Air raid blanket and cushion insert

Abstract

The air raid blank (10) includes natural fibers and a polymer binder. The air raid blank (10) includes a cushion portion (14) that includes a plurality of cavities (13) extending within the air raid blank (10). The air raid blank (10) includes a frame portion (15) lacking in any cavities extending within the air raid blank (10). The frame portion (15) surrounds the cushion portion (14). The air raid blank (10) is used to produce cushion inserts (60A, 60B) configured to be inserted within a packaging box (50) to protect an item or product (70) packaged within the packaging box (50).

Description

Technical Field

[0001] Embodiments of the present invention generally relate to airlaid blanks and methods for producing such airlaid blanks, and more particularly to airlaid blanks suitable for producing cushion inserts.

Background Art

[0002] Due to the growing awareness of the environment and anthropogenic climate change, disposable plastic items and products are becoming increasingly problematic. However, despite this concern, the use of these items and products has increased significantly over the past decade due to new trends in lifestyle and consumer habits. One reason for this is that an increasing number of goods are transported around the world and these goods need to be protected from impact or shock. A common way to protect goods is to include cushioning elements or products, such as appropriate inserts within the packaging. These can be made from a variety of materials, but are typically made from foamed polymers, among which expanded polystyrene (EPS) is the cheapest and most common by far. However, EPS is one of the most problematic plastic materials and many brand owners are looking for more sustainable solutions for these packaging applications. Many countries are also starting to take legal measures against disposable plastic items and products, which is increasing the pressure for alternative solutions.

[0003] There are more sustainable alternatives to polymer products today, such as inserts made by a process known as pulp molding, where a fiber suspension is drawn by vacuum against a wire mold. Another technique for forming such inserts is described in US Patent Application No. 2010 / 0190020, European Patent No. 1446286, and International Application No. 2014 / 142714, which relate to the thermocompression bonding of porous fiber mats produced by a process called air laying into a 3D structure by matched hard molds or film forming.

[0004] However, the above-exemplified method produces a cushion insert adapted to protect a particular product or article. Thus, the wire mold or matched mold design is selected based on the shape and size of the particular product or article to be protected by the cushion insert. However, there is a need for a general-purpose cushion insert that can be used to protect products and articles of various shapes and sizes and that can be manufactured using materials that are more environmentally friendly than polymer foams such as EPS. SUMMARY OF THE INVENTION

[0005] An object is to provide an airlaid blank that can be used to produce a general-purpose cushion insert.

[0006] This and other objects are met by embodiments of the present invention.

[0007] The present invention is defined in the independent claims. Further embodiments of the present invention are defined in the dependent claims.

[0008] Aspects of the present invention relate to an airlaid blank comprising natural fibers and a polymer binder. The airlaid blank includes a cushion portion including a plurality of cavities extending within the airlaid blank and a frame portion lacking in any cavity extending within the airlaid blank. The frame portion surrounds the cushion portion.

[0009] Another aspect of the present invention relates to a method for generating an airlaid blank. The method includes introducing natural fibers and a polymer binder, and / or a mixture of natural fibers and a polymer binder, into at least one inlet of a forming head; transporting the natural fibers and the polymer binder and / or the mixture to an outlet of the forming head; and capturing the natural fibers and the polymer binder and / or the mixture as an unbonded airlaid web on a collector disposed and configured to be connected to the outlet of the forming head. The method also includes applying a gas pulse onto the unbonded airlaid web to form a cushion portion including a plurality of cavities extending within the unbonded airlaid web. The cushion portion is surrounded by a frame portion of the unbonded airlaid web, and the frame portion is lacking in any cavities extending within the unbonded airlaid web. The method further includes heat-treating the unbonded airlaid web to at least partially melt the polymer binder and form an airlaid blank.

[0010] A further aspect of the present invention relates to a method for generating an airlaid blank. The method includes introducing natural fibers into at least one inlet of a forming head; transporting the natural fibers to an outlet of the forming head; and capturing the natural fibers as a web of natural fibers on a collector disposed and configured to be connected to the outlet of the forming head. The method also includes applying a gas pulse onto the web of natural fibers on the collector to form a cushion portion including a plurality of cavities extending within the web of natural fibers. The cushion portion is surrounded by a frame portion of the web of natural fibers, and the frame portion is lacking in any cavities extending within the web of natural fibers. The method further includes applying a polymer binder to the natural fibers, as well as heat-treating the web of natural fibers and the polymer binder to form an airlaid blank.

[0011] Yet another aspect of the present invention relates to a cushion insert made from an airlaid blank comprising natural fibers and a polymeric binder. The cushion insert includes a cushion portion including a plurality of cavities extending therein, and a frame portion lacking in any cavity extending therein. The frame portion surrounds the cushion portion.

[0012] The present invention also relates to a packaging assembly including a packaging box having a bottom and at least one sidewall attached to the bottom. The bottom and the at least one sidewall define a packaging volume. The packaging assembly also includes a first cushion insert as described above, in which a plurality of cavities are oriented in a direction opposite to the bottom of the packaging box and are disposed and configured on the bottom of the packaging box.

[0013] The present invention relates to an airlaid blank and a cushion insert made from such an airlaid blank. The cushion insert is highly suitable as a cushioning material for packaged goods and provides excellent shock absorption and damping properties. The airlaid blank and the cushion insert are designed to include a deformable cushion portion including a plurality of cavities, and this cushion portion conforms to various shapes and sizes of the packaged goods. The cushion portion is surrounded by a frame portion lacking in cavities, thereby providing structural integrity and strength to the airlaid blank and the cushion insert, and at the same time constituting shock absorption and damping protection for the packaged goods.

[0014] Embodiments can be best understood by reference to the following description, taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts, and in which:

Brief Description of the Drawings

[0015]

Figure 1

Figure 2

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Figure 3D

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Figure 15

DETAILED DESCRIPTION OF THE INVENTION

[0016] Embodiments of the present invention generally relate to airlaid blanks, methods and apparatuses for producing such airlaid blanks, and more particularly to airlaid blanks suitable for producing cushion inserts.

[0017] The airlaid blanks of embodiments of the present invention are useful for producing cushion inserts, also known in the art as cushion inlays or cushion elements, for packaging products, articles, or goods. These cushion inserts can then be used as a more environmentally friendly alternative to corresponding cushion inserts made of or from foamed polymers such as expanded polystyrene (EPS) or expanded polyurethane (PU). More sustainable alternatives to EPS or PU-based cushion inserts relate to the thermocompression bonding of porous fiber mats produced by a process called air laying into three-dimensional inserts by matched hard molding or film molding, as proposed in the art, such as U.S. Patent Application No. 2010 / 0190020, European Patent No. 1446286, and International Application No. 2014 / 142714. A significant limitation of these prior art inserts is that they are designed to protect specific products or articles. Thus, the matched mold design is selected based on the shape and size of the specific product or article to be protected by the cushion insert. This is clearly in contrast to embodiments of the present invention that produce a general-purpose cushion insert that can be used to protect products and articles of various shapes and sizes. Such general-purpose cushion inserts are particularly desirable for companies that offer or package multiple and diverse products and articles, such as e-commerce companies.

[0018] The cushion insert of an embodiment of the present invention is formed from an airlaid blank that includes natural fibers and a polymeric binder. An airlaid blank, sometimes referred to as a drylaid blank, airlaid mat, drylaid mat, airlaid web, or drylaid web, is formed by a process known as airlaying in which natural fibers and a polymeric binder are mixed with air to form a porous fiber mixture that is deposited on a support and consolidated or bonded by heat. This airlaid blank is porous and has the characteristics of an open cell foam and is produced by what is known as a dry forming process, i.e., generally characterized by the absence of added water. The airlay process was originally described in U.S. Patent No. 3,575,749.

[0019] FIG. 1 is a cross-sectional view of a portion of an airlaid blank 10. This airlay process typically produces an airlaid blank 10 in which the majority of the natural fibers are oriented such that their long axes are substantially parallel to the major surfaces 11, 12 (in FIG. 1, the x-y plane) of the airlaid blank 10, and there are few fibers oriented perpendicular to this plane, i.e., along the z-axis of FIG. 1. Thus, the fiber structure of the airlaid blank 10 tends to be substantially stratified or laminated within a plane perpendicular to the z-axis. The stratified fiber orientation of the airlaid blank 10 shown in FIG. 1 is favorable with respect to the strength and stiffness characteristics of the airlaid blank 10, thereby enabling the production of a cushion insert having the desired strength and stiffness characteristics from the airlaid blank 10.

[0020] Aspects of the present invention relate to the airlaid blank 10. Refer to the cross-sectional views of FIGS. 2 and 5 and the top views of FIGS. 3A through 3C. The airlaid blank 10 includes natural fibers and a polymeric binder. The airlaid blank 10 includes a cushion portion 14 and a frame portion 15. The cushion portion 14 includes a plurality of cavities 13 that extend into the airlaid blank 10, whereas the frame portion 15 is devoid of any cavities that extend into the airlaid blank 10. The frame portion 15 further surrounds the cushion portion 14.

[0021] Accordingly, the airlaid blanket 10 includes an inner portion, a cushion portion 14, as well as a peripheral portion, a frame portion 15. The cushion portion 14 includes a plurality of cavities 13 that extend into the airlaid blanket 10 of this cushion portion 14. FIG. 2 illustrates one such cavity 13, while FIG. 5 illustrates a plurality of cavities 13 of the cushion portion 14. The cavity 13 can be seen as a pore or channel, particularly a closed channel, that extends from one of the main surfaces 11 of the airlaid blanket 10 towards the opposite main surface 12 of the airlaid blanket 10.

[0022] Due to the presence of the plurality of cavities 13, the cushion portion 14 of the airlaid blanket 10 contains less natural fiber material compared to the frame portion 15. This means that this cushion portion 14 of the airlaid blanket 10 is more deformable compared to the harder frame portion 15, such that in the cushion inserts 60A, 60B seen in FIGS. 6 and 7 formed from the airlaid blanket 10, it will deform and conform to the specific shape and size of the product or article 70 that is to be packaged and protected within the cushion inserts 60A, 60B. The frame portion 15, which is lacking in cavities 13, then provides structural integrity to the airlaid blanket 10 and the formed cushion inserts 60A, 60B. Furthermore, the frame portion 15 simultaneously constitutes impact absorption and damping protection with respect to the packaged product or article 70.

[0023] In an embodiment, the plurality of cavities 13 extend through a portion of the thickness of the airlaid blank 10 from the first major surface 11 of the airlaid blank 10 towards the second, opposite major surface 12 of the airlaid blank 10. However, in certain embodiments, the plurality of cavities 13 do not extend through the full thickness of the airlaid blank 10 as shown in FIGS. 2 and 5. Thus, the cavities 13 preferably only extend downwardly from the first major surface 11 through a portion of the thickness. In an embodiment, the cavity 13 or at least a majority of the plurality of cavities 13 extend downwardly from the major surface 11 through a percentage of the thickness of the airlaid blank 10. In certain embodiments, this percentage is selected within the range of intervals from 25% to 90%, preferably within the range of intervals from 35% to 90%, more preferably within the range of intervals from 50% to 90%, for example within the range of intervals from 60% to 80%. In an exemplary, but non-limiting, example, the cavity 13 or at least a majority thereof extends downwardly from the first major surface 11 through two-thirds to three-quarters of the thickness of the airlaid blank 10.

[0024] In an embodiment, at least a majority of the plurality of cavities 13 extend only through a portion of the thickness of the airlaid blank 10, but not through the full thickness. However, in such an embodiment, at least a portion of the cavity 13 extends through the full thickness of the airlaid blank 10, thereby forming a channel through the airlaid blank 10 from the first major surface 11 to the second major surface 12. However, it is generally preferred that all or at least a majority of the cavities 13 only extend through a portion and not the full thickness. The reason for this is that the cushioning portion 14 will then also provide cushioning support and protection for the product and goods from "below" the lower cushion insert 60A and from "above" the upper cushion insert 60B in FIG. 7, and will include a bottom 17 comprising natural fibers and a polymer binder.

[0025] The cavity 13 may extend substantially the same distance into the airlaid blank 10 from the first major surface 11, i.e., may have substantially the same depth. However, the embodiments are not limited thereto. The cavity 13 may instead have various depths into the airlaid blank 10, thereby presenting various depth distributions. For example, the depth of the cavity 13 into the airlaid blank 10 may be greater (deeper) at the central portion of the cushion portion 14 so as to provide the highest deformability at this central portion, whereas the depth of the cavity 13 decreases towards the frame portion 15, thereby providing stronger structural support and rigidity at the more peripheral portions of the airlaid blank 10. In such embodiments, the depth of the plurality of cavities 13 generally decreases as it moves from the center of the cushion portion 14 towards the frame portion 15. In another embodiment, the depth of the plurality of cavities 13 generally increases as it moves from the center of the cushion portion 14 towards the frame portion 15.

[0026] The plurality of cavities 13 may be realized by applying gas pulses to the airlaid blank 10, or more precisely to the non-bonded or unbonded airlaid webs 30 seen in FIG. 14 formed in the airlaid blank 10 through heat treatment, particularly to the first major surfaces 11, 31 of the airlaid blank 10 or the non-bonded airlaid webs 30, as further described herein. The depth of the cavity 13 into the airlaid blank 10 depends on the force of the gas pulse. The depth may range from a shallow depression on the first major surface 11 to a deep pore.

[0027] In an embodiment, the force of the gas pulse is controlled such that it does not form any channels through the entire thickness of the airlaid blank 10, but can form the cavity 13 in the airlaid blank 10. The force of the gas pulse may be controlled to achieve various depths of the cavity 13 at various portions of the cushion portion 14.

[0028] The application of the gas pulse causes an accumulation of the natural fiber material 38 also on the frame portion 35 and on the portion 36 of the cushion portion 34 between the cavities 33, as schematically shown in FIG. 4, in the non-bonded airlaid web 30. This accumulated natural fiber material 38 is flattened during the production process and will cause a densification of at least a part 19 of the frame portion 15, as shown in FIG. 5. This then means that the average density of the frame portion 15 is higher than the average density of the airlaid blank 10 before the plurality of cavities 13 of the cushion portion 14 are formed. In other words, the average density of the airlaid material of the frame portion 15 is higher than the average density of the airlaid material of the cushion portion 14. Thus, the natural fiber material 3 blown off from the cushion portion 34 of the non-bonded airlaid web 30 will deposit on the frame portion 35 and will then be pushed into the frame portion 35. This means that the corresponding frame portion 15 of the airlaid blank 10 will thereby become even denser, i.e., have a higher density of natural fibers compared to the other parts of the airlaid blank 10. The higher density further improves the structural and rigidity properties of the frame portion 15.

[0029] The plurality of cavities 13 in the cushion portion 14 could be distributed to form a regular pattern, such as a regular grid or matrix shown in FIG. 3A, or a pattern predetermined in the airlaid blank 10. As shown in FIGS. 3B and 3C, it is also possible to form a denser distribution or pattern of the plurality of cavities 13 compared to a regular grid or matrix. In FIGS. 3B and 3C, the cavities 13 are distributed in a matrix arranged relative to each other so as to reduce the distance between adjacent cavities 13 in the cushion portion 14. FIG. 3C shows the distribution of the cavities 13 having at least partially overlapping or substantially overlapping cavities 13. Such a distribution of the cavities 13 significantly reduces the amount of airlaid material in the cushion portion 14, thereby forming pillars or protruding structures 16 as seen in FIG. 5 in the cushion portion 14. This results in a very deformable and flexible cushion insert 60A that is well adapted to the shape and size of any product or article 70 placed on the cushion portion 64 of the cushion insert 60A, see FIG. 6.

[0030] In an embodiment, the distance between adjacent cavities 13 in the cushion portion 14 is less than twice the maximum side length or diameter of the adjacent cavities 13. In a particular embodiment, the distance is equal to or less than 1.75 times or 1.5 times the maximum side length or diameter of the adjacent cavities 13.

[0031] In another embodiment, in the airlaid blank 10, i.e., the distance between adjacent cavities 13 in the cushion portion 14 of the airlaid blank 10, is less than twice the average side length or average diameter of the plurality of cavities 13 or less than twice the maximum side length or diameter in the case of cavities 13 of various sizes. In a particular embodiment, the distance is equal to or less than 1.75 times or 1.5 times the average side length or average diameter of the plurality of cavities 13, or in the case of cavities 13 of various sizes, equal to or less than 1.75 times or 1.5 times the maximum side length or diameter.

[0032] The distance between adjacent cavities 13 is defined as the center-to-center distance of adjacent cavities 13 parallel to the first and second major surfaces 11, 12. Thus, in an embodiment, the distance between the edges of adjacent cavities 13 in the cushion portion 14 is preferably less than the maximum side length or diameter of the adjacent cavities 13. In another embodiment, the distance between adjacent cavities 13 in the cushion portion 14 is preferably less than the average side length or average diameter of the plurality of cavities 13, or less than the maximum side length or diameter in the case of cavities of various sizes.

[0033] In fact, it may be possible to have an even shorter distance between adjacent cavities 13 in the cushion portion 14. For example, as already mentioned, the cavities 13 may in fact at least partially overlap. In such an embodiment, each cavity 13 of at least a portion of the plurality of cavities 13 overlaps with another cavity 13 of at least that portion of the plurality of cavities 13. Such an embodiment is shown in FIG. 3D with overlapping cavities 13. In such a case, a plurality of protruding structures 16 will be formed by the remaining airlaid material between the overlapping cavities 13, which will be described further later.

[0034] The (center-to-center) distance between adjacent cavities 13 may be substantially the same throughout the cushion portion 14. In another embodiment, a portion of the cushion portion 14 can have a denser distribution of cavities 13 compared to another portion of the cushion portion 14. For example, the distance between adjacent cavities 13 can be made even shorter at the center of the cushion portion 14 compared to the periphery of the cushion portion 14 near the frame portion 15. In such an embodiment, the (center-to-center) distance between adjacent cavities 13 generally increases when moving from the center of the cushion portion 14 towards the frame portion 15.

[0035] The frame portion 15 surrounds the cushion portion 14 shown in FIGS. 3A to 3C, thereby encircling the cushion portion 14. This means that the plurality of cavities 13 are framed or surrounded by a portion of the airlaid blank 15 that does not contain cavities.

[0036] In an embodiment, the width of the frame portion 15 is preferably at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, for example at least 25 mm, at least 30 mm, at least 35 mm, or at least 40 mm. The width of the frame portion 15 as used herein corresponds to the distance from the edge of the airlaid blank 10 to the cushion portion 14, as indicated by W in FIG. 3A.

[0037] In an embodiment, the width of the frame portion 15 of the airlaid blank 10 corresponds to a percentage of the width of the airlaid blank 10, and this percentage is within the range of intervals from 2.5% to 30%, preferably within the range of intervals from 2.5% to 25%, more preferably within the range of intervals from 5% to 25%, for example within the range of intervals from 7.5% to 25%, within the range of intervals from 10% to 25%, or within the range of intervals from 10% to 20%.

[0038] In an embodiment, the cushion portion 14 includes a bottom portion 17 containing natural fibers and a polymer binder, and a plurality of protruding structures 16 containing natural fibers and a polymer binder. The protruding structures 16 may then be separated from each other or simply interconnected through the bottom portion 17 of the cushion portion 14. In such a case, the cavities 13 overlap at least partially. In such an embodiment, the protruding portions 16 form pillars extending from the bottom portion 17. In another embodiment, the protruding structures 16 may be interconnected by (thin) portions of natural fibers and a polymer binder to adjacent protruding structures 16. In the latter embodiment, the adjacent cavities 13 do not overlap, but rather are separated by (thin) portions of the airlaid material. It is also possible to combine these embodiments, i.e., to have both individual protruding structures 16 and protruding structures 16 interconnected by (thin) walls, thereby having a combination of overlapping cavities 13 and non-overlapping cavities 13.

[0039] In an embodiment, the cavity 13 may have an average elongation, such as an average side length or an average diameter, parallel to the first and second main surfaces 11 and 12, which is preferably not more than 100 mm, preferably not more than 75 mm, more preferably not more than 50 mm, for example equal to or shorter than 40 mm, equal to or shorter than 30 mm, or equal to or shorter than 25 mm.

[0040] The cavity 13 may have substantially the same elongation, such as a side length or a diameter, or the airlaid blank 10 may include cavities 13 of various sizes having various elongations, such as various side lengths or diameters. Further, the overall shape of the cavity 13 can be made substantially the same, for example having a cylindrical shape as exemplified but not limited to. However, the embodiment is not limited thereto. Thus, the cushion portion 14 of the airlaid blank 10 can include cavities 13 having various overall shapes and forms.

[0041] Generally, the natural fibers of the airlaid blank 10 are preferably at least shorter compared to the fibers of glass or mineral wool. The relatively short natural fibers facilitate the formation of the porous airlaid blank 10. More specifically, such short natural fibers are suitable for use in embodiments of the present invention in which a gas pulse is applied to the airlaid blank 10 to generate cavities 13 in the cushion portion 14 of the airlaid blank 10.

[0042] The length of the fibers such as natural fibers referred to in this specification is the length-weighted average fiber length. The length-weighted average fiber length is calculated as the number obtained by dividing the sum of the squares of the individual fiber lengths by the sum of the individual fiber lengths, as described, for example, in ISO 16065-1:2014 Pulps - Determination of fibre length by automated optical analysis - Part 1: Polarized light method, or ISO 16065-2:2014 Pulps - Determination of fibre length by automated optical analysis - Part 2: Unpolarized light method.

[0043] In an embodiment, the natural fiber has a length-weighted average fiber length of up to 10 mm, preferably up to 8 mm, more preferably up to 6 mm, and most preferably up to 5 mm. In a specific embodiment, the natural fiber has a length-weighted average fiber length selected within the range of intervals from 1 mm to 10 mm, preferably within the range of intervals from 1 mm to 8 mm, more preferably within the range of intervals from 1 mm to 6 mm, and most preferably within the range of intervals from 1 mm to 5 mm.

[0044] It is also possible to include a small amount of longer fibers having a length-weighted average fiber length of 10 mm or longer.

[0045] In an embodiment, the airlaid blank 10 contains natural fibers at a concentration of at least 70% by weight of the airlaid blank 10 and a polymer binder at a concentration selected within the range of intervals from 2.5 to 30% by weight of the airlaid blank 10.

[0046] In a preferred embodiment, the airlaid blank 10 contains natural fibers at a concentration of at least 72.5%, more preferably at least 75%, for example at least 77.5%, at least 80%, at least 82.5%, at least 85% by weight of the airlaid blank 10. In some applications, even higher concentrations of natural fibers such as at least 87.5%, or at least 90%, at least 92.5%, at least 95%, or at least 97.5% by weight of the airlaid blank 10 may be used.

[0047] In some embodiments, the airlaid blank 10 contains a polymer binder at a concentration selected within the range of 5 to 30% by weight, preferably within the range of 10 to 25% by weight, for example within the range of 12.5 to 22.5% by weight, or within the range of 15 to 20% by weight, or within the range of 17.5 to 22.5% by weight of the airlaid blank 10.

[0048] In other embodiments, the airlaid blank 10 contains a polymer binder at a concentration selected within the range of 2.5 to 15% by weight, preferably within the range of 2.5 to 12.5% by weight, more preferably within the range of 2.5 to 10% by weight, for example within the range of 2.5 to 7.5% by weight of the airlaid blank 10.

[0049] In an embodiment, the natural fiber is or includes a lignocellulosic fiber. In an embodiment, the natural fiber is or includes cellulose and / or lignocellulosic fiber. Thus, in an embodiment, the natural fiber takes the form of cellulose such as cellulose and / or lignocellulose, i.e., contains a mixture of cellulose and lignin. The natural fiber may contain lignin such as taking the form of lignocellulose. The natural fiber may further contain hemicellulose. In a particular embodiment, the natural fiber is a cellulose and / or lignocellulosic pulp fiber produced by chemical, mechanical, and / or chemo-mechanical pulping of softwood and / or hardwood. For example, the cellulose and / or lignocellulosic pulp fiber takes a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fiber for which medium-density fiberboard is intended (MDF-fiber), chemi-thermomechanical pulp (CTMP), high-temperature chemi-thermomechanical pulp (HTCTMP), and combinations thereof.

[0050] Natural fibers such as cellulose and / or lignocellulosic pulp fibers may or may not be bleached.

[0051] Natural fibers can also be produced by other pulping methods and / or from other cellulose or lignocellulose raw materials such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, wheat straw, or rice husk. It is also possible to use natural fibers that are mixtures of fibers from various raw materials, such as a mixture of wood and any of the above materials.

[0052] The airlaid blank 10 may contain a small amount of synthetic material or fibers mixed with natural fibers. Such synthetic materials or fibers that can be mixed with natural fibers include, for example, glass or mineral wool, and / or carbon fibers. Any such synthetic material or fiber may be added in an amount of 10% (w / w) or less, preferably 8% (w / w) or less, for example 6% (w / w) or less, or preferably 4% (w / w) or less of the airlaid blank 10.

[0053] A polymer binder is included in the airlaid blank 10 to bind the airlaid blank 10 together and preserve its shape and structure during use, handling, and storage. In another embodiment, the polymer binder may also assist in constructing the foam-like structure of the airlaid blank 10. The polymer binder is mixed with the natural fibers during the airlaid process that forms the fiber mixture in such embodiments. The polymer binder may be added in powder form, but more frequently is added in the form of fibers mixed with the natural fibers in the airlaid process. Alternatively, or additionally, the polymer binder may be added as a solution, emulsion, or dispersion during the airlaid process, and to the interior and surface of the airlaid blank 10, as further described below in connection with FIG. 15.

[0054] In certain embodiments, the polymer binder is selected from the group consisting of polymer powders, polymer fibers, and combinations thereof.

[0055] The polymer binder can be a natural or synthetic polymer binder, or a mixture of natural polymer binders, synthetic polymer binders, or natural and synthetic polymer binders, but is preferably a thermoplastic polymer binder.

[0056] In an embodiment, the polymer binder is made from i) polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), such as styrene-butadiene rubber (SBR), or styrene acrylate copolymer, polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinyl pyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), polyvinyl acetate (PVAc), polyurethane (PU), copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0057] Thus, in an embodiment, the polymer binder is made of a material selected from the group described above. In another embodiment, the polymer binder is made of a material selected from the group described above and one or more additives.

[0058] In an embodiment, the polymer binder is a thermoplastic polymer binder, preferably selected from the group consisting of thermoplastic polymer powders, thermoplastic polymer fibers, and combinations thereof.

[0059] In an embodiment, the polymer binder is and / or comprises one-component and / or two-component thermoplastic polymer fibers, for example consisting of these. Two-component thermoplastic polymer fibers, also known as bicomponent fibers, comprise a first polymer, copolymer, and / or polymer mixture and a second different polymer, copolymer, and / or polymer mixture. Most frequently, the two-component thermoplastic polymer fibers comprise a core made of a first polymer, copolymer, and / or polymer mixture and a sheath made of a second polymer, copolymer, and / or polymer mixture, although other combinations of two or more polymers, copolymers, and / or polymer mixtures are possible.

[0060] In certain embodiments, the thermoplastic polymer binder is a one-component thermoplastic polymer fiber made of i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives, or includes or consists of, for example, these. In another particular embodiment, the thermoplastic polymer binder has a first material such as a core made of i) PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof and ii) optionally one or more additives, and a second material such as a sheath made of i) a second material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof, typically a different material, and ii) optionally one or more additives, and is a two-component thermoplastic polymer fiber that includes or consists of, for example, these. In a further embodiment, the thermoplastic polymer binder is a combination or mixture of a one-component thermoplastic polymer fiber made of i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof and ii) optionally one or more additives, and a two-component thermoplastic polymer fiber having a core and / or sheath and the like made of i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof and ii) optionally one or more additives, or includes or consists of, for example, these.

[0061] The thermoplastic polymer binder can be made of a single type of thermoplastic polymer fiber, i.e., it can be made of the same material in the case of a single-component thermoplastic polymer fiber, or it can be made of the same material in the case of a two-component thermoplastic polymer fiber. However, it is also possible to use a thermoplastic polymer binder made of one or a number of, i.e., two or more different single-component thermoplastic polymer fibers made of various materials, and / or one or a number of different two-component thermoplastic polymer fibers made of various materials.

[0062] The advantage of using two-component thermoplastic polymer fibers is that they can have a core with a higher melting point that retains its fibrous form during the binding operation, while the sheath melts and becomes viscous. The intact core will support the three-dimensional structure of the airlaid blank 10 and thus promote porosity, while the melted or viscous sheath will adhere to the natural fibers and preserve the strength of the airlaid blank 10.

[0063] In an embodiment, the polymer binder is a polymer powder, preferably a thermoplastic polymer powder made of i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, PVAc, PU, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0064] Also, as described above, it is possible to use a thermoplastic polymer binder that is a combination of thermoplastic polymer fibers and thermoplastic polymer powder.

[0065] The airlaid blanket 10 may include one or more additives in addition to natural fibers and a polymer binder. The one or more additives can be added to the polymer binder and / or can be added when producing the polymer binder. Alternatively, or additionally, the one or more additives can be added to the natural fibers. Alternatively, or additionally, the one or more additives can be added to the natural fibers and the polymer binder, such as during or before the airlaid process.

[0066] Exemplary but non-limiting examples of such additives include conductive or semiconductive fillers, coupling agents, flame retardants, dyes, impact modifiers, and the like.

[0067] In certain embodiments, the polymer binder is a natural polymer selected from the group consisting of starch, agar, guar gum, locust bean gum, carrageenan, and cellulose, such as fibrils, microfibrils, or nanofibrillated cellulose.

[0068] In embodiments, the polymer binder may take the form of an aqueous solution, emulsion, suspension, or dispersion of the polymer binder.

[0069] Another aspect of the present invention relates to a method for producing an airlaid blank 10. Refer to FIGS. 8 and 10 to 14 showing embodiments of an apparatus 100 for producing an airlaid blank 10. The method includes, in step S1, introducing natural fibers and a polymer binder, and / or a mixture of natural fibers and a polymer binder, into at least one inlet 111 of a forming head 110. The method also includes, in step S2, transporting the natural fibers and the polymer binder, and / or the mixture, to an outlet 113 of the forming head 110. The method further includes, in step S3, capturing the natural fibers and the polymer binder, and / or the mixture, as an unbonded airlaid web 30 on a collector 120 arranged and configured to be connected to the outlet 113 of the forming head 110. The method further includes, in step S4, applying a gas pulse to the unbonded airlaid web 30 to form a cushion portion 34 including a plurality of cavities 33 extending within the unbonded airlaid web 30. The cushion portion 34 is surrounded by a frame portion 35 of the unbonded airlaid web 30, and this frame portion 35 is lacking in any cavities extending within the unbonded airlaid web 30. The method further includes, in step S5, heat-treating the unbonded airlaid web 30 to at least partially melt the polymer binder and form an airlaid blank 10.

[0070] In an embodiment, step S5 includes heat-treating the unbonded airlaid web 30 to at least partially melt the polymer binder and form an airlaid blank 10 including a cushion portion 14 including a plurality of cavities 13 extending within the airlaid blank 10 and a frame portion 15 lacking in any cavities extending within the airlaid blank 10. The frame portion 15 surrounds the cushion portion 14.

[0071] The transport or passage of the natural fibers and the polymer binder, and / or the mixture, in the forming head 110 in step S2 contributes to separating the individual fibers, thereby facilitating a porous unbonded airlaid web 30 on the collector 120.

[0072] The apparatus 100 used to generate the airlaid web 10 includes a forming head 110, also referred to in the art as a forming chamber. Natural fibers and a polymer binder are input or introduced into the forming head 110 at one or more inlets 111 as one or more individual input streams and / or as one or more mixed input streams. For example, the forming head 110 may include one flow inlet for natural fibers and one flow inlet for the polymer binder, connected to its upper end 112 or with further dropping within the forming head 110. In another embodiment, the forming head 110 includes a number of flow inlets for natural fibers and one flow inlet for the polymer binder, one flow inlet for natural fibers and a number of flow inlets for the polymer binder, or a number of flow inlets for natural fibers and a number of flow inlets for the polymer binder. In these exemplary embodiments, the natural fibers and the polymer binder are mixed and blended during transport or passage through the forming head 110, and finally the airlaid web 10 is formed on the collector 120.

[0073] Instead of or complementary to having one or more input streams for natural fibers and / or one or more input streams for the polymer binder, a pre-formed mixture of natural fibers and the polymer binder may be introduced into the forming head 110 at one or a number of inlets 111.

[0074] The forming head 110 may include equipment arranged and configured within the forming head 110 to facilitate the separation and mixing of the natural fibers and the polymer binder and / or their mixture during transport or passage through the forming head 110. Such equipment may include, for example, rolls with interlocking spikes, one or more drums, such as a slotted drum, and / or one or more filters.

[0075] In an embodiment, the collector 120 is an air-permeable collector 120. In such an embodiment, step S3 includes capturing natural fibers and a polymer binder and / or a mixture thereof onto the air-permeable collector 120 to which a vacuum is applied on the surface.

[0076] The natural fibers and the polymer binder and / or their mixture are transported by air to the forming head 110 and enter the forming head 110 at at least one inlet 111 configured to be connected to the upper end 112 of the forming head 110, or further descend within the forming head 110. The natural fibers and the polymer binder and / or their mixture are then transported within the forming head 110 to an outlet 113 configured to be connected to the lower end 114 of the forming head 110. The natural fibers and the polymer binder and / or the mixture are then captured onto the air-permeable collector 120 at least partially by a vacuum applied on the air-permeable collector 120 connected to the outlet 113 of the forming head 110, i.e., by air suction or reduced pressure.

[0077] Thus, the vacuum applied on the air-permeable collector 120 draws the natural fibers and the polymer binder and / or their mixture down onto the air-permeable collector 120.

[0078] The collector 120 is preferably air-permeable such that a vacuum can be applied to its surface to draw natural fibers and the polymer binder onto the air-permeable collector 120. For example, the air-permeable collector 120 can include a plurality of openings, through-holes, or channels that allow air to be suctioned or drawn through the air-permeable collector 120. By way of illustrative but non-limiting example, the air-permeable collector 120 can be a mesh collector 120 that includes a plurality of fine through-holes. However, any such openings are preferably small enough so that the natural fibers and the polymer binder do not pass through the air-permeable collector 120. Thus, the natural fibers and the thermoplastic polymer binder are instead deposited as a mixture onto the air-permeable collector 120 in the form of the unbonded airlaid web 30.

[0079] The collector 120 can be a plate, disk, mesh, or similar planar collector 120 that is connected and disposed at the outlet 113 of the forming head 110. Once the unbonded airlaid web 30 is formed on the collector 120, the collector 120, together with the unbonded airlaid web 30 placed on its surface, can be transferred from the forming head 110 and subjected to gas pulses in the nozzle system 130.

[0080] In another embodiment enabling continuous production of the airlaid blank 10, the collector 120 can take the form of a belt or wire collector 120, preferably an air-permeable belt or wire collector 120, and can take the form of a collector that runs between the drive rollers 122, 124 shown in FIG. 14. Such an air-permeable belt or wire collector 120 is also referred to as an air-permeable belt or wire conveyor 120. In such an embodiment, step S4 includes applying gas pulses to the unbonded airlaid web 30 placed on the belt collector 120 downstream of the forming head 110.

[0081] Downstream is related to the moving direction of the belt collector 120 from the drive roller 122 towards the drive roller 124. Thus, the gas pulse is applied onto the non-bonded airlaid web 30 in step S4 when the non-bonded airlaid web 30 exits the forming head 110.

[0082] In an embodiment, the gas pulse is applied in step S4 by selectively applying the gas pulse using a number of fixed gas nozzles 132, such as those seen in one or more rows in FIGS. 11 and 13, arranged downstream of the forming head 110. Alternatively, or additionally, the gas pulse can be selectively applied in step S4 using at least one movable gas nozzle 132, which is arranged downstream of the forming head 110 and is selectively movable relative to the non-bonded airlaid web 30 placed on the belt collector 120.

[0083] Figures 11 and 13 schematically show a nozzle system 130 that includes a number of gas nozzles 132 distributed along the width of the non-bonded airlaid web 30 (Figure 11) or along at least a portion of the width of the non-bonded airlaid web 30 (Figure 13). These gas nozzles 132 can then be used to selectively apply gas pulses in step S4 to form cavities 33 in the non-bonded airlaid web 30. As used herein, selectively applying means that, in embodiments, the gas nozzles 132 are controlled by a controller 140 such as that seen in Figures 10 and 12, such that gas pulses are applied at selected time intervals or periods as the non-bonded airlaid web 30 passes over the nozzle system 130 on the belt collector 120. In such embodiments, the gas nozzles 132 may extend over most of the width of the non-bonded airlaid web 30 as shown in Figure 10, but may be prevented from extending to the ends of the non-bonded airlaid web 30 to prevent the formation of cavities 33 at the periphery of the non-bonded airlaid web 30 that form part of the frame portion 35. In another embodiment, the gas nozzles 132 are provided as a number of groups as shown in Figures 12 and 13, with gaps between adjacent groups of gas nozzles 132. Such an approach allows for the generation of a cushion portion 34 alongside the intermediate frame portion 35 of the non-bonded airlaid web 30. All of the gas nozzles 132 can then be operated by the controller 140 to apply gas pulses simultaneously.

[0084] In another embodiment, the controller 140 can selectively activate the gas nozzles 132 to apply gas pulses such that some of the gas nozzles 132 of the nozzle system 130 apply gas pulses simultaneously. This allows for the generation of a generally regular pattern, such as a matrix or grid of cavities 33, in the non-bonded airlaid web 30. This embodiment also allows for control of the width of the frame portion 35 of the non-bonded airlaid web 30.

[0085] In FIGS. 10 to 13, a row of gas nozzles 132 is arranged on the belt collector 120. However, the embodiment is not limited thereto. In clear contrast, a number of such rows of gas nozzles 132 could be arranged with respect to the collector 120. In such a case, the gas nozzles 132 could be arranged in a matrix or grid. It is also possible to have a number of rows of gas nozzles 132 arranged relative to each other to form the pattern of cavities 33 as shown in FIG. 3B or 3C.

[0086] Instead of, or complementary to, having the nozzle system 130 with the fixed gas nozzles 132, one or more movable gas nozzles 132 can be arranged downstream of the forming head 110. In such a case, the controller 140 can control at least one movable gas nozzle 132 to move relative to the unbonded airlaid web 30 and to selectively apply gas pulses onto the unbonded airlaid web 30. In such a case, at least one movable gas nozzle 132 is preferably movable at least along the width of the unbonded airlaid web 30.

[0087] The heat treatment applied in step S5 performs the bonding operation, such as when the unbonded airlaid web 30 is introduced into the bonding furnace path 150 as seen in FIG. 14 and heat circulates through the unbonded airlaid web 30 in the form of heated air to melt or partially melt the polymer binder. Thereby the polymer binder becomes sticky and adheres to the natural fibers, thus holding the fiber materials together and thereby obtaining the airlaid blank 10.

[0088] The heat treatment of step S5 causes at least partial melting of the polymer binder, thereby becoming sticky and adhering to the natural fibers of the non-bonded airlaid web 30. As a result, the natural fibers and the polymer binder are held together to form the airlaid blank 10. This heat treatment in step S5 preserves the cavities 33 formed in step S4 by applying gas pulses. Thus, the airlaid blank 10 includes a cushion portion 14 that includes a plurality of cavities 13 surrounded or encircled by the frame portion 15.

[0089] The bonding operation may include densification to create a greater number of bonding points within the fiber structure, and thus create a stronger and denser airlaid blank 10, and / or may be accompanied by such densification. Such densification operations can be applied either before the airlaid blank 10 is cooled after the bonding furnace 150 or after new heating in a calendering device or the like. It is also possible to perform densification operations within the bonding furnace 150, such as a combination of heating and densification operations. In the latter case, step S5 includes heat-treating the non-bonded airlaid web 30 to at least partially melt the polymer binder and, at the same time, applying pressure to the non-bonded airlaid web 30 to form the airlaid blank 10. Densification can include various types of operations including, but not limited to, calendering and / or pressing operations. FIG. 5 schematically shows a cross-sectional view of the airlaid blank 10 after heat treatment and densification of the non-bonded airlaid web 30 shown in FIG. 4. As shown in FIG. 5, the plurality of cavities 13 are preserved in the airlaid blank 10 after the heat treatment and densification operations.

[0090] In the above-described embodiment, the airlaid blank 10 is produced by introducing both natural fibers and a polymer binder into the forming head 110. FIG. 9 is a flowchart showing another embodiment of a method for producing the airlaid blank 10, and reference is also made to FIG. 15. The method includes, in step S10, introducing natural fibers into at least one inlet 111 of the forming head 110. The method includes, in step S11, transporting the natural fibers to the outlet 113 of the forming head 110, and in step S12, capturing the natural fibers as a web 40 of natural fibers on a collector 120 arranged and configured to be connected to the outlet 113 of the forming head 110. The method further includes, in step S13, applying a gas pulse to the web 40 of natural fibers on the collector 120 to form a cushion portion 44 including a plurality of cavities 43 extending within the web 40 of natural fibers. The cushion portion 44 is surrounded by a frame portion 45 of the web 40 of natural fibers, and the frame portion 45 is lacking in any cavity 43 extending within the web 40 of natural fibers. In this embodiment, the method also includes, in step S14, applying a polymer binder onto the natural fibers. The method further includes, in step S15, heat-treating the web 40 of natural fibers and the polymer binder to form the airlaid blank 10.

[0091] In an embodiment, step S15 includes heat-treating the web 40 of natural fibers and the polymer binder to form an airlaid blank 10 including a cushion portion 14 including a plurality of cavities 13 extending within the airlaid blank 10 and a frame portion 15 lacking in any cavity extending within the airlaid blank 10. The frame portion 15 surrounds the cushion portion 14.

[0092] In this embodiment of the method, it is different from what was discussed above in relation to FIG. 8 in that the polymer binder is not introduced into the forming head 110 in step S10. Clearly in contrast, one or a plurality of flows of natural fibers and / or mixtures thereof are introduced in step S10 through one or a plurality of inlets 111 of the forming head 110. The natural fibers are transported or passed through the forming head 110 in step S11 and then captured on the collector as a web 40 of natural fibers in step S12. Then a gas pulse is applied to this web 40 of natural fibers in step S13 in a manner similar to step S4 of FIG. 8 to form cavities 43 in the web 40 of natural fibers. Then in this embodiment, the polymer binder is applied to the web 40 of natural fibers in step S14 before exposing the web 40 of natural fibers and the polymer binder to the heat of the downstream binding furnace 150 in step S15.

[0093] Thus in this embodiment, the apparatus 100 includes a device 160 that is downstream of the nozzle system 130 but upstream of the binding furnace 150 for applying the polymer binder. This device 160 may apply the polymer binder to the interior and surface of the web 40 of natural fibers in step S14, for example, as a solution, emulsion, suspension, or dispersion. For example, the polymer binder may be sprayed onto the web 40 of natural fibers in step S14. In an exemplary embodiment, the polymer binder takes the form of an aqueous (water-based) solution, emulsion, suspension, or dispersion of at least one polymer binder in the form of one or more synthetic polymers and / or one or more natural polymers. In such a case, the polymer binder can be selected from among the polymer binder materials described so far.

[0094] The following step S15 in FIG. 9 is performed in the same manner as step S5 in FIG. 8. However, depending on the material of the polymer binder applied in step S14, the heat treatment applied in step S15 does not necessarily at least partially melt the polymer binder in the bonding furnace 150. When the polymer binder takes the form of a water-based solution, emulsion, suspension, or dispersion, the water can be completely dried to form the airlaid blank 10. Such a drying operation also applies to the use of solvents other than water for the polymer binder.

[0095] The various embodiments of steps S1 to S5 described above can be applied mutatis mutandis to the method shown in FIG. 9, except that no polymer binder is introduced in step S10.

[0096] The two described embodiments shown in FIGS. 8 and 9 may be combined. Thus, the polymer binder may be introduced into the above-described forming head associated with step S1 of FIG. 8, and then an additional polymer binder may be applied to the unbonded airlaid web 30 as described in step S14 of FIG. 9 to, for example, strengthen the surface of the resulting airlaid blank 10.

[0097] The methods described above, as well as those shown in the flowcharts of FIGS. 8 and 9, are suitable for producing the airlaid blank 10 according to the present invention, as shown in FIGS. 2, 3, and 5, etc. Thus, the airlaid blank 10 can be obtained or is obtainable by the methods described above and shown in the flowcharts of FIGS. 8 or 9.

[0098] The methods disclosed in FIGS. 8 and 9 may also include additional steps S6 or S16 that involve cutting the airlaid blank 10 into cushion inserts 60A, 60B. In a general embodiment, the airlaid blank 10 includes a number of cushion portions 14 surrounded by respective frame portions 15. In such a case, the airlaid blank 10 is preferably cut in step S6 or S16 to form a number of cushion inserts 60A, 60B.

[0099] The cutting operation in step S6 or S16 can be performed using any suitable cutter or cutting means. Exemplary, but non-limiting, embodiments of such cutting means include saws, punches, knives, and the like.

[0100] The present invention also relates to cushion inserts 60A, 60B made of an airlaid blank 10 comprising natural fibers and a polymer binder, see FIGS. 6 and 7. The cushion inserts 60A, 60B include a cushion portion 64 and a frame portion 65. The cushion portion 64 includes a plurality of cavities 63 extending therein. The frame portion 65 is free of any cavities extending within the cushion inserts 60A, 60B. The frame portion 65 surrounds the cushion portion 64.

[0101] The cushion inserts 60A, 60B are produced from the airlaid blank 10 of the present invention, such as by cutting the airlaid blank 10 into a number of cushion inserts 60A, 60B in step S6 or S16 in FIGS. 8 and 9. The cushion inserts 60A, 60B are then cut to have an overall size and shape that conforms to the packaging box 50 shown in FIGS. 6 and 7.

[0102] The various embodiments described above with respect to the airlaid blank 10 also apply to the cushion inserts 60A, 60B produced from the airlaid blank 10.

[0103] In an embodiment, the plurality of cavities 63 extend from the first major surface 61 of the cushion inserts 60A, 60B through a portion of the thickness of the cushion inserts 60A, 60B, but not through the entire thickness of the cushion inserts 60A, 60B, and toward the second opposite major surface 62 of the cushion inserts 60A, 60B. In an embodiment, the cavity 63, or at least a majority of the plurality of cavities 63, extends downward from the major surface 61 by a certain percentage of the thickness of the cushion inserts 60A, 60B. In a particular embodiment, this percentage is within a range of intervals from 25% to 90%, preferably within a range of intervals from 35% to 90%, more preferably within a range of intervals from 50% to 90%, for example within a range of intervals from 60% to 80%. In an exemplary but non-limiting example, the cavity 63 or at least a majority thereof extends downward from the first major surface 61 by two-thirds to three-fourths of the thickness of the cushion inserts 60A, 60B.

[0104] In an embodiment, the distance between adjacent cavities 63 in the cushion portion 64 is less than twice the maximum side length or diameter of the adjacent cavities 63. In a particular embodiment, the distance is equal to or less than 1.75 times or 1.5 times the maximum side length or diameter of the adjacent cavities 63.

[0105] In another embodiment, the distance between adjacent cavities 63 in the cushion portion 64 is less than twice the average side length or average diameter of the plurality of cavities 63, or less than twice the maximum side length or diameter in the case of cavities 63 of various sizes. In a particular embodiment, the distance is equal to or less than 1.75 times or 1.5 times the average side length or average diameter of the plurality of cavities 63, or equal to or less than 1.75 times or 1.5 times the maximum side length or diameter in the case of cavities 63 of various sizes.

[0106] As discussed above, the distance is defined as the center-to-center distance of the cavities 63 parallel to the first and second major surfaces 61, 62 of the cushion inserts 60A, 60B.

[0107] In fact, it may be possible to have an even shorter distance between adjacent cavities 63 of the cushion portion 64. For example, the cavities 63 may in fact at least partially overlap. In such an embodiment, each cavity 63 of at least a portion of the plurality of cavities 63 overlaps with another cavity 63 of at least that portion of the plurality of cavities 63.

[0108] In an embodiment, the width of the frame portion 65 is preferably at least 10 mm, preferably at least 15 mm, more preferably at least 20 mm, for example at least 25 mm, at least 30 mm, at least 35 mm, or at least 40 mm. The width of the frame portion 65 as used herein corresponds to the distance from the edge of the cushion inserts 60A, 60B to the cushion portion 64.

[0109] In an embodiment, the width of the frame portion 65 of the cushion inserts 60A, 60B corresponds to a percentage of the width of the cushion inserts 60A, 60B, and this percentage is selected within a range of intervals from 2.5% to 30%, preferably within a range of intervals from 2.5% to 25%, more preferably within a range of intervals from 5% to 25%, for example within a range of intervals from 7.5% to 25%, within a range of intervals from 10% to 25%, or within a range of intervals from 10% to 20%.

[0110] In an embodiment, the cushion portion 64 includes a bottom 67 and a plurality of protruding structures 66 extending from the bottom 67.

[0111] The cushion portions 14 of the air raid blanket 10 and, accordingly, the cushion portions 64 of the cushion inserts 60A, 60B may have various shapes with respect to the distribution of the cavities 13, 63 in the cushion portions 14, 64. For example, the cushion portions 14, 64 may be square, rectangular, circular, oval, or indeed any other shape. The shape and / or size of the cushion portions 14, 64 may, in an embodiment, depend at least in part on the shape and / or size of the product or article 70 that is to be packaged in the packaging box 50 and protected by the cushion inserts 60A, 60B. However, the advantage of the present invention is that the cushion inserts 60A, 60B can be used to protect various products and articles 70 from shock and impact regardless of whether the cavities 13, 63 in the cushion portions 14, 64 form a collective shape such as a square shape or a circular shape, for example.

[0112] The outer dimensions and shape of the cushion inserts 60A, 60B are preferably selected based on the dimensions and shape of the packaging box 50 into which the cushion inserts 60A, 60B are to be inserted as shown in FIGS. 6 and 7.

[0113] Accordingly, an aspect of the present invention relates to a packaging assembly including a packaging box 50 and a first cushion insert 60A. The packaging box 50 has a bottom 53 and at least one side wall 51, 52 attached to the bottom 53. The bottom 53 and the at least one side wall define a packaging volume 54. The first cushion insert 60A according to the present invention is arranged and configured on the bottom 53 of the packaging box 50 with a plurality of cavities 63 kicked in a direction opposite to the bottom 53 of the packaging box 50 as shown in FIG. 6.

[0114] In an embodiment, the packaging assembly also includes a second cushion insert 60B according to the present invention; see FIG. 7. In such an embodiment, the second cushion insert 60B is arranged and configured in the packaging volume 54 with a plurality of cavities 63 facing the first cushion insert 60A.

[0115] Any article or product to be packaged in the packaging assembly is positioned between the first and second cushion inserts 60A, 60B as shown in FIG. 7. The cavities 63 of the two cushion inserts 60A, 60B then face each other, and an article or product 70 is disposed therebetween. The cavities 63 present in the cushion portions 64 of the two cushion inserts 60A, 60B deform these portions of the cushion inserts 60A, 60B so as to conform to and accompany the article or product 70 and to the particular shape and / or size of the article or product 70. The surrounding frame portion 65 is lacking in the cavity, thereby having a harder and higher structural integrity compared to the cushion portion 64. This means that the frame portion 65 thereby provides support to the cushion inserts 60A, 60B but also provides protection against impacts and influences from the outside of at least one of the side walls 51, 52 of the packaging box 50.

[0116] The packaging assembly can be used to package a single article or product 70 or a number of articles or products 70 in the packaging box 50.

[0117] The packaging box 50, also referred to herein as a container, can include a single side wall attached to the bottom 53, for example when the packaging box 50 has a cylindrical shape with a circular or oval bottom 53. The side wall is then a curved side wall surrounding the circular or oval bottom 53. In such an embodiment, the packaging box 50 is a cylindrical packaging box 50. In other embodiments, the packaging box 50 can take the form of a cube or a rectangular parallelepiped. In such an embodiment, the packaging box 50 includes four side walls 51, 52 attached to the bottom 53.

[0118] The packaging box 50 can be made of various materials including, but not limited to, paper-based materials such as cardboard materials, also called container board materials, carton cardboard materials, or corrugated paper materials. In a particular embodiment, the packaging box 50 is a cardboard box or a corrugated box. Another material for the packaging box 50 can be wood.

[0119] The above-described embodiments should be understood as some exemplary examples of the present invention. It will be understood by those skilled in the art that various modifications, combinations, and changes may be made to the embodiments without departing from the scope of the present invention. In particular, the solutions of different parts in different embodiments can be combined with other configurations if technically possible.

Claims

1. Natural fibers, Polymer binder and An airlaid blank (10) including, A cushion portion (14) including a plurality of cavities (13) extending within the airlaid blank (10), The frame portion (15) surrounding the cushion portion (14) is missing from any cavity extending within the airlaid blank (10) Air raid blank (10) including.

2. The airlaid blank according to claim 1, wherein the plurality of cavities (13) extend from the first main surface (11) of the airlaid blank (10) toward the second opposite main surface (12) of the airlaid blank (10) through a portion of the thickness of the airlaid blank (10), but do not extend through the entire thickness of the airlaid blank (10).

3. The airlaid blank according to claim 1, wherein the distance between adjacent cavities (13) of the cushion portion (14) is less than twice the maximum side length or diameter of the adjacent cavities (13).

4. The airlaid blank according to claim 1, wherein the distance between adjacent cavities (13) of the cushion portion (14) is less than twice the average side length or average diameter of the plurality of cavities (13).

5. The airlaid blank according to claim 1, wherein at least a portion of each of the plurality of cavities (13) overlaps with at least another cavity (13) of the plurality of cavities (13) in that portion.

6. The cushion portion (14) The bottom portion (17) containing the natural fibers and the polymer binder, A plurality of protruding structures (16) extending from the bottom (17) include the natural fibers and the polymer binder. The airlaid blank according to claim 1, further comprising:

7. The airlaid blank according to claim 1, wherein the average density of the airlaid material in the frame portion (15) is higher than the average density of the airlaid material in the cushion portion (14).

8. The airlaid blank according to claim 1, wherein the natural fibers have a length-weighted average fiber length up to 10 mm.

9. The airlaid blank (10) At least 70% by weight of the aforementioned natural fibers, 2.5 to a maximum of 30% by weight of the polymer binder and An airlaid blank according to claim 1, including the following:

10. The airlaid blank according to claim 1, wherein the natural fibers include wood fibers.

11. The airlaid blank according to claim 10, wherein the natural fibers are cellulose and / or lignocellulose pulp fibers in a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fibers intended for medium-density fiberboard (MDF-fibers), chemical thermomechanical pulp (CTMP), high-temperature chemical thermomechanical pulp (HTCTMP), and combinations thereof.

12. The airlaid blank according to claim 1, wherein the polymer binder is selected from the group consisting of polymer powder, polymer fibers, and combinations thereof, or the polymer binder is selected from the group consisting of thermoplastic polymer powder, thermoplastic polymer fibers, and combinations thereof.

13. The airlaid blank according to claim 12, wherein the thermoplastic polymer fiber is selected from the group consisting of one-component thermoplastic polymer fiber, two-component thermoplastic polymer fiber, and mixtures thereof.

14. The airlaid blank according to claim 1, wherein the polymer binder is made of i) a material selected from the group consisting of polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene adipate terephthalate (PBAT), polybutylene polysuccinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), polyvinyl acetate (PVAc), polyurethane (PU), copolymers thereof, and mixtures thereof, and ii) one or more additives of any choice.

15. Introducing natural fibers and a polymer binder and / or a mixture of the natural fibers and the polymer binder into at least one inlet (111) of the forming head (110) (S1), (S2) Transporting the natural fibers and the polymer binder and / or the mixture to the outlet (113) of the forming head (110), The natural fibers and the polymer binder and / or the mixture are captured as an unbound airlaid web (30) on a collector (120) configured to be connected to the outlet (113) of the forming head (110) (S3), Applying a gas pulse to the unbonded airlaid web (30) (S4) in order to form a cushion portion (34) including a plurality of cavities (33) extending within the unbonded airlaid web (30), wherein the cushion portion (34) is surrounded by a frame portion (35) of the unbonded airlaid web (30), and the frame portion (35) is not present in any cavities extending within the unbonded airlaid web (30), The unbonded airlaid web (30) is heat-treated to at least partially melt the polymer binder and form an airlaid blank (10) (S5) A method for generating an airlaid blank (10) including the following.

16. The method according to claim 15, wherein heat treatment (S5) includes heat treatment (S5) of the unbonded airlaid web (30) to at least partially melt the polymer binder and form an airlaid blank (10) which includes a cushion portion (14) having a plurality of cavities (13) extending into the airlaid blank (10) and a frame portion (15) that is not in any of the cavities extending into the airlaid blank (10), the frame portion (15) surrounding the cushion portion (14).

17. Introducing natural fibers into at least one inlet (111) of the forming head (110) (S10), Transporting the natural fibers to the outlet (113) of the forming head (110) (S11), The natural fibers are captured as a web of natural fibers (40) on a collector (120) which is configured to be connected to the outlet (113) of the forming head (110) (S12), Applying a gas pulse to the natural fiber web (40) on the collector (120) (S13) in order to form a cushion portion (44) including a plurality of cavities (43) extending within the natural fiber web (40), wherein the cushion portion (44) is surrounded by a frame portion (45) of the natural fiber web (40), and the frame portion (45) is not present in any cavities (43) extending within the natural fiber web (40), Applying a polymer binder to the natural fibers (S14), To form the airlaid blank (10), the natural fiber web (40) and the polymer binder are heat-treated (S15) A method for generating an airlaid blank (10) including the following.

18. The method according to claim 17, wherein heat treatment (S15) comprises heat treatment (S15) of the natural fiber web (40) and the polymer binder to form an airlaid blank (10) comprising a cushion portion (14) having a plurality of cavities (13) extending within the airlaid blank (10) and a frame portion (15) lacking any cavities extending within the airlaid blank (10), the frame portion (15) surrounding the cushion portion (14).

19. The method according to claim 15, wherein the method is for producing an airlaid blank (10) according to any one of claims 1 to 14.

20. A cushion insert (60A, 60B) made of an airlaid blank (10) containing natural fibers and a polymer binder, A cushion portion (64) including a plurality of cavities (63) extending within the cushion insert (60A, 60B), and The frame portion (65) surrounding the cushion portion (64) is missing from any cavity extending within the cushion insert (60A, 60B) Cushion inserts (60A, 60B), including those included.

21. The cushion insert according to claim 20, wherein the plurality of cavities (63) extend from the first main surface (61) of the cushion insert (60A, 60B) toward the second opposite main surface (62) of the cushion insert (60A, 60B) through a portion of the thickness of the cushion insert (60A, 60B), but do not extend through the entire thickness of the cushion insert (60A, 60B).

22. The cushion insert according to claim 20, wherein the distance between adjacent cavities (63) of the cushion portion (64) is less than twice the maximum side length or diameter of the adjacent cavities (63).

23. The cushion insert according to claim 20, wherein the distance between adjacent cavities (63) of the cushion portion (64) is less than twice the average side length or average diameter of the plurality of cavities (63).

24. The cushion insert according to claim 20, wherein at least one portion of the plurality of cavities (63) overlaps with another cavity (63) of at least that portion of the plurality of cavities (63).

25. The cushion portion (64) is further, Bottom (67), and Multiple protruding structures (66) extending from the bottom portion (67) The cushion insert according to claim 20, including the following:

26. A cushion insert according to claim 20, made from an airlaid blank (10) according to any one of claims 1 to 14.

27. A packaging box (50) having a bottom (53) and at least one side wall (51, 52) attached to the bottom (53), wherein the bottom (53) and the at least one side wall define a packaging volume (54), A first cushion insert (60A) according to any one of claims 20 to 25, wherein a plurality of cavities (63) are oriented in the opposite direction to the bottom of the packaging box (50) and are arranged on the bottom (53) of the packaging box (50), and Packaging assembly, including.

28. The first and second cushion inserts (60A, 60B) according to any one of claims 20 to 25, A packaging box (50) having a bottom (53) and at least one side wall (51, 52) attached to the bottom (53), wherein the bottom (53) and the at least one side wall define a packaging volume (54), The first cushion insert (60A) is configured such that a plurality of cavities (63) are oriented away from the bottom of the packaging box (50) and positioned on the bottom (53) of the packaging box (50). The packaging assembly is configured such that the second cushion insert (60B) has a plurality of cavities (63) arranged in the packaging volume (54) facing the first cushion insert (60A).

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