioned at a certain distance from the folding box substrate. It is also possible to apply the adhesive using glue application wheels, whose outer surface serves to bond the adhesive to the folding box substrate.

[0082] The folding box bodies are bundled and delivered to a filling station. There, the folding box bodies are erected, filled, and sealed.

[0083] As an alternative to manufacturing, the packaging can also be manually formed into a three-dimensional shape by folding and inserting it, as is often done with pizza boxes that are delivered flat to the restaurant and erected there.

[0084] The invention also includes a folding box manufactured according to the manufacturing methods disclosed in the patent specification.

[0085] The device for producing the folding box blank according to the invention typically comprises the following elements: The present device comprises a feed device for fiber mats in sheet or roll form. The device comprises an unwinding device, a roll feeder, or a sheet feeder. At least one compacting or condensing device is required, designed, for example, in the form of two corresponding rollers. These transport the fiber mat through a roller gap, where the fiber mat is compressed. Optionally, one or more laying or laminating devices can be installed which are suitable for loosely laying a fibrous web, such as tissue paper, or a paper or film web onto the fibrous web or for bonding the web to the fibrous web to create an adhesive bond.

[0086] A device is required for applying a coating agent. This can be done, for example, using spray heads, spin coaters, or curtain coaters.

[0087] The printing form used in the process according to the invention is designed such that a prefabricated fiber mat is converted into a predetermined flat geometry under the combined influence of pressure and temperature. For this purpose, the printing form comprises at least one shaping mold insert, which has a contouring mold surface corresponding to the subsequent shape of the folding box blank or a flat substrate as a folding box blank precursor. The printing form can be designed as a two-part tool consisting of a lower mold part (negative mold) and an upper mold part (positive mold), which work cooperatively to accommodate the fiber mat between them and compact it under defined process parameters.

[0088] To thermally activate the fiber mat and increase the bonding forces between the fibers, at least one or both mold halves are designed to be heated. Electric heating elements or integrated heating channels for thermal oil or steam can be used for this purpose. Optionally, the printing form can be equipped with cooling systems to enable accelerated cooling of the substrate and thus reduce the process cycle times.

[0089] The forming surfaces of the printing form can also be provided with structuring features that allow functional elements to be incorporated into the fiber mat during the compaction process. These include, in particular, crease lines, cutting edges for the outer contour of the folding box blank, and decorative surface textures. Alternatively, these structural elements can be incorporated in a downstream process station.

[0090] The geometry and surface finish of the printing form must be adapted to the specific material properties of the fiber mat. The forming surfaces preferably have an arithmetic roughness (Ra) in the range of 0.4 µm to 1.6 µm to ensure uniform compaction. Textured areas can have micropatterns with depths of 5 µm to 50 µm to create decorative effects.

[0091] The temperature of the heated mold surfaces typically ranges from 120 °C to 250 °C, preferably between 140 °C and 200 °C, depending on the fiber material used and its residual moisture content. The contact pressure exerted on the fiber mat during the molding process is preferably 2 bar to 20 bar, particularly preferably 5 bar to 15 bar. The residence time of the fiber mat in the mold is generally between 1 s and 10 s.

[0092] In addition, the printing form can be provided with venting structures, such as micro-holes or fine channels with diameters of 50 µm to 300 µm, to remove air and water vapor from the fiber mat during the compaction process and thus ensure flawless formation of the contours.

[0093] The present printing form thus makes a decisive contribution to reproducibly converting the fiber mat into the desired shape, while simultaneously optimizing the mechanical properties of the final product and integrating additional functional elements such as creasing lines and outer contours in a single process step.

[0094] The device can comprise a decorating device designed, for example, to insert a printed inlet into the printing form. The decorating device can also comprise a device for laminating a printed web or sheet, or a digital printing unit that follows the forming process. The decorating devices preferably have devices that ensure precise registration of the printed image with the folding box blank. Examples of implementation:

[0095] The Fig. illustrate examples of folding box blanks (Z) and the corresponding erected folding box frames. (4) A common feature of the folding box blanks (Z) is the presence of several creasing lines (3) and at least one adhesive or connecting flap (2). The adhesive flap (2) is connected to the corresponding element of the folding box, which represents a side panel (1), by means of adhesive or a heat-sealing process. In the case of a connecting flap, the connection is not made by gluing, but rather the flap is inserted into an opening and hooked. The folding box blank can have additional flaps, such as dust flaps (6) and tuck-in flaps (7). The folding box blank (Z) can contain cutouts (5), as can be seen in this example for hangers. The cutouts can also take the form of windows.The folding box blank (Z) can also have an automatic base (8) which is glued so that it automatically forms a base when the frame (4) is erected.

[0096] In the present application, a crease line (3) is understood to be a linear material weakening deliberately introduced into the flat material of a folding box blank, which forms a defined predetermined bending point. The crease line (3) is arranged along the intended bending lines of the folding box and ensures that the blank folds preferentially and reproducibly along the crease line (3) during folding. This achieves a precise formation of the box geometry and ensures the dimensional accuracy of the final product.

[0097] The crease line (3) results from a local compression, indentation, or plastic deformation of the substrate, whereby the material fibers along the crease line are partially reoriented and compacted. In preferred embodiments, the crease line is created by a cooperating tool pair consisting of a creasing die and a corresponding creasing groove during a punching or embossing process or, within the scope of this invention, in the compression molding process. The substrate is subjected to a defined pressure, resulting in a linear cross-sectional modification with reduced flexural strength.

[0098] The geometry of the crease line (3) is adapted to the material properties of the substrate and preferably has a V-shaped, U-shaped, or trapezoidal cross-section. The width of the crease line (3) is in a range from 0.1 mm to 2.0 mm, while the depth is preferably 10% to 50% of the total thickness of the substrate. The crease line (3) can be formed on the side facing the subsequent folding direction (creasing inward) or on the opposite side (creasing outward).

[0099] The function of the creasing line (3) is to significantly reduce the bending forces required for the folding process, thus enabling easier and gentle processing of the blanks in automated packaging systems. At the same time, targeted guidance of the bending line is achieved, ensuring even folding of the material and minimizing the risk of uncontrolled folding, tearing, or delamination.

[0100] The elements (Z), referred to as folding carton blanks, have side surfaces (1), also called panels. These side surfaces can have different widths (A, B) and typically have a common height (h).

[0101] It was determined that all folding carton blanks (Z) are fed flat after production to the next processing station, which includes either gluing or manual insertion. The goal of this process is to form at least one body. The wall thickness of the side surfaces or panels (1) varies within a range of 0.2 mm to 1.5 mm.

[0102] The manufacturing process of the folding box blank according to the invention is exemplified in Fig.2. In a first process step (20), which corresponds to process step a of the description, a fiber mat is formed from a fluff material. For this purpose, a loose fiber mat is created by dispersing the fibers in an air stream. The fiber mat thus formed is then fed to the thermoforming machine as a sheet or roll.

[0103] In a second process step (21), which corresponds to process step b of the description, at least one densification and compaction step takes place. The fiber mat is mechanically densified to increase the density and stability of the substrate. Alternatively or additionally, the densification or compaction process can be carried out in several stages and take place at several stations within the process.

[0104] In a further process step (22), which corresponds to process step c of the description, at least one coating agent is applied to the fiber mat. The coating agent can be aqueous and preferably comprises functional substances that improve the barrier properties, surface quality, or other functional parameters of the substrate. The coating process can also be carried out in multiple stages and arranged at different positions in the overall process.

[0105] In the subsequent process step (23), which corresponds to process step d of the description, the fiber mat is subjected to an optional drying after the application of the coating agent in order to reduce the moisture content to a value suitable for further processing.

[0106] In a subsequent process step (24), which corresponds to process step e of the description, the fiber mat is introduced into a heated printing form. There, further compaction takes place under the influence of temperature, compressing the substrate to a final thickness in the range of 0.2 mm to 1.5 mm. Preferably, the crease lines and / or the outer contour of the folding box blank are formed simultaneously in this step. Alternatively, the introduction of the crease lines and / or the cutting of the outer contour can also take place in a separate, downstream process station.

[0107] In a further optional process step (25), which corresponds to process step f of the description, the fiber mat is laminated. This lamination can be applied loosely, mechanically joined, or by gluing. For this purpose, a liner made of tissue paper, a paper web, or a film can be applied to one or both sides. The top and bottom sides of the substrate can be covered with different materials. The lamination can take place before the compaction step (21), between several compaction steps (21) in the case of stepped compactions, or after the compaction step (21), in particular after the application of the coating agent.

[0108] In a further optional process step (26), which corresponds to process step g of the description, a decoration process is performed. This can take place before compression, during thermoforming in the heated printing form, or in a subsequent process step.

[0109] Finally, the produced folding box blanks are packaged in a final process step (27) and prepared for further transport or subsequent processing. Identifier list A Panel / Side Width B second panel / side width H Height panel / side surface Z Folding box cutting 1 side panel 2 adhesive tab / connecting tab 3 creasing lines / folding lines 4 folding box body 5 punched outs 6 dust flaps 7 plug-in tabs 8 Automatic floor 20-27 process steps as described

Claims

[1] A method for producing a folding box body, comprising a method section for producing a flat folding box blank (Z) which has a plurality of creasing lines (3) which represent defined predetermined bending points, wherein the thickness of the substrate of the folding box blank (Z) in the region of the panels or side surfaces (1) is between 0.2 mm and 1.5 mm, preferably between 0.2 mm and 0.8 mm, the method comprising the following steps: a) providing a dry, air-laid fibre mat formed from a fluff material in the form of a roll or sheet; b) Pre-compression of the fibre mat by single or multi-stage mechanical compression / compaction; c) applying at least one functional coating agent to the fibre mat; d) thermoforming the pre-coated fiber substrate in a heated printing form with simultaneous further compaction, whereby a highly compacted and flat folding box blank (Z) is produced; e) introducing the creasing lines (3) and cutting the outer contour of the folding box blank (Z), this step being carried out completely or partially during the thermoforming according to step d) and / or in a separate process station; f) forwarding the folding box blank (Z) to a folding process in which it is folded along the creasing lines (3) and connected to a corresponding section of the folding box blank (Z) by at least one gluing process on an adhesive flap, so that the folding box body is formed, or a folding process in which the corresponding sections are mechanically connected or hooked by folding or inserting in the area of ​​a connecting flap, [2] Method according to claim 1, characterized by , that • before, after or between the compaction / compacting step (b) o a lining in the form of a cover material applied on one or both sides is applied to the fiber mat, wherein the lining comprises a thin printing paper, preferably a tissue paper, which optionally has a print on the side facing away from the fiber mat, and ◯ the connection of the lining to the fibre mat is achieved by the moisture of the fibre mat, a mechanical connection, an adhesive application, preferably with a starch adhesive, or a coating that can be activated under pressure and temperature, preferably a rubber coating, and ◯ the final solid bond between lining and fibre mat is created during the thermoforming process; • or a cover material in the form of a paper with a barrier coating or a film is laminated onto the fibre mat, whereby the lamination is also carried out by means of the moisture of the fibre mat, an adhesive application or an activatable coating, and the final connection is made in the thermoforming process, [3] Method according to claim 1 or 2, characterized by that the folding box blank is decorated during the forming process by placing a printed, dimensionally accurate inlet into the printing form and then bonding it to the fiber layer under pressure and heat, or by laminating a printed paper web with the fiber web, [4] Method according to claim 1 or 2, characterized bythat the formed folding box blank is decorated after the forming process by being digitally printed, whereby the printing process may be preceded by a priming step to improve printability, or by applying at least one printed label or sleeve to the erected folding box blank or the folding box body during the filling process, [5] Method according to one of the preceding claims, characterized by that at least one coating agent is applied to the fiber mat in a contactless manner, wherein the contactless application is defined by the fact that there is no mechanical contact between the application system and the fiber mat in order to prevent fibers from being torn out or picked up from the fiber web, and wherein the application is carried out by spraying, ultrasonic spraying, ultrasonic atomization, spin coating, curtain coating or, in the case of dry coating agents, by a trickle coating process, [6] Method according to one of the preceding claims, characterized by that the coating agent comprises natural or synthetic resins and starch or modified starch as a functional component, which are applied in liquid or dry form and serve as a cross-linking medium for the fibers, at least in the case of certain resins and modified starches also to increase the moisture resistance of the folding box substrate, wherein the application is carried out by a spraying, trickling or spin-coating process and the temperature used in the thermoforming process is selected such that the resins or starches reach a melting point or gelling point and produce adhesion to the fibers. [7] Method according to one of the preceding claims, characterized bythat the coating agent comprises at least one functional component selected from biopolymers, synthetic polymers, fillers, binders, pigments, dyes, surfactants, alcohols, strengthening agents or barrier formers, wherein the application is carried out as a single treatment or in the form of a mixture in order to specifically influence the barrier properties, the printability, the strength or the surface quality of the substrate. [8] Apparatus for producing a folding box blank from a fiber mat according to one or more of the preceding method claims, comprising: • a feeding device for providing the fiber mat in sheet or roll form, • at least one compacting device that guides the fiber mat through a roller gap and compacts it, • at least one coating device for the contactless application of coating agents, • optionally a decoration device that inserts a printed web or inlay in register or enables subsequent digital printing, as well as • a printing form which is designed in such a way that the fiber mat is formed into a predetermined folding box blank under the combined effect of pressure and temperature, wherein the printing form has at least one shaping mold insert with a contouring mold surface which is designed to be heatable and / or coolable, contains venting structures for discharging air and water vapor and comprises devices for introducing creasing lines as well as punching and cutting devices which are arranged alternatively within the printing form or in a downstream separate device. [9] Device according to claim 8, characterized bythat the printing form has shaping surfaces with an arithmetic roughness (Ra) of 0.4 µm to 1.6 µm, optionally micropatterns with depths of 5 µm to 50 µm are integrated to create decorative surface structures, the shaping surfaces can be heated to a temperature of 120 °C to 250 °C and / or cooled to below 60 °C, a contact pressure of 2 bar to 20 bar can be generated and ventilation structures with micro-bores or channels of 50 µm to 300 µm in diameter are provided to remove air and water vapor from the fiber mat during the shaping process. [10] Folding box, produced according to process claim 1 and optionally further claims from 2-7.

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