Solid cellulose foam products for protecting objects

Abstract

The present invention relates to a solid cellulose foam product for protecting an object, the solid cellulose foam product comprising at least one base including at least one hole and at least one housing, the at least one housing of the at least one base arranged to receive a protruding portion of the object, and at least one plug arranged within the at least one hole of the at least one base. The present invention further relates to a method for making the solid cellulose foam product.

Description

[Technical Field]

[0001] The present invention relates to the field of cellulose foam materials for packaging, and more particularly to a solid cellulose foam product for protecting objects. The present invention further relates to a method for producing a solid cellulose foam product. [Background technology]

[0002] Plastic packaging materials, such as fossil-based foams, are becoming increasingly outdated in a society striving to reduce plastic use and waste and move toward renewable materials. With regulatory agencies now driving policies toward restricting or banning fossil-based foam materials in packaging, new solutions are needed.

[0003] Finding foam materials from renewable resources presents many challenges. Many bio-based foams have higher production costs, lower mechanical performance, and lower stability in water and at high temperatures compared to existing foams from petroleum-based resources. Bio-based, recyclable protective materials must possess the same superior characteristics and properties as petroleum-based materials to be the first choice over petroleum-based materials.

[0004] The low weight and good impact absorption of bio-based foams are examples of important features, and the ability to customize the shape and form of the bio-based foam to match the shape and form of the item to be protected by the protective material is of utmost importance.

[0005] Very often, the goods to be protected have protruding parts, such as corners and / or edges, that require additional protection from the packaging material during storage and transport. Additionally, the goods may be made of very fragile materials, such as glass or porcelain, that require protection due to their fragile nature. Commercially available bio-based foams do not provide the necessary protection when the foam is constantly subjected to impacts from corners and edges during the delivery cycle.

[0006] Several bio-based foams containing cellulose have been described. WO20200011587 describes a porous material prepared by aerating a paste containing cellulose fibers and gluten and depositing the aerated paste into a dried mold. WO2015036659 describes a molded fiber product prepared by foaming an aqueous suspension of natural fibers in combination with synthetic fibers and surfactants, feeding the fiber foam into a mold, and drying it to produce a dry fiber product.

[0007] However, a need remains for a solid cellulose foam that can be tailored around delicate products of any shape and that can protect all parts of the product. Protruding parts of the product, such as corners and edges, must be sufficiently protected so that impacts occurring during storage and transportation can be absorbed by the surrounding cellulose foam without damaging the protruding parts.

[0008] Additionally, solid cellulose foams should be renewable, biodegradable, and fully recyclable within the normal paper and board flow, allowing them to become part of the circular material flow in existing packaging waste management systems. The manufacturing costs for not only producing the foams but also tailoring them to any product shape must be modest to be a competitive option. Summary of the Invention

[0009] The object of the present invention is to obviate at least some of the drawbacks of the prior art by providing a solid cellulose foam product for protecting objects as claimed in claim 1.

[0010] The solution according to claim 1 provides excellent protection of protruding parts of objects against shocks and vibrations during storage and transport. Protruding parts, such as corners of objects, are held in place by the housing in the base of the solid cellulose foam product. The cushioning properties of the solid cellulose foam product also protect the protruding parts. The presence of the plug improves the protective properties of the solid cellulose foam product.

[0011] Another advantage is that waste of cellulosic material is reduced or even eliminated, thereby reducing production costs and saving raw materials.

[0012] Compared to known methods, the present process is easy to implement in large scale setups.

[0013] Further aspects and embodiments are defined in the appended claims, which are specifically incorporated herein by reference.

[0014] The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which: [Brief explanation of the drawings]

[0015] [Figure 1] FIG. 1 is an exploded view of a preferred embodiment of a solid cellulose foam product. [Figure 2] FIG. 2 is a perspective side view of the preferred embodiment of FIG. 1 with assembled components of the product. [Figure 3] FIG. 2 is a top perspective view of the preferred embodiment of FIG. 1 with the parts assembled. [Figure 4] 1 shows an object having protruding portions protected by a solid cellulose foam product of the present invention according to a second preferred embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] Before the present invention is disclosed and described in detail, it is to be understood that the invention is not limited to the particular compounds, compositions, method steps, substrates, and materials disclosed herein, as such compounds, compositions, method steps, substrates, and materials may vary somewhat. It is also to be understood that the terminology used herein is used for the purpose of describing particular embodiments only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims and equivalents thereof.

[0017] The expression "flat object" as used herein refers to an object having a height, a width, and a length. The width and length define two surfaces, and the height defines at least one sidewall. The height is so small compared to the length and width that the object is referred to as a flat object. Examples of flat objects are a countertop, a wall mirror, a door, a glass pane, and a solar panel. The expression "flat" refers to an object having a flat surface with no protrusions or depressions from its surface.

[0018] As used herein, "protruding portion" means a portion that projects or protrudes from a main portion, and is more susceptible to damage or impact than the main portion. An example of a protruding portion is the corner of a flat object, such as the corner of a countertop.

[0019] As used herein, "a shape corresponding to the shape of the protruding portion" means a shape that is arranged to fit the shape of the protruding portion so that a protective material having a corresponding shape is placed around the protruding portion (or protruding portion) of the object to be protected by the protective material and can tightly surround the protruding portion.

[0020] As used herein, the term "substantially perpendicular" includes a tolerance of accuracy well known and acceptable to those skilled in the art, said tolerance being ±10%.

[0021] The expression "corner edge" as used herein refers to an edge extending between two corners. In the case of a flat object, it is the edge extending between two corners of a side wall.

[0022] As used herein, the term "foam" refers to a material created by entrapping air or gas bubbles within a solid or liquid. Generally, the volume of gas is much greater than the volume of the liquid or solid, and a thin film separates the air bubbles. To form a foam, three requirements must be met: Mechanical work is required to increase the surface area. This can occur by agitation, dispersion of a large amount of gas into the liquid, or injection of gas into the liquid. The second requirement is the presence of a blowing agent, typically an amphiphile, surfactant, or surface-active component, to reduce surface tension. Finally, the foam must form more quickly than it can break down.

[0023] The term "cellulose foam" as used herein refers to a foam containing cellulose and other components such as thickeners, surfactants, and additives. The main component of cellulose foam is cellulose, which constitutes at least 70% by weight of the dry content of the cellulose foam. The cellulose is in the form of fibers, and therefore the foam can also be defined as a fiber foam or a cellulose fiber foam. The cellulose foam can be wet or solid.

[0024] As used herein, the term "wet foam" or "wet cellulose foam" refers to a wet foam containing cellulose and other components such as thickeners, surfactants, and additives. Air bubbles exist within the wet foam. The wet foam is self-supporting and behaves as a viscoelastic solid, meaning that the wet foam has both viscous and elastic properties. The wet foam behaves as a solid and is therefore self-supporting unless a sufficiently large force is applied that the wet foam begins to flow and instead behaves as a viscous material. Depending on the magnitude and time scale of any applied shear stress, the wet foam can exhibit predominantly viscous or elastic behavior.

[0025] As used herein, the terms "solid cellulose foam" or "dried cellulose foam" refer to a dry porous cellulose material formed from a wet cellulose foam, i.e., a foam-molding material. During the drying process, the closed wet cellulose foam is converted into an open solid cellulose foam. The cellulose fiber network is prevented from collapsing during drying. The resulting solid cellulose foam has a shape that largely conforms to the shape of the wet cellulose foam. The dry content of the solid cellulose foam can be at least 95% by weight, calculated based on the total weight of the solid cellulose foam. The shape and density of the solid cellulose foam are retained even in an unconstrained state. The solid cellulose foam has an open-cell structure, allowing air to enter the pores within the foam. The solid cellulose foam can also be described as a porous or low-density material.

[0026] The following detailed description and the examples included therein are provided only for the purpose of describing and illustrating certain embodiments of the invention, and are not intended to limit the scope of the invention in any way.

[0027] In a first aspect, the present invention relates to a solid cellulose foam product for protecting an object.

[0028] In a second aspect, the present invention provides a method for making a solid cellulose foam product for the protection of an object.

[0029] The first aspect of the present invention, namely a solid cellulose foam product for protecting an object, is described in detail below with reference to the drawings.

[0030] 1 shows an exploded view of a preferred embodiment of a solid cellulose foam product 1 for protecting an object, illustrating the components of said product 1. The components are oriented in the X-, Y-, and Z-planes in said Figure 1.

[0031] The solid cellulose foam product 1 comprises two bases 2, 2'. Each base 2, 2' comprises an inner surface 21, an outer surface 22, a rear surface 23, a front surface 24, an upper surface 25 and a lower surface 26.

[0032] An inclined surface 27 connects the top surface 25 and the front surface 24 .

[0033] Preferably, the inner surface 21 includes a densified layer 210. More preferably, the outer surface 22 also includes a densified layer 220. Most preferably, both the inner surface 21 and the outer surface 22 include densified layers 210, 220.

[0034] The two bases 2, 2' are provided with a compressed region 3 including a compressed surface 31, a wall surface 32, and a bottom surface 33. The compressed region 3 further has a first compressed depth DCR (Depth of Compressed Region) that corresponds to the width 32W of the wall surface 32 and also corresponds to the width of the bottom surface 33.

[0035] As can be seen in FIG. 1, the compressed area 3 is limited by the non-compressed area 28 and the inclined surface 27 of the base 3 .

[0036] When the housings of the two or more bases (e.g., the compression regions 3, 3') oppose one another, a housing 5 is formed (best seen in Figures 2-3). Note that each base includes its own housing (e.g., the compression regions 3, 3'), and these housings (e.g., the compression regions 3, 3') when opposed to one another form housing 5. Thus, the term "housing" is used to refer both to the housings of the individual bases and to the void formed by arranging two or more bases such that the housings of the individual bases oppose one another.

[0037] Each base 2, 2' further comprises three holes 4A, 4B.

[0038] In FIG. 1, said holes are shown as through holes and will therefore be referred to as through holes in the following.

[0039] However, in some embodiments, at least one of the holes may be a blind hole having an opening on the inner surface 21 and extending in a direction from the inner surface 21 of the at least one base 2, 2' towards the outer surface 22 of the at least one base, but not all the way to the outer surface 22, i.e., not reaching the outer surface 22.

[0040] The through holes 4A, 4B are arranged in a direction perpendicular or nearly perpendicular to the inner and outer surfaces 21, 22 of the bases 2, 2'.

[0041] The through holes 4A, 4B are further arranged in the non-compressed areas 28 of the bases 2, 2'.

[0042] In FIG. 1, the through holes 4A, 4B located in the non-compressed area 28 are shown to be in direct contact with the compressed area 3.

[0043] Two of the side holes 4B of the through holes are arranged in direct contact with the compression zone 3 by their respective surfaces 41b, such that the respective surfaces 41b form part of the wall surface 32 and the bottom surface 33 of the compression zone 3, respectively, so that openings 320, 330 are arranged in the respective wall surface 32 and bottom surface 33.

[0044] The third of the through holes is a square hole portion 4A arranged at a corner edge portion 3e of the corner of the compression region 3.

[0045] The corner edge 3e of the compression area 3 is formed by the wall surface 32 meeting the bottom surface 33. In the embodiment shown, the corner comprises a right angle.

[0046] The through-hole 4A is arranged to extend from the inner surface 21 of each base 3, 3' to the outer surface 22 of each base 3, 3' in a direction parallel to the edge 36 between the wall surface 32 of the compression region 3 and the bottom surface 33 of the compression region 3.

[0047] Preferably, the rectangular hole 4A is disposed in the rectangular edge 3e at an angle A relative to the wall surface 32 and the bottom surface 33. The angle A is preferably in the interval 30-60°, preferably 35-55°, more preferably 40-50°. In Figure 1, the angle A is approximately 45°.

[0048] Also shown in Figure 1 are three plugs 6. In the embodiment shown, the plugs 6 have a rectangular shape corresponding to the rectangular shape of the through holes 4A, 4B.

[0049] The plugs 6 include respective contact surfaces 61 arranged to contact the compression regions 3 when inserted into the respective through holes 4A, 4B.

[0050] The contact surface 61 preferably includes a densified surface 610 .

[0051] It will be appreciated that the shape of the through hole may be other than rectangular, however the plug will preferably have a shape corresponding to the shape of the through hole in order to fit into the hole.

[0052] It is further contemplated that embodiments in which a pair of holes and plugs may be one shape and another pair of plugs and holes may have a different shape than the first pair without departing from the scope of the present invention.

[0053] In the preferred embodiment shown in Figure 1, the bases 2, 2' differ somewhat from each other, i.e. they do not exactly mirror each other, i.e. they are not mirror-image halves, and this difference will now be explained.

[0054] One of said bases 2, 2', namely base 2', comprises not just one but two compressed regions 3, 3'.

[0055] The second compression region 3' is arranged on a part of the compression surface 31 of the compression region 3. The second compression region 3' has a second compression depth DCR' which may be the same as the first compression depth DCR of the first compression region or may be greater or less than the first compression depth DCR.

[0056] With respect to the uncompressed surface 28, the total depth from said compressed surface 28 to the compressed surface 31' of the second compressed region 3' is the sum of the first compressed depth DCR and said second compressed depth DCR'.

[0057] The second compression region 3' further includes a wall surface 32', a bottom surface 33', and a width 32'W of the wall surface 32' (corresponding to the second compression depth DCR'). The width of the bottom surface 33' corresponds to the second compression depth DCR'. The second compression region 3' and the compression surface 31' are limited by the inclined surface 27 of the base 2'.

[0058] The compression surface 3, 3' preferably comprises a densified layer 310, 310'.

[0059] By making partial cuts and pressing to different compression depths, the solid cellulose foam product can be tailored to fit around protruding portions of the object to be protected, eliminating air transport, thereby reducing the overall size and cost of the packaged product. The compressed areas are also more rigid than the uncompressed areas, which helps to hold the object in place, for example, during transport.

[0060] The cushioning properties of the solid cellulose foam further ensure that the object is protected.

[0061] Figures 2 and 3 show the solid cellulose foam product 1 in the assembled state.

[0062] The two base parts 2, 2' containing the compression areas 3, 3' are arranged fixedly to one another by fastening means, which is achieved by irremovably fitting the inner surfaces 21, 21' to one another.

[0063] In some embodiments, the plug 6 is the fixing means or at least serves to fix the bases 2, 2' to each other.

[0064] The fastening means may further comprise, for example, an adhesive, preferably a bio-based adhesive.

[0065] In some embodiments, the fastening means comprises both the plug and an adhesive.

[0066] By fitting the inner surfaces 21 of the bases 2, 2' together a cavity V is formed, which is defined by said compression areas 3, 3'. Said cavity will be referred to as housing 5 in the following.

[0067] When configured differently, the two or more base housings (the compression areas 3 , 3 ′) face each other, thereby forming the housing 5 .

[0068] By forming said housing 5 from two or more bases 2, 2', each containing a housing (the compression zones 3, 3'), the housing 5 (and therefore also the protruding parts of the object to be protected) is located in the center of the solid cellulose foam product 1, which provides good protection due to an optimal distribution of forces. In contrast, if only one base 2, 2' contained a housing, the protruding parts of the object to be protected would be located only within that base 2, 2', which would reduce the protective properties of the product 1 due to uneven distribution of forces, for example in the event of an impact.

[0069] The housing 5 includes a bottom surface 33, 33', a compression surface 31, 31' and a wall surface 32, 32', each of the surfaces included in the housing 5 that together form the three-dimensional (3D) shape of the housing 5.

[0070] The housing 5 is an open housing arranged to accommodate a protruding portion of an object to be protected and adapted to fit tightly and completely around the shape of the protruding portion, preferably without leaving any empty space between the surface of the housing 5 and the protruding portion.

[0071] The plug 6 is placed in the through-hole 4 with only the bottom / top surface 62 of the plug visible.

[0072] Preferably, the bottom and top surfaces 62 are aligned with the outer surfaces 22 of the bases 2, 2'.

[0073] In a second preferred embodiment, the two bases 2, 2' are mirror images of each other, i.e., they are mirror halves, as shown in Figure 4. Each of the two bases includes only one compression region 3. If the two bases 2, 2' are mirror images of each other, manufacturing is simplified.

[0074] Figure 4 shows an object O comprising four protruding portions, each of which is protected by a solid cellulose foam product 1 of the present invention.

[0075] The object O may preferably be a flat object O, for example a baking sheet including four corners. To prevent the corners from breaking or cracking during storage and transportation, the solid cellulose foam product 1 of the present invention is attached to the corners in the form of a corner protector. The solid cellulose foam product 1 absorbs shocks in an excellent manner according to the aspects defined in claim 1 and the dependent claims.

[0076] The protruding portion is disposed within the housing 5 of the solid cellulose foam product 1, the housing having a shape corresponding to the shape of the protruding portion of the object.

[0077] The housing surrounding each protrusion comprises two bases 2, each comprising a respective compression zone 3. The cavities of said compression zones 3 together form said housing 5.

[0078] For more complex shapes of protruding portions, it is conceivable that the solid cellulose foam product may comprise not only two but three or more bases fixedly arranged to one another by fastening means, the housings of the three or more bases facing one another, thereby forming the housing having a shape corresponding to the shape of the protruding portion of the object.

[0079] The holes 4A, 4B are arranged so that they are perpendicular to the protruding portion of the flat object O. In Figure 4 this is shown by the flat object O extending in the x / y plane and the holes extending in the z direction. The holes extend in a direction perpendicular to the surface S of the flat object O.

[0080] At least one hole, ie, a square hole 4A, is disposed at a corner of the protruding portion, preferably at a corner edge of the protruding portion.

[0081] The housing 5 has a shape corresponding to the shape of the protruding portion, so that the corner edge 3e of the compression region 3 of the housing corresponds to the corner edge of the protruding portion.

[0082] The holes 4A are further arranged to have an angle (A) with respect to the corner edge portion, the angle (A) being within the interval of 30 to 60°, preferably 35 to 55°, more preferably 40 to 50°.

[0083] The two side holes 4B are arranged to be in direct contact with the housing 5 (and thereby the protruding portion) by means of the openings 320, 330 shown in FIG.

[0084] The holes 4A, 4B are positioned so as to be in direct contact with the housing 5, so that the plugs placed in the holes come into contact with the protruding parts of the object to be protected inside the housing at the positions of the openings 320, 330.

[0085] Preferably, the plugs are positioned such that their respective surfaces including the densified layer contact the protruding portions.

[0086] Embodiments are envisaged in which the holes 4 are arranged at a short distance, for example 0.5 to 10 mm, from the wall surface 32 and the bottom surface 33 of the compressed area 3. An area of ​​non-compressible material 28 is then present between the holes 4 and the compressed area 3. In these embodiments, the plug is not in direct contact with the housing and thereby also not in direct contact with the protruding portion.

[0087] The rectangular hole portion 4A is preferably positioned adjacent to the edge line 36 between the bottom surface 33 and the wall surface 32 of the compression region 3, as described above, with the contact surface 61 positioned perpendicular to the edge line 36.

[0088] The square hole 4A may be positioned close to the wall surface 32 and the bottom surface 33, and this positioning may eliminate the edge line 36.

[0089] However, embodiments are envisaged in which there may be a small distance between the contact surface 61 and the edge line 36, for example 0.1 to 5 mm.

[0090] Materials and Material Properties The solid cellulose foam product comprises: - at least one base 2, 2' comprising at least one hole and at least one housing, - said at least one housing 5 of said at least one base is configured to accommodate a protruding portion of said object; at least one plug 6 arranged in said at least one hole 4 of said at least one base 2, 2';

[0091] The density of the uncompressed area 28 of the at least one base 2, 2' is between 10 and 80 kg / m 3 , preferably 10 to 60 kg / m 3 , more preferably 20 to 50 kg / m 3 is within the interval.

[0092] The average density of the at least one base 2, 2', including the uncompressed area 28 and the compressed area 3, 3', is preferably between 10 and 80 kg / m 3 , preferably 20 to 55 kg / m 3 The interval can be:

[0093] The density of said at least one compressed area 3, 3' is 110% or more, preferably 120% or more, more preferably 130% or more of said density of said uncompressed area of ​​said at least one base.

[0094] The density of the at least one plug 6 is higher than the density of the at least one uncompressed area of ​​the at least one base.

[0095] Said density of said at least one plug 6 is 110% or more, preferably 120% or more, more preferably 130% or more of the density of said at least one uncompressed area of ​​said at least one base.

[0096] Preferably, the higher density of the plug 6 is achieved by compressing the plug to the higher density.

[0097] The at least one plug 6 provides improved protection for protruding parts that need to be protected. During an impact, the cushioning properties of the cellulose-based foam may not be sufficient to protect the protruding parts, and the plug provides additional protection for protruding parts such as corners and / or edges. By providing a plug with a higher density, the stiffness and resilience of the plug are increased. This further improves the plug's ability to protect the protruding parts during an impact.

[0098] The at least one base 2, 2' comprises at least one surface comprising a densified layer.

[0099] Said at least one compressed region 3, 3' of said at least one base 2, 2' further comprises said densified layer.

[0100] The at least one compressed region 3, 3' of the at least one housing 5 comprises the densified layer.

[0101] The at least one plug 6 includes at least one surface that includes a densified layer. A surface that includes a densified layer is more rigid than a surface without a densified layer. Therefore, it is advantageous for the at least one plug 6 to include a densified layer on at least one surface. This provides additional rigidity to the plug 6, which is important for adequate protection of the protruding portion.

[0102] At least one surface of said at least one housing 5 is arranged to be in direct contact with said protruding portion.

[0103] The at least one surface of the at least one housing 5 arranged in direct contact with the protruding portion comprises the densified layer.

[0104] A surface comprising a densified layer is stiffer than a surface without a densified layer, and therefore it is advantageous for at least one surface of said at least one housing 5 that is placed in direct contact with said protruding portion to comprise a densified layer, as this helps to hold the protruding portion in place within the housing 5.

[0105] The at least one base 2, 2' and the at least one plug 6 preferably have: a) 71 to 95% by weight of cellulose fibers, calculated based on the total weight of the solid content of the composition; b) 4 to 24% by weight of a water-soluble thickener, calculated based on the total weight of the solid content of the composition; c) at least two surfactants; The cellulose foam may be prepared from a cellulose foam composition comprising:

[0106] Cellulose fibers suitable for use in the present invention can be derived from wood, such as softwood or hardwood, leaves, or fiber crops (including cotton, flax, and hemp). Cellulose fibers suitable for use in the present invention can also be derived from regenerated cellulose, such as rayon and lyocell. Cellulose fibers suitable for use in the present invention may contain lignin or hemicellulose, or both, or the cellulose fibers may be free of lignin and hemicellulose. Preferably, the cellulose fibers are derived from wood, and more preferably, they are pulp fibers obtained by a pulping process that liberates fibers from the wood matrix. They can be liberated by mechanical pulping, such as thermomechanical pulping (TMP) or chemothermomechanical pulping (CTMP), or by chemical pulping, such as kraft pulp or pulps obtained by sulfite, soda, or organosolv pulping processes. More preferably, the cellulose fibers are pulp fibers liberated by chemical pulping. The different characteristics of each cellulose fiber affect the properties of the final cellulose foam. Cellulose fibers are significantly longer than they are wide. Cellulose fibers can have an average width of 0.01 to 0.05 mm. Softwood fiber lengths can be 2.5 to 4.5 mm, while hardwoods can have fiber lengths of 0.7 to 1.6 mm, and eucalyptus can have fiber lengths of 0.7 to 1.5 mm. However, fiber lengths can vary considerably depending on the growing location. Cellulose fibers in the cellulose foams disclosed herein can have lengths of 0.1 mm to 65 mm, or 0.1 mm to 10 mm, or 0.5 mm to 65 mm, or 0.5 mm to 10 mm, or 0.5 mm to 7 mm. Fiber length can impart various mechanical characteristics to the foam. Due to the fiber length, the fibers can intertwine with each other, providing fiber-to-fiber interconnections that provide strength to the foam. The aspect ratio of the cellulose fibers in the cellulose foams according to the present invention, i.e., the ratio of fiber length to fiber width, can be at least 10, at least 25, at least 50, at least 75, or at least 100, which helps maintain and stabilize the foam structure during the drying process and allows the wet cellulose foam to dry while retaining its shape.The aspect ratio can be up to 6500, or preferably up to 2000.

[0107] The cellulose fibers may be modified to impart different properties to the final cellulose foam, for example, phosphated or periodate oxidized fibers may also be used when producing cellulose foams according to the present invention.

[0108] The cellulose fibers of the cellulosic foam composition may be selected from wood pulp, regenerated cellulose fibers, and vegetable fibers such as fibers from bamboo, cotton, hemp, flax, and jute.

[0109] Preferably, the cellulose fibers are selected from wood pulp, such as softwood pulp, hardwood pulp, chemical thermomechanical pulp and dissolving pulp, or a combination of one or more of these.

[0110] More preferably, the cellulose pulp fibers are selected from softwood pulp, chemical thermomechanical pulp, or dissolving pulp.

[0111] Most preferably, the cellulose pulp fibers are selected from softwood pulps, such as softwood kraft bleached pulp.

[0112] The water-soluble thickener may be present in an amount of 4 to 24 wt. %, or 5 to 20 wt. %, calculated based on the total weight of the solids content of the foam. The thickener may have a molecular weight of 80,000 to 250,000 g / mol or 83,000 to 197,000 g / mol. Exemplary water-soluble thickeners are selected from carboxymethyl cellulose (CMC), methyl cellulose (MC), hydroxyethyl cellulose (HEC), ethyl hydroxyethyl cellulose (EHEC), methyl hydroxypropyl cellulose (MHPC), starch, xanthan, guar gum, and xyloglucan, or mixtures thereof.

[0113] The foam preferably comprises a mixture of at least two surfactants. One of the at least two surfactants is preferably a fast-acting surfactant, which quickly settles to the air-water interface during mechanical agitation during foam preparation, which helps to form a foam with high density and viscosity, thus enabling a self-supporting foam. A surfactant suitable for this purpose is an anionic surfactant, preferably a low-molecular-weight anionic surfactant. The low-molecular-weight anionic surfactant may be selected from sodium dodecyl sulfate (SDS), potassium dodecyl sulfate, sodium laureth sulfate (SLES), sodium dodecylbenzenesulfonate, sodium cocoyl sarcosinate, and sodium lauroyl sarcosinate. The low-molecular-weight anionic surfactant is preferably selected from sodium dodecyl sulfate (SDS), sodium pn-dodecylbenzenesulfonate, sodium cocoyl sarcosinate, and sodium lauroyl sarcosinate. More preferably, the low-molecular-weight anionic surfactant is sodium cocoyl sarcosinate. The anionic surfactant may be biodegradable.

[0114] The other of at least two surfactants is preferably a co-surfactant.Co-surfactant may be selected from plant-derived raw materials, such as tetradecanoic acid (myristic acid), sodium oleate, lauric acid, palmitic acid and stearic acid, glucose-based co-surfactants with aliphatic carbon tails, such as alkylglycosides, alkylpolyglucosides, alkylthioglycosides and alkylmaltosides, amphoteric betaines, such as cocamidopropyl betaine (CAPB), sodium cocoiminodipropionate (CADP), polyethylene glycol sorbitan monolaurate, i.e., tween (for example, tween 20, tween 80 and tween 85), and high pKa fatty acids, such as polyoxyethylene lauryl ether, for example, polyethylene glycol dodecyl ether, pentaethylene glycol monododecyl ether and octaethylene glycol monododecyl ether.

[0115] The foam composition preferably comprises: a) disintegrating cellulose fibers in water to obtain a slurry of cellulose fibers; b) adding a thickener to the slurry obtained in a) to obtain a mixture of thickener and cellulose fibers in water; c) adding at least two surfactants to the mixture obtained in b) to obtain a fiber suspension; d) aerating the suspension obtained in c) to obtain a wet foam, the wet foam comprising 10-38% by weight of cellulose fibers, 0.5-10% by weight of a water-soluble thickener, and 0.1-2% by weight of a surfactant, calculated based on the total weight of the wet foam, and the wet foam has a viscosity of 140-500 kg / m 3 and a yield stress of 40 to 400 Pa; e) drying the wet foam obtained in d) to obtain a dry cellulose foam; It can be prepared by a method comprising:

[0116] The wet foam can be dried without the use of a mold, i.e., the wet foam is free-standing and retains its shape during drying without the need for a mold.

[0117] The wet foam is homogeneous and has good stability due to the small cell size (typically less than 100 μm) obtained when aerating a mixture of cellulose fibers, thickener, and surfactant. The wet foam does not aggregate during processing. The average cell size is largely maintained during any subsequent processing or drying steps, and the cellulose fibers remain well dispersed. The solid cellulose foam obtained by drying the wet foam is uniform in structure, strong, has good mechanical properties, a smooth surface, and is free of defects. In comparison, less stable wet cellulose foams have a large average cell size (i.e., typically greater than 100 μm), and the cells coalesce quickly during processing and drying, resulting in the formation of larger cells. Furthermore, the cellulose fibers form clusters during processing and drying, which causes the wet foam to collapse during drying. The resulting solid cellulose foam does not have a homogeneous structure and also contains defects in the morphology of the cavities caused by the coalesced cells in the wet foam. Due to these defects, such solid cellulose foams have a weak and rough surface.

[0118] The dried cellulose foam obtained in step e) can be used as a solid cellulose foam material.

[0119] The dried cellulose foam obtained in step e) depositing discrete units of cellulose foam on a surface to obtain a first foam deposit; depositing wet cellulose foam between the discrete units to obtain a subsequent foam deposit; and drying the wet foam to obtain a solid foam having the discrete units of foam embedded in a foam matrix. The solid cellulose foam may then be used as a solid cellulose foam according to claim 1 and its dependent claims.

[0120] However, the solid cellulose foam may be prepared by other methods without departing from the scope of the present invention. For example, the solid cellulose foam may be prepared by depositing a wet foam in a single step into any desired shape. Optionally, any suitable confining means, such as a mold or frame, may be used.

[0121] The solid cellulose foam material may be prepared, for example, by depositing a foam composition onto a conventional papermaking machine for forming a foam web, or onto the forming section of a papermaking machine suitably modified for that purpose.

[0122] The cellulose foam composition of the at least one base 2, 2' and the at least one plug 6 may be the same or different.

[0123] The solid cellulose foam is preferably not a shape-memory foam that returns to its original shape; rather, the foam remains in its compressed shape. The solid cellulose foam has an open-cell structure in the bulk of the foam. When compressed, the cellulose foam deforms and is unable to recover its original shape.

[0124] In example of possible dimensions, the solid cellulose foam plank has a thickness in the range of 1-20 cm, or 1-10 cm, or 1-5 cm, or 4-6 cm. In one embodiment, the thickness is 50 mm. The at least one base may be cut from such a plank, the thickness of the plank preferably corresponding to the width of the back surface 23 of the at least one base.

[0125] In embodiments where compression results in a denser plug, the plug may be compressed to, for example, 40% of the thickness of the plank, ie the thickness of the compressed plug is 20 mm.

[0126] The dimensions stated above serve as examples only and should not be considered to limit the products of the present invention to the dimensions stated above.

[0127] As mentioned above, embodiments in which at least one surface of the at least one base 2, 2', the at least one compressed region 3, 3', the non-compressed region 28, and the at least one plug 6 comprises a densified layer may be preferred.

[0128] The production of solid cellulose foam involves different manufacturing steps, one of which is the drying step. During this drying step, the outer surfaces (top, bottom, and sides) of the foam acquire an outer layer with different properties from the bulk part of the foam, which contains a more uniform open-celled porous fiber network. The outer layer has a higher density than the bulk part because the fibers are more densely packed and partially oriented in a different direction. The outer layer is called the "densified layer." The densified layer improves the mechanical stability and strength of the foam.

[0129] The densified layer provides increased mechanical stability and strength to the foam, so that the surface containing the densified layer is preferably oriented in directions where additional shock absorption may be required, and the enhanced properties of the densified layer are used in locations on the product where they can contribute to the protective properties of the product.

[0130] Although having a higher density, the densified layer is still very porous and air permeable and has a negligible effect on the overall density of the solid cellulose foam.

[0131] The second aspect of the present invention, namely a method for producing a solid cellulose foam product intended for the protection of objects, is described in detail below with reference to the drawings.

[0132] The method for producing a solid cellulose foam product comprises: a) providing at least one base; b) forming a housing on said at least one base arranged to receive a protruding portion of an object; c) providing at least one hole in said at least one base; d) providing at least one plug arranged to be introduced into said at least one hole; Includes.

[0133] Preferably, the method comprises: step b1) applying at least one cutting line of a predetermined cutting depth to at least one surface of said at least one base, said at least one cutting line forming at least one pattern on said at least one surface; and preferably step b2) pressing at least one pressing tool into the at least one pattern on the at least one surface of the at least one base, thereby forming at least one compressed region of the base, the at least one compressed region forming a housing arranged to accommodate a protruding portion of an object; Further includes:

[0134] Step a) comprises providing at least one base 2, 2'.

[0135] The base 2, 2' may preferably have a rectangular or square shape to easily fit into surrounding rectangular packaging.

[0136] The base 2, 2' further has a thickness X corresponding to the width of the rear and front surfaces 23, 24.

[0137] In FIG. 1, the base 2 , 2 ′ includes an inclined surface 27 .

[0138] Step b) forms a housing 5 in said at least one base 2, 2' arranged to accommodate the protruding portion of the object O.

[0139] Step b) further comprises step b1). At least one cutting line of a predetermined cutting depth is provided on at least one surface 21 of the at least one base 2, 2', whereby the at least one cutting line forms at least one pattern on the at least one surface 21.

[0140] In the area where at least one cutting line is provided, the at least one base 2, 2' has a thickness X, the thickness X being within an interval of 2 to 20 cm, preferably 3 to 10 cm, most preferably 4 to 6 cm.

[0141] A cutting tool (not shown), such as a knife or cutting blade or any other type of related sharp cutting tool, is preferably placed at a starting position near at least one surface 21 to be cut.

[0142] After positioning the cutting tool in a suitable starting position, the cutting tool is moved in a direction towards the at least one surface 21. This movement brings the cutting tool into direct contact with said at least one surface 21, and the movement of the cutting tool is continued such that the cutting tool penetrates the surface(s) 21 and initiates a cut into the core of said at least one base 2, 2′.

[0143] The at least one cutting line is arranged to cut partially through the thickness X of the at least one base 2, 2' to a predetermined cutting depth, such that the predetermined cutting depth is less than the thickness X of the at least one base 2, 2'.

[0144] The movement (and cutting action) of the cutting tool towards the at least one base 2, 2' continues until the predetermined cutting depth is reached, and then the cutting tool is removed from the at least one base 2, 2', leaving a cutting line in the at least one base 2, 2'.

[0145] The predetermined cutting depth of the at least one cutting line is preferably not more than 90% of the thickness X of the cellulose foam material 1, more preferably not more than 70%, and most preferably not more than 60%.

[0146] In some embodiments, the cutting tool comprises two or more knives or blades. When using a cutting tool with two or more knives or blades, two or more patterns can be cut in one and the same cutting action, i.e., in one step. It is further contemplated that the two or more knives or blades may apply cutting lines of different cutting depths.

[0147] It is also conceivable to use a cutting tool with only one knife or blade, or to use two or more cutting tools with variable shapes and cutting depths, repeating step b1) for all cutting tools.

[0148] The repetition of step b1) of providing at least one cutting line may be carried out before pressing step b2) or may be alternated with pressing step b2).

[0149] In some embodiments, the cutting tool, in its simplest form, may have a linear shape that provides a straight cut.

[0150] In other embodiments, the cutting tool may be more complex in shape and may provide curved cuts and / or cuts formed as closed loops.

[0151] The at least one cutting line arranged on the at least one surface 21 of the at least one base 2, 2' forms at least one pattern on the at least one surface 21 of the at least one base 2, 2'.

[0152] In the embodiment shown in FIG. 1, the surface of said at least one pattern is defined by at least one cutting line and at least one edge of said at least one base 2, 2'.

[0153] In other embodiments, the surface of the at least one pattern may be defined by at least one straight cutting line and at least one curved cutting line.

[0154] Step b1) of the method is followed by step b2), which is a pressing step.

[0155] Step b2) comprises pressing at least one pressing tool into the at least one pattern on the at least one surface of the at least one base, thereby forming at least one compressed region 3, 3' of the base, the at least one compressed region 3, 3' forming a housing 5 arranged to accommodate a protruding portion of the object O.

[0156] The pressing step b2) preferably begins with positioning the at least one pressing tool at a starting position near the at least one pattern, and then moving the at least one pressing tool towards the pattern of the at least one surface 21 so that the at least one pressing tool contacts the surface of the pattern and applies pressure to the surface of the pattern, thereby compressing the material of a portion of the at least one base 2, 2'.

[0157] The pressure exerted by the at least one pressing area of ​​the at least one pressing tool causes the at least one pattern to be compressed in a direction consistent with the direction of the pressure and further compressed into the core of the at least one base 2, 2'.

[0158] The pressing tool is removed after the pressing reaches a predetermined compression depth.

[0159] In FIG. 1, it is shown that at least one compression is performed in a direction perpendicular to the inner surface 21 towards the outer surface 22 and parallel or approximately parallel to the front surface 24 and rear surface 23 of the at least one base 2, 2'.

[0160] After the at least one pressing step is completed, at least one compressed area 3, 3' is formed in the at least one base 2, 2'.

[0161] The at least one pressing tool may preferably have at least one pressing area which corresponds to or is smaller than the area / surface of the at least one pattern of the at least one surface 21 .

[0162] In some embodiments, the at least one pressed area may include an edge line surrounding the at least one pressed area, and the pressed edge line may preferably be positioned to coincide with the at least one cutting line during the pressing process.

[0163] The edge line may preferably be a right-angled edge line.

[0164] For more complex shaped articles, the at least one pressing tool may have two or more pressing areas, which may be of different sizes.

[0165] In some embodiments, each pressed area may have respective pressed edge lines that form a right angle.

[0166] However, embodiments are also contemplated in which at least one of the pressure areas may have a curved edge line.

[0167] The pressing areas of different sizes may also be different shapes and may be arranged to compress to different pressing depths through the at least one surface 21. The thickness of the pressing tool corresponds to the different pressing depths.

[0168] In some embodiments, the pressing direction may be at an angle rather than parallel to the front surface 24 and the back surface 23 of at least one base 2, 2'. In these embodiments, preferably, at least one cutting line may also have the same angle as the pressing direction.

[0169] In some embodiments of the invention, steps b1) and b2) are performed simultaneously. The cutting tool and the pressing tool are one and the same tool, i.e. a combined tool that performs both cutting and pressing operations.

[0170] The composite tool preferably comprises at least one sharp blade for effecting the cutting and at least one pressing area for effecting the compression of the at least one base 2, 2'.

[0171] In embodiments where the composite tool is used to perform steps b1) and b2) simultaneously as a combined process, it is conceivable to repeat the combined process two or more times rather than performing the combined process only once.

[0172] Whether cutting and pressing are performed as separate steps or as a combined step, said at least one base 2, 2' now comprises at least one compressed region 3, 3' and at least one uncompressed region .

[0173] The at least one compressed region 3, 3' comprises a compressed solid cellulose foam having a compressed thickness CMT, CMT', and the compressed region 3, 3' further has a volume.

[0174] In some embodiments, the pressing step is performed to a pressing depth equal to a predetermined cutting depth.

[0175] In other embodiments, the pressing depth PD may be less than or greater than the predetermined cutting depth DC.

[0176] The compressed thickness CMT, CMT' can be calculated as the thickness X of the uncompressed area 28 of the at least one base 2, 2' at the location of the at least one cutting line minus the depth DCR, DCR' of the compressed area, i.e. CTM=X-DCR CTM'=X-(DCR+DCR')

[0177] The at least one base 2, 2' provided in step a) preferably has a uniform bulk density and preferably also has at least one densified layer. By pressing the at least one pressing tool into the at least one pattern of the at least one base 2, 2', the density of the solid cellulose foam contained in the at least one compressed region 12 becomes higher than the density of the provided—and uncompressed—solid in the at least one base 2, 2'.

[0178] Said density of at least one compressed area 3, 3' is 110% or more, preferably 120% or more, more preferably 130% or more of said density of said uncompressed area of ​​said at least one base.

[0179] An embodiment is conceivable in which the pressing tool is the object O to be protected, i.e., when inserting said protruding part of said object, a pressure is exerted by the object such that the object itself compresses the foam to form the housing 5.

[0180] In other embodiments, the pressing tool only partially compresses, with the remaining compression being achieved by inserting the object O.

[0181] As shown in Figures 1 to 3, one of the bases 3, 3', i.e., base 3', has two compressed regions 3, 3'. Two or more compressed regions can be created by either repeating step b1) of providing at least one cutting line, which may be performed before pressing step b2), or alternating with pressing step b2).

[0182] Step c) comprises providing at least one hole in said at least one base.

[0183] The at least one hole 4 may be a through hole or a blind hole. Embodiments including more than one hole 4 may include a mixture of through holes and blind holes.

[0184] In the figures, the at least one hole 4 is a through hole having a rectangular cross-sectional area, although other shapes are contemplated without departing from the scope of the invention, for example, square, triangular, cylindrical, star-shaped, or other possible shapes.

[0185] In some embodiments, the square hole 4A may have an L-shape arranged to surround the corner edge 3e of the compression region 3 and therefore the corner of the protruding portion.

[0186] Preferably, the at least one hole 4 is arranged from the inner surface 21 of the uncompressed region 28 towards the outer surface 22 of the at least one base 2, 2'. In the embodiment shown, the hole 4 extends to the surface 22 and forms an opening in the surface 22.

[0187] In embodiments in which the at least one hole 4 is a blind hole, the blind hole terminates inside the at least one base 2 , 2 ′ and does not reach the outer surface 22 .

[0188] The at least one hole 4 may be provided by a cutting tool.

[0189] Said at least one hole is arranged at the location of said at least one base 2, 2' as already disclosed in relation to the first aspect of the invention.

[0190] Step c) includes providing at least one plug arranged to be introduced into said at least one hole.

[0191] The at least one plug 6 may be manufactured as a rod that is cut into pieces of plug of suitable length. All mantle surfaces of the at least one plug 6 have a dense layer. However, the surfaces of the cut portions do not have the dense layer.

[0192] The plug 6 may be manufactured individually and all sides of the plug 6 have a dense layer.

[0193] The at least one plug 6 has a density higher than the density of the uncompressed region 28 of the at least one base 2, 2′. The thickness of the dense layer is very small, i.e., the dense layer is so thin that the higher density of the dense layer does not affect the density of the at least one plug 6.

[0194] The density / average density of the at least one plug 6 is higher than the average density of the at least one base 2, 2' comprising the compressed region 3, 3', preferably higher than the average density of the at least one densified layer.

[0195] It should be noted that the densification layer is so thin that its density has a much smaller effect on the average density of each plug and base compared to the average density of each plug and base in embodiments without a densification layer. The densification layer is like a thin coating on the surface.

[0196] The density of the at least one plug 6 is 110% or more, preferably 120% or more, more preferably 130% or more of the density of the uncompressed area 28 of the at least one base.

[0197] Said higher density of said at least one plug may be obtained by compressing said at least one plug 6 .

[0198] Said compression of said at least one plug 6 is at least 10% of its thickness before said compression, more preferably 20%, most preferably 30%, measured in the direction of compression.

[0199] Preferably, said at least one plug 6 has a shape complementary to the shape of said at least one hole 4 into which said plug 6 is inserted.

[0200] In the embodiment in which the hole 4A is L-shaped, the plug 6 intended to be placed in the hole 4A has a corresponding L-shape.

[0201] In an embodiment in which the at least one plug 6 has only one mantle surface including the densified layer, this mantle surface including the densified layer is the contact surface 61 arranged to contact the protruding portion of the object O to be protected.

[0202] In embodiments where the solid cellulose product comprises two or more bases 2, 2', the method further comprises the step of arranging the two or more bases 2, 2' so that they are fixedly secured to one another by a fixing means; The housings 5 ​​of the two or more bases 2, 2' face each other, thereby forming the housings 5 ​​arranged to accommodate the protruding portion of the object O.

[0203] It should be understood that it is the voids V of the at least one compressed region 3, 3' of each base that form the housing of each base. The volume of the formed housing 5 is the sum of the volumes of the voids V.

[0204] In some embodiments of the present invention, the solid cellulose foam product comprises only one base 2. The housing may be provided in the one base by cutting out a volume of cellulose foam from the one base, thereby forming the housing 5.

[0205] In yet another embodiment of the invention, the solid cellulose foam product comprises three or more bases fixedly arranged relative to one another, with compression regions / housings of two or more bases facing one another, thereby forming a shape corresponding to the shape of the protruding portion of the object.

[0206] As will be appreciated by those skilled in the art, many variations and modifications can be made to these and other embodiments of the present invention without departing from the scope of the invention, which is defined in the appended claims.

[0207] For example, embodiments are envisaged that do not have a sloped surface connecting the top surface and the front surface, instead the top surface meets the front surface, preferably in perpendicular contact.

[0208] It should be noted that the above aspect may be the subject of its own protection, such as in a separate divisional application. It is therefore anticipated that this aspect of the invention may require its own protection, for example because it may be essentially applicable to concepts other than those defined by the independent claims of the present application. [Example]

[0209] [Example 1] A solid cellulose foam product for protecting the corners and edges of flat objects was prepared from a 5 cm thick solid cellulose foam plank. The cellulose foam was dry and had a strength of 32-35 kg / m². 3 The foam planks had densities ranging from 83 to 88% by weight of cellulose fiber (softwood bleached kraft pulp), 10 to 15% by weight of a thickener (CMC), and approximately 2% by weight of a surfactant (a mixture of myristic acid and sodium cocoyl sarcosinate). The foam planks had densified layers on the top and bottom. The corner protection products were formed by cutting the foam planks into two bases corresponding to those shown in Figure 1. A cutting table was used for cutting. After cutting, the densified layers remained on the top and bottom, meaning the bases had the same thickness as the foam planks. Three through-holes were cut into each base. Housings were formed by pre-cutting a pattern corresponding to the housings and then pressing them. Three plugs were formed by cutting and compressing the foam planks to form plugs with densified layers on both surfaces. The plugs were 5 cm thick before compression and 2 cm thick after compression.

[0210] The corner protection product was assembled by attaching the two bases together with adhesive. The plug was inserted into the hole and positioned with the densified layer facing the housing. The assembled corner protection product was similar to that shown in Figures 2 and 3.

[0211] To test the protective properties of the corner protector, a corner of a flat baking sheet was inserted into the corner protector's housing. A drop test was performed in which the baking sheet was dropped onto the corner protected by the corner protector. After the drop, the baking sheet was inspected for damage.

[0212] We found that the corner protection product was able to protect the corners of the tabletop.

[0213] Example 2 - Comparison In the comparative example, a cellulose foam plank was cut into two bases as described in Example 1, but no holes were formed or plugged.

[0214] The corner protection product was assembled by attaching two bases together with adhesive. The protection properties were tested as described in Example 1. It was found that upon impact, the corner protection product broke into two pieces and therefore failed to protect the countertop.

Claims

1. A solid cellulose foam product (1) for protecting an object (O), - Includes at least one base (2, 2') including at least one hole (4) and at least one housing (5), - The at least one housing (5) of the at least one base (2, 2') is configured to accommodate the protruding portion of the object (O), - Including at least one plug (6) disposed in the at least one hole (4) of the at least one base (2, 2'), Solid cellulose foam product (1).

2. The solid cellulose foam product according to claim 1, wherein the at least one housing (5) has a shape corresponding to the shape of the protruding portion of the object.

3. The solid cellulose foam product according to claim 1, wherein the at least one hole (4) is positioned perpendicular to the protruding portion of the object (O) when the object (O) is placed inside the at least one housing (5).

4. The solid cellulose foam product according to claim 1, wherein at least one hole (4) is located at the corner of the protruding portion.

5. The solid cellulose foam product according to claim 4, wherein the at least one hole (4) is located at the corner edge portion of the corner and is further located at an angle (A) with respect to the corner edge portion.

6. The solid cellulose foam product according to claim 5, wherein the angle (A) is within the range of 30 to 60°.

7. The solid cellulose foam product according to any one of claims 1 to 6, wherein at least one hole (4) is arranged to be in direct contact with the housing (5).

8. The solid cellulose foam product according to claim 7, wherein at least one of the holes (4) is a through hole or a blind hole.

9. The solid cellulose foam product according to claim 8, wherein the blind hole extends in a direction toward the outer surface of the at least one base portion (2, 2') from the inner surface of the at least one base portion (2, 2').

10. The solid cellulose foam product according to claim 1, wherein the solid cellulose foam product includes two or more bases (2, 2') fixed to each other by fixing means, and the housings (5) of the two or more bases (2, 2') face each other, thereby forming the housing (5) having a shape corresponding to the shape of the protruding portion of the object.

11. The solid cellulose foam product according to claim 10, wherein the fixing means includes at least one stopper (6).

12. The solid cellulose foam product according to claim 1, wherein the at least one stopper (6) has a shape complementary to the shape of the at least one hole (4).

13. The solid cellulose foam product according to claim 1, wherein the at least one base portion (2, 2') includes at least one compressible region (3, 3') having a higher density than the uncompressible region (28) of the at least one base portion (2, 2').

14. The solid cellulose foam product according to claim 13, wherein the density of the incompressible region of at least one base portion (2, 2') is within the range of 10 to 80 kg / m³.

15. The solid cellulose foam product according to claim 13, wherein the density of the at least one compressed region (3, 3') is 110% or more of the density of the uncompressed region (28) of the at least one base (2, 2').

16. The solid cellulose foam product according to claim 13, wherein the at least one housing (5) includes the at least one compression region (3, 3').

17. The solid cellulose foam product according to claim 1, wherein the density of the at least one stopper (6) is higher than the density of the at least one base (2, 2').

18. The solid cellulose foam product according to claim 17, wherein the density of the at least one stopper (6) is 110% or more of the density of the at least one base (2, 2').

19. The solid cellulose foam product according to claim 1, wherein the at least one base portion (2, 2') includes at least one surface (21) containing a densified layer.

20. The solid cellulose foam product according to claim 13, wherein the at least one compression region (3, 3') of the at least one base portion (2, 2') includes a densified layer.

21. The solid cellulose foam product according to claim 13, wherein the at least one compression region (3, 3') of the at least one housing (5) includes a densification layer.

22. The solid cellulose foam product according to any one of claims 19 to 21, wherein the at least one stopper (6) includes at least one surface containing a densified layer.

23. The solid cellulose foam product according to claim 1, wherein at least one surface of the at least one housing (5) is arranged to be in direct contact with the protruding portion.

24. The solid cellulose foam product according to claim 23, wherein at least one surface of the at least one housing (5) arranged to be in direct contact with the protruding portion includes a densifying layer.

25. The solid cellulose foam product according to claim 1, wherein the at least one stopper (6) positioned in the at least one hole (4) is further positioned to be in direct contact with the protruding portion in the housing (5).

26. The solid cellulose foam product according to claim 22, wherein the at least one stopper (6) arranged to be in direct contact with the protruding portion is further arranged to be in contact with the protruding portion by the at least one surface (61) including a densified layer.

27. The at least one base (2, 2') and the at least one stopper (6) are a cellulose foam composition, a) containing 71 to 95% by weight of cellulose fibers, calculated based on the total weight of the solid content of the composition. b) A water-soluble thickener in an amount of 4 to 24% by weight, calculated based on the total weight of the solid content of the composition, and c) at least two surfactants The solid cellulose foam product according to claim 1, comprising a cellulose foam composition containing the following.

28. The solid cellulose foam product according to claim 27, wherein the cellulose foam composition of the at least one base portion (2, 2') and the at least one stopper (6) may be the same or different.

29. The solid cellulose foam product according to claim 27, wherein the cellulose fibers are preferably selected from wood pulp, regenerated cellulose fibers, and plant fibers, and preferably selected from coniferous pulp, chemothermetic pulp (CTMP), and dissolved pulp or any combination thereof.

30. A method for producing the solid cellulose foam product described in claim 1, a) A step of providing at least one base (2, 2'), b) A step of forming a housing (5) configured to accommodate a protruding portion of an object on at least one base (2, 2'), c) The step of providing at least one hole (4) in at least one base portion (2, 2'), d) A step of providing at least one stopper (6) positioned to be introduced into the at least one hole (4) A method that includes this.

31. The above-mentioned forming process is Step b1) Step of making at least one cutting line of a predetermined cutting depth on at least one surface (21) of the at least one base (2, 2'), wherein the at least one cutting line forms at least one pattern on the at least one surface (21), preferably, Step b2) Step of pressing at least one pressing tool into the at least one pattern on the at least one surface (21) of the at least one base (2, 2') thereby forming at least one compression region (3, 3') of the base, wherein the at least one compression region (3, 3') is arranged to accommodate a protruding portion of an object (O) and A method for producing the solid cellulose foam product according to claim 30, further comprising:

32. The method described above is The invention further includes arranging two or more bases (2, 2') to be securely fixed to one another by fastening means, wherein each of the two or more bases (2, 2') forms a housing (5) that faces each other and is thereby arranged to accommodate a protruding portion of an object (O). The method according to claim 30 or 31.

33. The method according to claim 30, wherein the at least one stopper (6) has a density higher than the density of the at least one base (2, 2').

34. The method according to claim 33, wherein the density of the at least one stopper (6) is 110% or more of the density of the at least one base (2, 2').

35. The method according to claim 33, wherein the higher density of the at least one stopper (6) is obtained by compressing the at least one stopper (6) before performing step c).

36. The method according to claim 30, further comprising compressing the at least one stopper (6) to a thickness of less than 90% of the original uncompressed thickness of the at least one stopper.

37. The method according to claim 31, further comprising step b1) being arranged so that the at least one cutting line partially cuts the thickness of the at least one base (2, 2') such that a predetermined cutting depth is less than the thickness of the at least one base (2, 2').

38. The method according to claim 30, wherein the at least one base portion (2, 2') and / or the at least one plug (6) includes at least one surface (31, 61) comprising a densified layer, and the densified layer is arranged to be in direct contact with the protruding portion.

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