Method for producing a three-dimensional product and blanks useful for producing a three-dimensional product

Abstract

The present invention relates to a method for producing a three-dimensional product (1) having a base (10) and an upstanding peripheral wall (20) extending from said base (10), by hot pressing in a press cavity (C) a blank (100) cut from a web (W) comprising at least a first layer (L2) of nonwoven airlaid fluff material.

Description

[Technical field]

[0001] The present invention relates in particular to a method for producing hot-pressed three-dimensional products, especially packaging products, based on webs containing natural fibers, which exhibit a high degree of stability and leak resistance. [Background technology]

[0002] It is well known in the art to produce three-dimensional packaging products based on nonwoven airlaid fluff material webs.

[0003] An example of a three-dimensional packaging product made based on a cushioning nonwoven airlaid fluff material web is disclosed in WO 2022 / 009130 A. This packaging product cannot be considered leak-proof in that no provision is made for firmly connecting the upstanding side panels to one another.

[0004] An example of a leak-proof three-dimensional packaging product based on a nonwoven airlaid fluff material web is disclosed in WO 2007 / 113750. In general, when producing such a packaging product, a flat rectangular blank cut from the web is hot-pressed in a mold cavity to form a three-dimensional packaging product having a rectangular base and upright peripheral walls that define the upright corners of the packaging product. The blank has a first part that defines the rectangular base of the packaging product and is integral with a surrounding second part that defines the upright peripheral walls after hot-pressing the blank. By hot-pressing, such packaging products exhibit high dimensional stability.

[0005] Known packaging products of the aforementioned leak-proof type have been found to be aesthetically problematic, particularly where such packaging products have relatively high peripheral upright walls, and the upright corners may not be sufficiently resistant to leakage of liquid contents over as long a period of time as may be desired where the packaging product is used to contain meat with juices that should not leak from the packaging product.

[0006] The aforementioned problems have been found to be mainly related to damage caused by the formation of the densely compressed fibrous structure obtained in the upright corners of the prior art packaging products, especially during hot pressing. Summary of the Invention [Means for solving the problem]

[0007] The present invention aims to solve these problems by providing an improved method for producing in a very economical manner three-dimensional products useful as packaging or for other applications based on a monolithic blank made from a web of nonwoven airlaid fluff material comprising a) natural fibers, b) less than 10 percent thermoplastic fibers by dry weight, preferably completely zero thermoplastic fibers, c) preferably less than 10 percent adhesive by dry weight, preferably completely zero adhesive by dry weight, and d) preferably less than 2 percent thermosetting resin by dry weight, preferably completely zero thermosetting resin.

[0008] The improved method includes the steps defined in the attached method claim 1, in which a blank cut to define a first central segment and further adjacent adjacent segments protruding from the first segment is shaped and processed using a hot press mold having male and female portions defining a press cavity. Upon redirecting the protruding segments and applying sufficient pressure and heat to establish hydrogen bonds, the natural fibers of the overlapping or otherwise contacting edges of the adjacent redirected segments are bonded together to form seam lines and thus the leak-proof upstanding corners of the three-dimensional product, resulting in the desired leak-proof three-dimensional product. In this way, the first segment defines the base of the three-dimensional product and the further segments together define the peripheral walls with the upstanding corners of the three-dimensional product.

[0009] For example, hydrogen bonds can form between hydroxyl groups of cellulose fibers and hydroxyl groups of hemicellulose fibers. The presence of thermoplastic fibers has been found to inhibit the formation of hydrogen bonds. Thus, the layer in which hydrogen bonds are established has less than 10% thermoplastic fibers by dry weight or no thermoplastic fibers.

[0010] The natural fibers may preferably be cellulosic fibers having a Kajaani length (weighted) preferably in the average length range of 1.8 to 4.0 mm. It has been found that the use of cellulosic fibers having a defined range of Kajaani lengths (weighted) results in a high strength network of such hydrogen bonded fibers, with each cellulosic fiber bonded to several other such fibers.

[0011] Cutting the blank may preferably involve making a number of V-shaped or essentially V-shaped cuts in the blank to form a corresponding number of protruding segments, with the tip of the V being at or near the first segment referred to above.

[0012] Preferably, when hot pressing is performed, the surface temperature of the opposing press surfaces of the hot press mold is about 20°C to 200°C, and the pressure applied to the blank is preferably about 2.0 to 200 kg / cm. 2 Preferably, the pressing time is about 1 to 5 seconds. Also, the moisture content of the web from which the blanks are cut is preferably about 2 w% to 25 w% or less. Preferably, the reorientation is performed entirely using a hot press mould, although pre-reorientation of some of the further segments may be performed in a previous manufacturing step.

[0013] To reduce the tendency of the packaging material to absorb moisture, an internal or surface sizing agent selected from the group of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch, and water glass may be used. The nonwoven airlaid fluff material may contain less than 2% by weight of such additives in total.

[0014] The web from which the blanks are cut in the manner described above may include a single layer, i.e., a layer of nonwoven airlaid fluff material for hydrogen bonding, or a layer of nonwoven airlaid fluff material for hydrogen bonding plus a layer of natural fibers and a layer of thermoplastic fibers. If two such additional layers are used, the nonwoven airlaid fluff material for hydrogen bonding is sandwiched between the two additional layers. If only a single such additional layer is used, the hot press may be such that the additional layer faces the inside or outside of the product. Any such additional layer may include a hydrogen bonding inhibiting amount of thermoplastic fibers and may include the aforementioned internal and / or surface sizing agents.

[0015] The independent claims are also directed to blanks which can be processed using the aforementioned method to form three-dimensional products.

[0016] Preferred embodiments are defined in the dependent claims.

[0017] As used herein, the term "upright wall" may preferably refer to a wall that extends upward and outward from the bottom of the product at an angle α of about 90° to 135°, preferably about 95° to 105°, relative to the bottom of the product.

[0018] As used herein, the term "web" may refer to material supplied in long lengths or as sheets of relatively short lengths for use in the present methods. [Brief description of the drawings]

[0019] [Figure 1] FIG. 1 is a perspective view of a three-dimensional product having four corners and including a lid, made in accordance with the present invention. [Diagram 2] FIG. 2 is a top view of the product of FIG. 1 before a lid is applied. [Diagram 3] FIG. 2 is a top view of a flat cut blank for use in the method of the present invention. [Figure 4a] FIG. 2 is a cross-sectional view showing a blank inserted into a hot press mold before hot pressing. [Figure 4b] FIG. 2 is a cross-sectional view showing a blank being hot pressed, inserted into a hot press mold. [Figure 5a] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 5b] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 5c] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 5d] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 5e] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 5f] FIG. 2 is a schematic partial cross-sectional view illustrating a seam line that may be formed in an upright corner of the product of FIG. 1 by hydrogen bonds established between overlapping or otherwise contacting edges of adjacent segments of the blank as a result of hot pressing. [Figure 6] FIG. 13 is a perspective view of another taller, three-dimensional product made in accordance with the present invention. [Figure 7] FIG. 7 is a top view of another flat cut blank for use in the method of the present invention to produce the product of FIG. 6. [Figure 8a]FIG. 8 shows, in schematic form, a cross-sectional view of a portion of a one-ply web from which the blanks of FIGS. 3 and 7 may be cut. [Figure 8b] FIG. 8 shows diagrammatically a cross-sectional view of a portion of a three-ply web from which the blanks of FIGS. 3 and 7 may be cut. [Figure 9a] 1 shows diagrammatically how a cutting die for cutting the blank can be configured to allow for the formation of an overlap bond or a type of butt joint between adjacent segments of the blank. [Figure 9b] 1 shows diagrammatically how a cutting die for cutting the blank can be configured to allow for the formation of an overlap bond or a type of butt joint between adjacent segments of the blank. [Figure 9c] 1 shows diagrammatically how a cutting die for cutting the blank can be configured to allow for the formation of an overlap bond or a type of butt joint between adjacent segments of the blank. [Figure 9d] 1 shows diagrammatically how a cutting die for cutting the blank can be configured to allow for the formation of an overlap bond or a type of butt joint between adjacent segments of the blank. [Figure 10a] 9a-9d dies are used to cut a blank, the wall segments move into contact with each other during pressing. FIG. [Figure 10b] 9a-9d dies are used to cut a blank, the wall segments move into contact with each other during pressing. FIG. [Figure 11] An example of a cutting die useful for making the notches when pressing produces a butt joint of the type shown in FIG. 5b is shown. [Figure 12a] 13 shows another embodiment of a three-dimensional product made in accordance with the present invention, with the lower portion of the upstanding corner pressed into the inside of the product. [Figure 12b] 13 shows another embodiment of a three-dimensional product made in accordance with the present invention, with the lower portion of the upstanding corner pressed into the inside of the product. [Figure 13a]FIG. 12c is a side view of a press mould for producing the product of FIGS. 12a-12b. [Figure 13b] FIG. 12c is a top view of a press mould for producing the product of FIGS. 12a-12b. [Figure 13c] FIG. 12c is a top view of a press mould for producing the product of FIGS. 12a-12b. [Figure 13d] FIG. 12c is a side view of a press mould for producing the product of FIGS. 12a-12b. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0020] Detailed Description The invention will now be described in more detail hereinafter by reference to presently preferred embodiments.

[0021] 1 shows an exemplary three-dimensional product, designated as a packaged product, i.e. a package 1 produced according to the method of the invention, having a peripheral wall 2 defining rounded upright corners 500 of the package 1. In the illustrated embodiment, the package 1 comprises an optional lid 200, such as a plastic foil, attached to the peripheral rim of the package 1, e.g. by thermal bonding, gluing, etc. The illustrated wall 2 may, by way of example, extend upwards and outwards at an angle α of about 95°-105° relative to the package bottom. The height of the package 1, measured perpendicularly to the bottom, may be, for example, about 50-100 mm for a food tray, e.g. a package for meat.

[0022] Figure 2 shows the packaging of Figure 1 from above, without the lid 200, and showing the walls 2 and the bottom 10 of the packaging 1. The packaging 1 shown is an example of a final product 1 produced according to the method of the present invention.

[0023] The base 10 of the illustrated packaging 1 has a generally polygonal shape, and the wall 2 integrally connected to the base 10 is made up of four segments 110, 115, 120, 125 extending upwardly and outwardly, respectively, at a selected angle α from each side of the base 10, each segment 110 having an opposed edge 101, 102 that is joined to an adjacent segment 115 to form a respective one of four upstanding corners 500. The joins define a seam line where the edge 101 of each segment 110 overlaps or otherwise contacts the corresponding edge 102 of the adjacent segment 115. The joints or seams are established by hydrogen bonding when practicing the invention as described below, where the shape of the product 1 is formed by hot pressing, the edges are butted together or otherwise brought into contact and engagement, and the temperature and / or pressure are such that hydrogen bonds are established between the natural fibers of one segment contacting the natural fibers of an adjacent segment.

[0024] 2 also shows wall segments 110, 115, 120, 125 having respective extensions 140, 145, 150, 155 configured to define the aforementioned peripheral rim of packaging material 1. Extensions 140, 145, 150, 155 each have opposing edges 103, 104, and at each one of corners 500, one extension 140 is joined to an adjacent extension 145 via abutting edges 103, 104, as in the case of the aforementioned segments 110, 115, 120, 125 of wall 2.

[0025] Referring now to Figure 3, there is shown a flat blank 100 used to manufacture the product 1 of Figure 2. The blank 100 is cut in a punching operation from an elongated web W (see Figures 8a and 8b). The web W is comprised of a layer of nonwoven airlaid fluff material including a) natural fibers, b) less than 10 percent thermoplastic fibers by dry weight, preferably zero thermoplastic fibers, c) preferably less than 10 percent adhesive by dry weight, preferably zero adhesive by dry weight, and d) preferably less than 2 percent thermosetting resin by dry weight, preferably zero thermosetting resin. The web W typically has a moisture content of about 2 wt% to 25 wt% or less at the time the hot pressing is performed.

[0026] As shown in FIG. 3, the blank 100 includes a first segment 105 configured to define the product bottom 10 and the aforementioned four further segments 110, 115, 120, 125 projecting outwardly from the first segment 105. The further segments 110, 115, 120, 125 are configured to together define the upstanding peripheral wall 20 after hot pressing, each having an edge 101, 102 opposite each other. It will be understood that the further segments 110, 115, 120, 125 of the blank 100 are not connected to each other except through the first segment 105 by removing a portion of the web W during cutting. Thus, in this embodiment, cutting involves making four V-shaped cuts in the blank 100 to form a corresponding number of segments 110, 115, 120, 125. The cutting process may also result in localized modifications of the structure of the blank 100 in areas where cuts are made and where the fibers of the resulting edges 101, 102 will subsequently be bonded to one another by hydrogen bonds.

[0027] 4a and 4b show diagrammatically the hot pressing operation performed on the cut-out blank 100. Preferably, when hot pressing is performed, the surface temperature of the opposing press faces of the hot press mould M is about 80°C-200°C and the pressure applied to the blank is preferably about 2.0-200 kg / cm2. Preferably, the pressing time is about 1-5 seconds. Pressing leads to a reorientation, i.e. a change of direction, of said further segments 110, 115, 120, 125 in that said further segments 110, 115, 120, 125 are folded by a predefined angle of 180°-α around the respective imaginary fold line L shown in FIG. 3 compared to the corresponding angle α shown in FIG. 4a, resulting in a product 1 having a peripheral wall 2 extending as shown in FIG. 1. The said cuts / slits preferably do not reach the expected fold line L but extend towards the expected fold line L resulting from the design of the press mould M.

[0028] Figures 5a-5f show schematic partial cross-sectional views illustrating variations in the joint between the respective edges 101, 102; 103, 104 where hydrogen bonds are established during hot pressing. The seam-like connection can occur, for example, by overlapping edges as shown in Figure 5a, by forming a butt joint as shown in Figure 5b, or by forming a tongue and groove as shown in Figures 5c-5f.

[0029] Now referring to Fig. 6, another embodiment is shown in which the product 1 takes the form of a ready-to-use drinking cup with a substantially circular cross section. Fig. 7 shows a blank 100 with a relatively large number of V-shaped cuts for producing the cup of Fig. 6, in which the edges 101, 102 of adjacent wall segments 110, 115 extending radially outward from a first segment 105 with a rounded profile are engaged during pressing and bonded to each other by hydrogen bonds of the contacting natural fibres of the adjacent wall segments 110, 115 resulting from the hot pressing. In this embodiment, the height of the peripheral wall 20 measured perpendicularly to the base 10 of the obtained three-dimensional product 1 defined by the first segment 105 may be, for example, about 100-150 mm.

[0030] 8a shows an embodiment in which the web W from which the blanks 100 are cut has only a single layer L2, i.e., a nonwoven airlaid fluff material type for hydrogen bonding. A surface sizing agent may be provided as a coating SC and is selected from the group of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), waxes, lignins, modified starches, and water glass.

[0031] On the other hand, Fig. 8b shows another embodiment in which the web W from which the blank 100 is cut and subsequently hot-pressed consists of three layers, the central layer L2 being of the nonwoven airlaid fluff material type for hydrogen bonding, and the outer layers L1, L3 being layers bonded to the central layer L2 and comprising natural fibres and preferably thermoplastic fibres of the type that are home- and / or industrially compostable. In this case, the above-mentioned hydrogen bonds across the adjacent abutting segments 110, 115, 120, 125 are established between the natural fibres of the central layer L2 as a result of the hot pressing. Further bonds between the thermoplastic fibres of the layers L1, L3 of the abutting segments 110, 115, 120, 125 may also result from the hot pressing. A coating SC as described above may be provided.

[0032] Alternatively, a web W containing only a layer L2 of nonwoven airlaid fluff material for hydrogen bonding may be used with only a single layer L3 containing natural fibers and thermoplastic fibers of the type described above. A coating SC as described above may be provided.

[0033] The natural fibers mentioned above may be selected from the following groups: virgin cellulosic fibers, cellulosic fibers having a Kajaani length (weighted) in the average length range of 1.8 to 4.0 mm, recycled fibers such as recycled paper fibers, recycled kraft fibers, recycled carton fibers, recycled milk carton fibers, recycled sackcloth fibers, TMP1 newspaper or magazine fibers, textile waste fibers, viscose fibers, bamboo fibers, nonwoven waste fibers, peat moss fibers, home compostable bonded fibers, and annual crop fibers such as hemp fibers, cotton fibers, jute fibers, wheat fibers, coconut fibers, seaweed fibers, or straw fibers.

[0034] The fibers may optionally be untreated or may be chemically and / or mechanically treated, such as to reduce or substantially remove lignin, but still allow hydrogen bonds to form.

[0035] 9a-9b and 9c-9d show schematic cross-sectional views of how cutting dies D1, D2 with knives 901 for cutting out blanks 100 from a web W can be configured to cause the subsequent formation in a press mould M of either an overlap joint of the type shown in FIG. 5a or a butt joint (end-to-end joint as illustrated in FIG. 5c) between adjacent wall segments 110, 115 of the blank 100, respectively, by using die structures 902, 902' capable of compressing or deforming the opposing edges 101, 102. These cross-sectional views show that the dies D1, D2 are located near the expected fold line L with the tip end of the knife 901, i.e. where the pointed end of the aforementioned V-shaped cut is created. The local structural modification as described above in FIGS. 9b and 9d is performed by locally compressing the material.

[0036] Figures 10a and 10b show diagrammatically by means of arrows how adjacent wall segments 110, 115 are displaced towards each other when the press mould M is closed in order to bring their edges 101, 102 into contact, if a blank is cut out using one of the cutting dies of Figures 9a to 9d or the other. This displacement is so small in the area where the folding around the line L takes place that the aforementioned cuts forming the segments 110, 115, 120, 125, 130 preferably do not extend completely to the expected position of the fold line L, but may only extend from it to a distance of, for example, 2 to 5 mm, so that in this area of ​​the product very close to the bottom 10, the corners 500 of the product 1 are only defined by the folding.

[0037] FIG. 11 is a top view of a cutting die D3 having closed loop knives 901 useful for making the cuts when closing and pressing the pressure mold M to produce a butt joint of the type shown in FIG. 5b.

[0038] Figures 12a-b show another embodiment of a three-dimensional product 1 in the form of a ready-to-use tray that can be used to contain, for example, food products including juices without leakage, manufactured according to a claimed embodiment of the present invention, for example with the aforementioned layers L2, L1 and L2, or with layers L1, L2 and L3, and with a lower part 503. The aforementioned hydrogen bonds of the inwardly extending upright corners 500 of the product 1 are established as a result of the engagement between the female part 600 with the cavity C and the male part 700 corresponding parts 603, 703 of the press mould M shown in Figures 13a, 13b and 13c, 13d, respectively.

Claims

1. A method for producing a three-dimensional product (1) having a base (10) and an upstanding peripheral wall (20) extending from the base (10), by hot pressing in a press cavity (C) a blank (100) cut from a web (W) comprising at least a first layer (L2) of nonwoven airlaid fluff material, comprising: - the nonwoven airlaid fluff material comprises Natural fibers and less than 10 percent by dry weight thermoplastic fibers; Preferably less than 10 percent adhesive by dry weight, preferably zero adhesive by dry weight; Preferably less than 2 percent thermosetting resin by dry weight, preferably zero thermosetting resin; Including, said blank (100) A first segment (105) configured to define the bottom (10); A plurality of further segments (110, 115, 120, 125, 130) extending from said first segment (105) and configured to together define said upstanding peripheral wall (20) after said hot pressing. a plurality of further segments (110, 115, 120, 125, 130...), each of said further segments (110, 115, 120, 125, 130...) having respective opposite edges (101, 102); Including, the method comprising the steps of reorienting the further segments (110, 115, 120, 125, 130...) such that edges (101, 102) of adjacent further segments (110, 115) are in contact with each other, the hot pressing is selected such that hydrogen bonds between the natural fibers of the contacting edges (101, 102) result from the hot pressing to provide the three-dimensional product (1), method.

2. The method of claim 1 , wherein the natural fibers are virgin cellulosic fibers.

3. The method according to claim 1 or 2, wherein the natural fibres are cellulosic fibres, preferably having a Kajaani length (weighted) in the average length range of 1.8 to 4.0 mm.

4. The method of claim 1, 2 or 3, wherein any thermoplastic fibers of the nonwoven airlaid fluff material are domestically and / or industrially compostable thermoplastic fibers, preferably having a length in the range of 3.0 to 18.0 mm.

5. The method of claim 1 , 2 or 3 , wherein the nonwoven airlaid fluff material is free of thermoplastic fibers.

6. The method according to any one of the preceding claims, wherein said redirecting is performed in the press cavity (C) such that said edges (101, 102) contact each other in the press cavity (C).

7. When the hot pressing is performed, the blank (100) has a temperature of 80° C. to 200° C., and / or when the hot pressing is performed, the pressure applied to the blank (100) is at least 50 kg / cm ２ , preferably at least 200 kg / cm ２ , preferably 220 to 300 kg / cm ２ The method according to any one of claims 1 to 6, wherein the range is

8. A method according to any one of the preceding claims, wherein a plurality of said blanks (100) are cut out successively from said web (W), said web (W) and said cut out blanks (100) being advanced preferably successively into said press cavity (C).

9. The method according to any one of claims 1 to 8, wherein the web (W) comprises only the first layer (L2) of nonwoven airlaid fluff material, the first layer (L2) defining an opposite surface of the blank (100), and the hot pressing is selected such that hydrogen bonds between the natural fibers of the contacting edges (101, 102) of the first layer (L2) result from the hot pressing to provide the three-dimensional product (1).

10. A method according to any one of the preceding claims, wherein said contact is by arranging said edges (101, 102) to overlap by 1-5 mm or to form a butt joint.

11. 11. The method of claim 9 or 10, wherein the first layer (L2) comprises an internal sizing agent and / or a surface sizing agent selected from the group consisting of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch, and water glass, or the nonwoven airlaid fluff material comprises less than 2 wt. % in total of additives selected from the group consisting of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch, and water glass, and the additives cover the natural fibers of the first layer (L2).

12. 9. The method according to any one of claims 1 to 8, wherein the web (W) from which the blanks (100) are cut comprises a further layer (L3) carrying the first layer (L2) of nonwoven airlaid fluff material, the first layer (L2) defining a first surface of the blank (100) and the further layer (L3) defining a second surface of the blank (100), the further layer (L3) comprising natural fibres and thermoplastic fibres, preferably domestically and / or industrially compostable thermoplastic fibres, the thermoplastic fibres preferably having a length in the range of 3.0 to 18.0 mm.

13. The method according to any one of claims 1 to 8, wherein the web (W) from which the blanks (100) are cut comprises the first layer (L2) of nonwoven airlaid fluff material sandwiched between second and third further layers (L1, L3), each further layer (L1, L3) comprising natural and thermoplastic fibres, preferably home and / or industrially compostable thermoplastic fibres having a preferred length in the range of 3.0 to 18.0 mm, defining a respective surface of the blank (100), and the hot press is selected such that bonds are formed between the thermoplastic fibres over edges (101, 102) of the adjacent further segments (110, 115) that are in contact with each other.

14. 14. The method according to claim 12 or 13, wherein at least one of the further layers (L1, L3) comprises an internal and / or surface sizing agent selected from the group consisting of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch and water glass, or wherein the at least one further layer (L1, L3) comprises less than 2% by weight in total of additives selected from the group consisting of fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch and water glass, the additives covering the natural fibres of the at least one further layer (L1, L3).

15. The method according to any one of the preceding claims, wherein the first segment (10) has a polygonal or rounded contour.

16. 16. The method according to any one of claims 1 to 15, wherein the further segments (110, 115, 120, 125, 130...) each have an extension (140, 145, 150, 155) with respective opposite edges (103, 104), the edges (103, 104) of adjacent extensions (140, 145) coming into contact with each other when the blank (100) is hot pressed in the press cavity (C), and hydrogen bonds between the natural fibres of the contacting edges (103, 104) of the extensions (140, 145, 150, 155) result from the hot pressing, and a peripheral rim of the three-dimensional product (1) is provided, optionally configured for attaching a lid (200) to the product (1).

17. The natural fibers are virgin cellulosic fibres, preferably cellulosic fibres having a Kajaani length (weighted) in the average length range of 1.8 to 4.0 mm, recycled fibres such as recycled paper fibres, recycled kraft fibres, recycled carton fibres, recycled milk carton fibres, recycled sackcloth fibres, TMP1 newspaper or magazine fibres, textile waste fibres, viscose fibres, bamboo fibres, non-woven waste fibres, peat moss fibres, home compostable bonded fibres or annual crop fibres such as hemp fibres, cotton fibres, jute fibres, wheat fibres, coconut fibres, seaweed fibres or straw fibres, - the fibers are optionally untreated or chemically and / or mechanically treated, such as to reduce or substantially remove lignin; - the fluff optionally contains internal and / or surface sizing agents that increase the hydrophobic properties and / or mechanical strength of the blank (100), such as fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch, or water glass, The method according to any one of claims 1 to 16.

18. The method according to any one of the preceding claims, wherein the cutting is by a punching operation and / or the cutting involves forming a V-shaped or essentially V-shaped cut in the blank (100).

19. The method according to any one of the preceding claims, wherein the blank (100) has a thickness selected in the range of 1.5 mm to 20 mm, preferably 1.5 mm to 9.5 mm.

20. The blank (100) has a strength of 30 kg / cm ３ ~350kg / m ３ and the three-dimensional product (1) has a density selected in the range of 700 kg / cm ３ ~1,500kg / cm ３ The method according to any one of claims 1 to 19, wherein the granular material has a density of

21. A three-dimensional product (1) manufactured by the method according to any one of the preceding claims.

22. A flat or substantially flat blank (100) suitable for use in the method according to any one of claims 1 to 20, said blank (100) comprising a layer (L2) of non-woven airlaid fluff material, a first segment (105) with a polygonal or rounded contour, a number of further segments (110, 115, 120, 125, 130...) projecting outwardly from said first segment (105); having The blank (100) has a strength of 30 kg / cm ３ ~350kg / m ３ and a thickness selected in the range of 1.5 mm to 20 mm, preferably 1.5 mm to 9.5 mm; Blank(100).

23. The first layer (L2) is Natural fibers and less than 10 percent thermoplastic fibers by dry weight, preferably zero thermoplastic fibers; Preferably less than 10 percent adhesive by dry weight, preferably zero adhesive by dry weight; Preferably less than 2 percent thermosetting resin by dry weight, preferably zero thermosetting resin; The blank (100) of claim 22, comprising:

24. The natural fibers are virgin cellulosic fibres, preferably cellulosic fibres having a Kajaani length (weighted) in the average length range of 1.8 to 4.0 mm, recycled fibres, such as recycled paper fibres, recycled kraft fibres, recycled carton fibres, recycled milk carton fibres, recycled sackcloth fibres, TMP1 newspaper or magazine fibres, textile waste fibres, viscose fibres, bamboo fibres, non-woven waste fibres, peat moss fibres, home compostable bonded fibres, and / or annual crop fibres, such as hemp fibres, cotton fibres, jute fibres, wheat fibres, coconut fibres, seaweed fibres or straw fibres, is selected from the group - the fibers are optionally untreated or have been chemically and / or mechanically treated, such as to reduce or substantially remove lignin; - the fluff optionally contains internal and / or surface sizing agents that increase the hydrophobic properties and / or mechanical strength of the blank (100), such as fluorine compounds, alkyl ketene dimers (AKD), alkenyl succinic anhydrides (ASA), rosin (acid sizing), wax, lignin, modified starch, or water glass, 24. A blank (100) according to claim 22 or 23.

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