Foldable package inserts containing multiple cellulose-based airlaid or solid foam substrates

Abstract

The package insert (10) includes a number of cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) having first and second major sides (22, 22A, 22B, 22C; 24, 24A, 24B, 24C), respectively. The package insert (10) also includes a first paper-based sheet (30) attached to the first major sides (22, 22A, 22B, 22C) and a second paper-based sheet (40) attached to the second major sides (24, 24A, 24B, 24C). The opposing edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C) are beveled edges (26, 26A, 26B, 28, 28B, 28C) and form an angle (α) of less than 90° between them. At least one hinge section (50, 50A, 50B) is interposed between the beveled edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C). The package insert (10) is foldable at the hinge section (50, 50A, 50B) and can be positioned within a package (80) to protect the packaged goods. The present invention also relates to a method for making the package insert (10).

Description

[Technical Field]

[0001] The present invention relates generally to package inserts, and more particularly to package inserts suitable for protecting packaged goods from impact and / or for insulating packaged goods. [Background technology]

[0002] As awareness of the environment and man-made climate change grows, the use of plastic insulation and / or cushioning products has increasingly come into question. However, despite these concerns, the use of these products has increased significantly over the past decade due to new trends in lifestyle and consumer habits. One reason for this is the ever-increasing number of goods being transported around the world, which need to be protected from impacts, shocks, and / or extreme temperatures. A common way to protect goods is to include cushioning and / or insulation materials, such as appropriately shaped inserts, in the packaging. These can be made from a variety of materials, but are typically made from foamed polymers, of which expanded polystyrene (EPS) is by far the cheapest and most common. In some cases, the entire package can be made from EPS. However, EPS is one of the most questioned plastic materials, and many brand owners are seeking more sustainable solutions for these packaging applications.

[0003] U.S. Patent No. 10,787,303 discloses a package insulation material for insertion into a package container, the package insulation material including an airlaid natural fiber batt having a foldable paper sheet material adhered to both sides. U.S. Patent No. 2021 / 0061542 discloses an insulated package assembly including a box defining a box cavity containing an insulating liner. The insulating liner is disclosed to be made of polyethylene terephthalate (PET), polyethylene, polyurethane, or polypropylene. Biodegradable insulating liners can be made from recycled cotton.

[0004] U.S. Patent No. 10,625,918 discloses a foldable, biodegradable cushion sheet that includes a flexible base film and a plurality of cushions disposed on the upper surface of the flexible base film. The cushion sheet can be folded in one direction, and the inner corners can be firmly fixed.

[0005] A disadvantage of prior art inserts is that they cannot be easily folded when placed inside a box or container due to the thickness of the insulating material of the insert. Therefore, there is a need for an improved packaging insert that can be easily folded to fit into a box or container and can be used therein to protect the product from impact and / or to insulate the packaged product. Summary of the Invention

[0006] The general purpose is to provide a packaging insert to protect the product from impact and / or to insulate the packaged product.

[0007] It is a specific object to provide a package insert that is bendable.

[0008] These and other objectives are achieved by the embodiments disclosed herein.

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

[0010] One aspect of the present invention relates to a package insert including a plurality of cellulose-based airlaid or solid foam substrates, each having a first major side and a second major side opposite the first major side. The package insert also includes a first paper-based sheet attached to the first major side of the plurality of cellulose-based airlaid or solid foam substrates, and a second paper-based sheet attached to the second major side of the plurality of cellulose-based airlaid or solid foam substrates. The edges of adjacent adjacent cellulose-based airlaid or solid foam substrates are beveled, forming an angle of less than 90° between them. At least one hinge section is interposed between the beveled edges of the adjacent cellulose-based airlaid or solid foam substrates. The package insert is foldable at the at least one hinge section.

[0011] Another aspect of the present invention relates to a package assembly including a package including a base and a number of sidewalls defining a cavity. The package assembly also includes a package insert according to the above disposed within the cavity.

[0012] A further aspect of the invention relates to a method for making a package insert, the method comprising cutting a cellulose-based airlaid substrate or solid foam substrate blank at a first angle less than 45° relative to a normal to a major side of the cellulose-based airlaid substrate or solid foam substrate blank and at a second angle equal to but opposite in sign to the first angle to obtain at least a first cellulose-based airlaid substrate or solid foam substrate including a beveled edge, a second cellulose-based airlaid substrate or solid foam substrate including two beveled edges, and a third cellulose-based airlaid substrate or solid foam substrate including a beveled edge. The method also includes inverting the second cellulose-based airlaid substrate or solid foam substrate so that the beveled edge of the first cellulose-based airlaid substrate or solid foam substrate faces the first beveled edge of the second cellulose-based airlaid substrate or solid foam substrate and the beveled edge of the third cellulose-based airlaid substrate or solid foam substrate blank faces the second beveled edge of the second cellulose-based airlaid substrate or solid foam substrate blank. The beveled edges of the first cellulose-based airlaid substrate or solid foam substrate and the first beveled edge of the second cellulose-based airlaid substrate or solid foam substrate form an angle of less than 90° between the beveled edges. The beveled edge of the third first cellulose-based airlaid substrate or solid foam substrate and the second beveled edge of the second first cellulose-based airlaid substrate or solid foam substrate form an angle of less than 90° with each other. The method further includes attaching a first paper-based sheet to a first major side of at least the first, second, and third second beveled edges and a second paper-based sheet to a second major side of at least the first, second, and third second beveled edges to form a package insert, the package insert including a first hinge section interposed between the beveled edge of the first cellulose-based airlaid or solid foam substrate and the first beveled edge of the second cellulose-based airlaid or solid foam substrate.The package insert also includes a second hinge section interposed between the second beveled edge of the second cellulose-based airlaid or solid foam substrate and the beveled edge of the third cellulose-based airlaid or solid foam substrate.

[0013] The package insert is designed to be foldable while still providing effective impact protection and insulation for products. The foldable nature of the package insert allows it to fit snugly into a variety of packages, boxes, and containers without significantly compromising the cushioning and insulating properties of the package insert at the fold. This is achieved by having continuous or adjacent cellulose-based airlaid or solid foam substrates with beveled edges that form an angle of less than 90°. The opposing beveled edges form a hinge section. The package insert is designed to be easily folded at the hinge section, and when folded at the hinge section, the continuous cellulose-based airlaid or solid foam substrates are positioned adjacent to each other, providing cushioning and insulating properties at the fold.

[0014] The embodiments, together with further objects and advantages thereof, will be best understood by referring to the following description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0015] [Figure 1] 1 is a cross-sectional view of a package insert according to an embodiment. [Figure 2] FIG. 10 is a cross-sectional view of a package insert according to another embodiment. [Figure 3] 10 is a cross-sectional view of a package insert according to a further embodiment. [Figure 4A] 10A-10C illustrate an embodiment of manufacturing a package insert. [Figure 4B] 10A-10C illustrate an embodiment of manufacturing a package insert. [Figure 4C]10A-10C illustrate an embodiment of manufacturing a package insert. [Figure 4D] 10A-10C illustrate an embodiment of manufacturing a package insert. [Figure 5] 1 illustrates a package assembly including a package insert according to an embodiment. [Figure 6] 1 illustrates a package assembly including a package insert according to an embodiment. [Figure 7] FIG. 7 is an enlarged view of a portion of the packaging assembly shown in FIG. 6. [Figure 8] 1 is a flowchart illustrating a method for manufacturing a package insert according to an embodiment. [Figure 9] FIG. 4 is a top view of the package insert shown in cross section in FIG. 3. DETAILED DESCRIPTION OF THE INVENTION

[0016] The present invention relates generally to package inserts, and more particularly to package inserts suitable for protecting packaged goods from impact and / or for insulating packaged goods.

[0017] The package inserts of the present embodiments are useful as environmentally friendly alternatives to corresponding package inserts made from foamed polymers, such as expanded polystyrene (EPS). As disclosed in U.S. Patent No. 10,787,303 and U.S. Patent Application Publication No. 2021 / 0061542, some package inserts are made from environmentally friendly materials, such as recycled cotton. While these package inserts are said to be foldable, the thickness of the package inserts means that they cannot be easily folded to fit into the corners of various packages, boxes, and containers without significantly compressing at the folds. Compression at the folds reduces the effectiveness of the package insert in protecting the product from impact at the compressed folds. Furthermore, if the package insert is intended to insulate heated or cooled products, the compressed folds create weak spots that reduce the insulating ability of the package insert.

[0018] The package insert of this embodiment is designed to be foldable while still providing effective impact protection and insulation for products. This means that the package insert can be folded to fit snugly into various packages, boxes, and containers without significantly compromising the cushioning and insulating properties of the package insert at the fold. This is achieved by using a continuous cellulose-based airlaid or solid foam substrate with beveled edges that form an angle of less than 90° with each other. A hinge section is interposed between the opposing beveled edges. The package insert is designed to be easily folded at the hinge section, and when folded at the hinge section, the continuous cellulose-based airlaid or solid foam substrates are adjacent to each other, providing cushioning and insulating properties even at the fold.

[0019] FIG. 1 illustrates a package insert 10 according to an embodiment. The package insert 10 includes a plurality of, i.e., at least two, cellulose-based airlaid or solid foam substrates 20, each having a first major side 22 and a second major side 24 opposite the first major side 22. The package insert 10 also includes a first paper-based sheet 30 attached to the first major side 22 of the plurality of cellulose-based airlaid or solid foam substrates 20, and a second paper-based sheet 40 attached to the second major side 24 of the plurality of cellulose-based airlaid or solid foam substrates 20. The edges 26, 28 of consecutive cellulose-based airlaid or solid foam substrates 20 facing each other are beveled edges 26, 28. These beveled edges 26, 28 form an angle of less than 90° between each other. The package insert 10 includes at least one hinge section 50 interposed between the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20. The package insert 10 is then foldable at the at least one hinge section 50.

[0020] 1 , a number of cellulose-based airlaid or solid foam substrates 20 are sandwiched between first and second paper-based sheets 30, 40, thereby forming a number of sandwich sections 52. The package insert 10 further includes at least one hinge section 50 interposed between adjacent sandwich sections 52 of the number of sandwich sections 52. Thus, each hinge section 50 is located between two consecutive sandwich sections 52. The package insert 10 is then easily foldable at the at least one hinge section 50.

[0021] The package insert 10 includes a number of separate cellulose-based airlaid or solid foam substrates 20, also referred to herein as panels. These multiple cellulose-based airlaid or solid foam substrates 20 are separated from one another, thereby comprising individual substrates or panels 20. The multiple cellulose-based airlaid or solid foam substrates 20 are arranged one after the other along a longitudinal axis A that passes through the multiple cellulose-based airlaid or solid foam substrates 20. The multiple cellulose-based airlaid or solid foam substrates 20 are held together by first and second paper-based sheets 30, 40 attached to first and second major sides or surfaces 22, 24 of the multiple cellulose-based airlaid or solid foam substrates 20. The package insert 10 thereby includes a so-called sandwich section 52 in which the multiple cellulose-based airlaid or solid foam substrates 20 are sandwiched between the first and second paper-based sheets 30, 40. Each sandwich section 52 thereby includes a cellulose-based airlaid or solid foam substrate 20 sandwiched between two paper-based sheets 30, 40. Successive sandwich sections 52 within the package insert 10 are separated from one another by respective hinge sections 50. The diagonal lines in FIG. 1 separate the sandwich sections 52 and the hinge sections 50.

[0022] Many cellulose-based airlaid or solid foam substrates 20 are relatively thick compared to the two paper-based sheets 30, 40, as shown in FIG. 1 . The cellulose-based airlaid or solid foam substrate 20 provides cushioning and / or insulation for the package insert 10. This relatively large thickness of the cellulose-based airlaid or solid foam substrate 20 means that it cannot be easily folded without causing significant compression of the cellulose-based airlaid or solid foam substrate 20. However, the relatively thin paper-based sheets 30, 40 can be easily folded. This means that the package insert 10 can be simply folded at one or more hinge sections 50, and the cellulose-based airlaid or solid foam substrate 20 can be placed into the package 80 without significant compression at the corners 12A, 12B of the package 80 (see FIGS. 5-7 ).

[0023] In one embodiment, the average thickness of each of the multiple cellulose-based airlaid or solid foam substrates 20 is preferably at least 10 times the average thickness of each of the two paper-based sheets 30, 40, and preferably at least 15 times, e.g., at least 20 times, at least 25 times, or at least 30 times the average thickness of each of the two paper-based sheets 30, 40. In certain embodiments, the average thickness of each of the multiple cellulose-based airlaid or solid foam substrates 20 is preferably at least 50 times the average thickness of each of the two paper-based sheets 30, 40.

[0024] At least one hinge section 50 is interposed between two consecutive or adjacent beveled edges 26, 28. The two beveled edges 26, 28 face each other and together form an angle α when multiple cellulose-based airlaid or solid foam substrates 20 are positioned one after the other along the longitudinal axis A of the package insert 10. This angle α formed by the two beveled edges 26, 28 facing each other lies in a cross-sectional plane of the package insert 10 along the longitudinal axis A and is further shown in FIG. 1 . The beveled edges 26, 28 are edges of the cellulose-based airlaid or solid foam substrate 20 that are not perpendicular to the major sides 22, 24 of the cellulose-based airlaid or solid foam substrate 20. This causes the beveled edges 26, 28 to be cut at an angle β of less than 90° (see FIG. 2 ). In fact, the sum of the angles β at which the two opposing beveled edges are cut forms an angle α of less than 90°. If two opposing beveled edges 26, 28 of a continuous cellulose-based airlaid or solid foam substrate 20 are cut at the same angle β but with opposite signs, the angle α formed by the two opposing beveled edges 26, 28 is equal to 2×β, i.e., α=2×β.

[0025] As shown in FIG. 1 , the two beveled edges 26, 28 face each other to form a wedge-shaped channel or gap 51 between the first and second paper-based sheets 30, 40 within at least one hinge section 50, particularly between portion 34 of the first paper-based sheet 30 and portion 44 of the second paper-based sheet 40, when the continuous cellulose-based airlaid or solid foam substrate 20 is positioned one after the other along axis A. In FIG. 1 , this wedge-shaped channel 51 has its base located on portion 34 of the first paper-based sheet 30 within hinge section 50, its tip located on portion 44 of the second paper-based sheet 40 within hinge section 50, and its sides aligned with the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20. In this case, the tip of the wedge-shaped channel 51 extends along the second paper-based sheet 40 and has an angle α.

[0026] Thus, in one embodiment, at least one hinge section 50 includes a wedge-shaped channel 51 defined by the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20 and the first and second paper-based sheets 30, 40. In particular, at least one hinge section 50 includes a channel or gap 51 that is wedge-shaped when multiple cellulose-based airlaid or solid foam substrates 20 are placed one after the other along the longitudinal axis A of the package insert 10.

[0027] As shown in FIG. 1, the portions 25, 27 of the beveled edges 26, 28 adjacent to the second paper-based sheet 40, i.e., the portions 25, 27 of the beveled edges 26, 28 that form the tip of the wedge-shaped channel 51, are preferably positioned close to each other and may meet at the tip of the wedge-shaped channel 51.

[0028] As shown in FIG. 2 and further described above, the beveled edges 26A, 28B, 26B, 28C (see FIG. 2) of the continuous cellulose-based airlaid or solid foam substrates 20A, 20B, 20C are cut at an angle of less than 45° relative to the normal 1 to the first and second major sides 22A, 22B, 22C, 24A, 24B, 24C of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C.

[0029] In one embodiment, each beveled edge 26A, 28B, 26B, 28C of successive cellulose-based airlaid or solid foam substrates 20A, 20B, 20C is cut at the same angle β that is less than 45° relative to normal 1. However, embodiments are not limited to cutting beveled edges 26A, 28B, 26B, 28C at the same angle. In one embodiment, opposing beveled edges 26A, 28B, 26B, 28C may be cut at different angles β relative to normal 1. For example, beveled edge 26A of first cellulose-based airlaid or solid foam substrate 20A in FIG. 2 may be cut at angle β1 relative to normal 1, while beveled edge 28B of second cellulose-based airlaid or solid foam substrate 20B may be cut at angle β2 relative to normal 1. These two angles β1, β2 are both less than 45°, but may be different. In such an embodiment, the angle formed by the two beveled edges 26A, 28B is β1 + β2. Thus, opposing beveled edges 26A, 28B, 26B, 28C are cut at angles β1 and β2, respectively, which together form angle α. These angles β1 and β2 may be the same or different for each pair of opposing beveled edges 26A, 28B, 26B, 28C. Furthermore, if package insert 10 includes multiple hinge sections 50A, 50B, angles β1 and β2 may be the same or different for different pairs of beveled edges 26A, 28B, 26B, 28C.

[0030] In one embodiment, the beveled edges 26, 28 of the continuous cellulose-based airlaid or solid foam substrate 20 form an angle α selected from the range of 45° to less than 90°. In a preferred embodiment, the angle is selected from the range of 45° to 85°, and more preferably from the range of 45° to 80°.

[0031] In one embodiment, at least one hinge section 50 includes a portion 34 of the first paper-based sheet 30 that is not attached to either the cellulose-based airlaid or solid foam substrate 20 or the second paper-based sheet 40, and a portion 44 of the second paper-based sheet 40 that is not attached to either the cellulose-based airlaid or solid foam substrate 20 or the first paper-based sheet 30. The portions 34, 44 of the first and second paper-based sheets 30, 40, respectively, in the hinge section 50 correspond to the portions 34, 44 of the first or second paper-based sheets 30, 40 that are between successive sandwich sections 52. Thus, the first paper-based sheet 30 comprises sheet portions or sections 31 within the sandwich sections 52, each attached to the first major side 22 of a respective cellulose-based airlaid or solid foam substrate 20, and comprises intermediate sheet portions or sections 34 within at least one hinge section 50, each intermediate sheet portion or section 34 being attached to neither any cellulose-based airlaid or solid foam substrate 20 nor the second paper-based sheet 40. Each intermediate sheet portion or section 34 is positioned between successive sheet portions or sections 31 of successive sandwich sections 52. Accordingly, the second paper-based sheet 40 comprises sheet portions or sections 41 within the sandwich sections 52, each attached to the second major side 24 of a respective cellulose-based airlaid or solid foam substrate 20, and each intermediate sheet portion or section 44 being attached within at least one hinge section 50. However, each such intermediate sheet portion or section 44 of the second paper-based sheet 40 is not attached to the cellulose-based airlaid or solid foam substrate 20 or to the first paper-based sheet 30. Each intermediate sheet portion or section 44 is positioned between successive sheet portions or sections 41 of successive sandwich sections 52.

[0032] In one embodiment, package insert 10 comprises two sandwich sections 52 with an intermediate hinge section 50, as shown in Figure 1. Such package insert 10 can be folded at hinge sections 50 to form an L-shaped package insert 10 when inserted into package 80.

[0033] In other embodiments, the package insert 10 comprises two or more sandwich sections 52A, 52B, 52C, thereby comprising one or more hinge sections 50A, 50B (see FIGS. 2 and 3). In these embodiments shown in FIGS. 2 and 3, the package insert 10 comprises at least a first cellulose-based airlaid or solid foam substrate 20A, a second cellulose-based airlaid or solid foam substrate 20B, and a third cellulose-based airlaid or solid foam substrate 20C. In such embodiments, the opposing edges 26A, 28B of the first and second cellulose-based airlaid or solid foam substrates 20A, 20B are beveled edges 26A, 26B, forming an angle α of less than 90° between them. Correspondingly, the opposing edges 26B, 28C of the second and third cellulose-based airlaid or solid foam substrates 20B, 20C are beveled edges 26B, 26A, forming an angle α of less than 90° between them.

[0034] In this embodiment, the package insert 10 includes three sandwich sections 52A, 52B, and 52C and two hinge sections 50A and 50B. The first hinge section 50A is interposed between the first sandwich section 52A and the second sandwich section 52B, and the second hinge section 50B is interposed between the second sandwich section 52B and the third sandwich section 52C. Because the package insert 10 has two hinge sections 50A and 50B, it can be folded twice. When inserted into a package 80, the folded package insert 10 forms a U-shaped package insert 10, as shown in FIGS. 5 and 6 .

[0035] However, embodiments are not limited to package insert 10 consisting of two or three sandwich sections 52, 52A, 52B, 52C and one or two hinge sections 50, 50A, 50B as shown in Figures 1-3. Thus, package insert 10 may include three or more sandwich sections 52, 52A, 52B, 52C, with each hinge section 50, 50A, 50B interposed between consecutive sandwich sections 52, 52A, 52B, 52C.

[0036] The angle α formed by the beveled edges 26A, 28B of the first and second cellulose-based airlaid or solid foam substrates 20A, 20B may be the same as the angle α formed by the beveled edges 26B, 28C of the second and third cellulose-based airlaid or solid foam substrates 20B, 20C. However, embodiments are not limited thereto. For example, the beveled edges 26A, 28B of the first and second cellulose-based airlaid or solid foam substrates 20A, 20B form an angle α1, and the beveled edges 26B, 28C of the second and third cellulose-based airlaid or solid foam substrates 20B, 20C form an angle α2. In such an example, the angles α1 and α2 are both less than 90° but need not be the same, i.e., α1 ≠ α2.

[0037] In one embodiment, a first cellulose-based airlaid or solid foam substrate 20A includes a straight edge 28A and a beveled edge 26A, a second cellulose-based airlaid or solid foam substrate 20B includes two beveled edges 26B, 28B, and a third cellulose-based airlaid or solid foam substrate 20C includes a straight edge 26C and a beveled edge 28C (see FIG. 2). Thus, in a preferred embodiment, the only edges of multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C that face another cellulose-based airlaid or solid foam substrate 20A, 20B, 20C when arranged one after the other along longitudinal axis A are beveled edges 26A, 26B, 28B, 28C. However, the first or front edge 28A of the first or front cellulose-based airlaid or solid foam substrate 20A, and thus the package insert 10, and the last edge 26C of the third or last cellulose-based airlaid or solid foam substrate 20C, and thus the package insert 10, are cut into straight edges 28A, 26C, i.e., at an angle equal to 90°. The straight edges 28A, 26C are perpendicular to the major sides 22, 24 of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C.

[0038] The multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C preferably have the same dimensions, i.e., average thickness, average length, and average width. However, embodiments are not limited thereto. Preferably, the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C have the same or substantially the same thickness and width, but not necessarily the same length. For example, when positioning a package insert 10 in a cavity 85 of a rectangular package 80 having side walls 86 that are longer than the front wall 88 (and rear wall), the length of the first and third cellulose-based airlaid or solid foam substrates 20A, 20C is substantially the same as, but preferably longer than, the length of the second cellulose-based airlaid or solid foam substrate 20B to obtain a U-shaped package insert 10 extending along the side walls 86 and front wall 88, as shown in FIG. 5 . Additionally, the cellulose-based airlaid or solid foam substrates 20, 20A, 20C, 20C of the package insert 10 can have different thicknesses (but the same length and width), different widths (but the same thickness and width), different lengths (but the same thickness and width), different thicknesses and widths (but the same length), different thicknesses and lengths (but the same width), different widths and lengths (but the same thickness), or different thicknesses, lengths, and widths.

[0039] The first and second paper-based sheets 30, 40 preferably have a length equal to or greater than the combined length of the multiple sandwich sections 52, 52A, 52B, 52C (and thereby the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C) and the at least one hinge section 50, 50A, 50B. The width of the first and second paper-based sheets 30, 40 is preferably substantially equal to the width of the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, or, if the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C have different widths, preferably a width selected within an interval equal to the smallest and largest widths of the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C. In a preferred embodiment, as shown in FIG. 9, the first paper-based sheet 30 has a size and general shape to cover the first major side 22 of the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, and the second paper-based sheet 40 has a corresponding size and general shape to cover the second major side 24 of the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C.

[0040] In one embodiment, as shown in Figure 3, an edge 38 of the first paper-based sheet 30 extends beyond the last cellulose-based airlaid or solid foam substrate 20C of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C, i.e., the third cellulose-based airlaid or solid foam substrate 20C in Figure 3. Similarly, an edge 48 of the second paper-based sheet 40 extends beyond the last cellulose-based airlaid or solid foam substrate 20C of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C. In such cases, it is preferred that the edges 38, 48 of the first and second paper-based sheets 30, 40 be attached to one another.

[0041] In another embodiment, the front portion 36 of the first paper-based sheet 30 extends beyond the front cellulose-based airlaid or solid foam substrate 20A of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C, i.e., the first cellulose-based airlaid or solid foam substrate 20A in Figure 3. Similarly, the front portion 46 of the second paper-based sheet 40 extends beyond the front cellulose-based airlaid or solid foam substrate 20A of the multiple cellulose-based airlaid or solid foam substrates 20A, 20B, 20C. In such cases, the front portions 36, 46 of the first and second paper-based sheets 30, 40 are preferably attached to one another.

[0042] It is also possible to combine these two embodiments, with the front portions 36, 46 of the first and second paper-based sheets 30, 40 attached to one another and the end portions 38, 48 of the first and second paper-based sheets 30, 40 attached to one another, as shown in FIG.

[0043] The front portions 36, 46 may be attached to one another and / or the end portions 38, 48 may be attached to one another using an adhesive, preferably the same adhesive used to attach the first and second paper-based sheets 30, 40 to the multiple cellulose-based airlaid or solid foam substrates 20, 20A, 20B, 20C, as further described herein.

[0044] By attaching the front and / or end portions 36, 46, 38, 48 of the first and second paper-based sheets 30, 40 to one another, the end sides of the front and / or last cellulose-based airlaid or solid foam substrate 20A, 20C are protected by the paper-based sheets 30, 40. This reduces the risk of cellulose-based particles or fibers falling off the package insert 10 when the package insert 10 is inserted into the package 80. During this process, the end sides of the front and / or last cellulose-based airlaid or solid foam substrate 20A, 20C can engage with another package insert 10 already inserted into the cavity 85 of the package 80 or the walls 86, 88 of the package 80. This contact between the unprotected end sides of the front and / or last cellulose-based airlaid or solid foam substrate 20A, 20C and the other package insert 10 or the walls 86, 88 can cause the cellulose-based particles or fibers to fall off the end sides and into the cavity 85 of the package 80. Furthermore, the paper-based sheets 30, 40 generally have a smoother surface than the cellulose-based airlaid or solid foam substrates 20A, 20B, 20C and slide more easily along the package walls 86, 88 and along the paper-based sheets 30, 40 of another package insert 10. As a result, the embodiment shown in FIG. 3 with attached front portions 36, 46 and / or end portions 38, 48 is generally easier to handle when inserting the package insert 10 into the cavity 85 of the package 80 compared to the embodiment of the package insert 10 shown in FIG. 2 with free front and end portions of the first and second paper-based sheets 30, 40.

[0045] The front portions 36, 46 and end portions 48, 48 can be attached to one another anywhere along the end sides of the front and final cellulose-based airlaid or solid foam substrates 20A, 20C. Figure 3 shows an embodiment in which the front portions 36, 46 and end portions 48, 48 are attached to one another closer to one of the major sides of the front and final cellulose-based airlaid or solid foam substrates 20A, 20C rather than to the center of the end sides. In such an embodiment, the attached front portions 36, 46 and end portions 48, 48 can be folded into a U-shaped package insert 10 when folded into the package 80, as shown in Figure 6. The attached front portions 36, 46 and end portions 38, 48 respectively form sealing lips that seal the package insert 10 against the side walls 86, 88 or bottom 82 of the package 80, or against another package insert 10 inserted into the package 80.

[0046] Additionally, the attached front portions 36, 46 and end portions 38, 48 provide protruding structures that can be easily grasped by a user when removing the folded package insert 10 from the cavity 85 of the package 80. Thus, these attached front and end portions 36, 38, 46, 48 can be used as retainers when handling the package insert 10.

[0047] In one embodiment, the first paper-based sheet 30 includes an adhesive 60 provided or applied, such as by coating or spraying, to at least a portion of a major side 32 of the first paper-based sheet 30, with the major side 32 of the first paper-based sheet 30 facing the first major side 22 of the multiple cellulose-based airlaid or solid foam substrates 20, as shown in Figure 1. Correspondingly, the second paper-based sheet 40 preferably includes an adhesive 60 provided to at least a portion of a major side 42 of the second paper-based sheet 40, with the adhesive 60 attached to the second major side 24 of the multiple cellulose-based airlaid or solid foam substrates 20, with the major side 42 of the second paper-based sheet 40 facing the second major side 24 of the multiple cellulose-based airlaid or solid foam substrates 20.

[0048] The first and second paper-based sheets 30, 40 may both be coated with the same adhesive 60, or the first and second paper-based sheets 30, 40 may both be coated with different adhesives 60.

[0049] Next, adhesive 60 can be provided or applied, such as by coating or spraying, to the entire portions 31, 41, 44 of the major sides 32, 42 of the first and second paper-based sheets 30, 40. Alternatively, adhesive 60 can be provided only to portions of the major sides 32, 42 of the sandwich section 52 and at least one hinge section 50 of the major surface 42 of the second paper-based sheet 40. For example, adhesive 60 can be applied along a frame around the circumference of the portions 31, 41, 44 of the major sides 32, 42 of the first and second paper-based sheets 30, 40. It is also possible to apply adhesive 60 to multiple separate locations on the major sides 32, 42 of the first and second paper-based sheets 30, 40.

[0050] Alternatively, or as a complement, instead of providing adhesive 60 on at least a portion 31, 41, 44 of the major sides 32, 42 of the first and second paper-based sheets 30, 40, adhesive 60 may be applied onto at least a portion of the first major side 22 and / or at least a portion of the second major side 42 of multiple cellulose-based airlaid or solid foam substrates 20.

[0051] In one embodiment, the adhesive is selected from the group consisting of pressure-sensitive adhesives, solvent-based adhesives, polymer dispersion adhesives, contact adhesives, and hot melt adhesives. Pressure-sensitive adhesives adhere to the substrate with the application of light pressure. Solvent-based adhesives are mixtures of polymer components dissolved in a solvent. The adhesive hardens when the solvent evaporates. Similarly, polymer dispersion adhesives, also known as emulsion adhesives, are often milky white dispersions based on polyvinyl acetate (PVAc). The adhesive is applied to both the paper-based sheet 30, 40 and many cellulose-based airlaid or solid foam substrates 20 and must be allowed to dry for some time before attaching the paper-based sheet 30, 40 to the cellulose-based airlaid or solid foam substrate 20. Hot melt adhesives are thermoplastic polymers that are applied in a molten state and solidify upon cooling to form a strong bond.

[0052] Presently preferred adhesives include pressure sensitive adhesives, solvent-based adhesives, polymer dispersion adhesives, and hot melt adhesives, as they can provide strong adhesion between the first and second paper base sheets 30, 40 and the multiple cellulosic airlaid or solid foam substrate 20, but only need to be applied to the major sides 32, 42 of the paper base sheets 30, 40 or the major sides 22, 24 of the multiple cellulosic airlaid or solid foam substrate 20.

[0053] Illustrative non-limiting examples of adhesives that can be used to attach the paper-based sheets 30, 40 to the cellulose-based airlaid or solid foam substrate 20 include low density polyethylene (LDPE), an example of a hot melt adhesive. Other non-limiting examples include wood glues or adhesives, such as polyvinyl acetate-based wood glues or adhesives, and wallpaper glues or adhesives, such as starch-based wallpaper glues or adhesives.

[0054] The first and second paper-based sheets 30, 40 can be any paper-based sheets 30, 40 that can be attached to a number of cellulose-based airlaid or solid foam substrates 20 and are flexible enough to be folded at at least one hinge section 50. In one embodiment, the first and second paper-based sheets 30, 40 are selected from the group consisting of paper sheets, paperboard sheets, tissue paper sheets, and nonwoven paper sheets.

[0055] As an example, the first and second paper-based sheets 30, 40 may be selected from the group consisting of kraft paper sheets, cardboard sheets, cartonboard sheets, and corrugated cardboard sheets. Generally, kraft paper sheets are thinner and more flexible than cardboard sheets, cartonboard sheets, and corrugated cardboard sheets. Specific examples of kraft paper sheets that can be used for package inserts include those having a basis weight of 15 to 135 g / m². 2 Preferably, the basis weight is 20 to 60 g / m 2 , and more preferably, the basis weight is 30 to 50 g / m 2 Includes kraft paper sheets.

[0056] The first and second paper-based sheets 30, 40 are typically made from the same type of paper-based material, such as the same type of kraft paper sheet, but different types of paper-based materials, such as different types of kraft paper sheets, can also be used for the first and second paper-based sheets 30, 40.

[0057] The outer major sides of the first and / or second paper-based sheets 30, 40 away from the cellulose-based airlaid or solid foam substrate 20 may optionally be coated to provide, for example, a water-repellent coating or barrier, an oil-repellent coating or barrier, a colored coating, and / or a structured coating. The first and / or second paper-based sheets 30, 40 may include one or more layers of paper-based material. Thus, the first and / or second paper-based sheets 30, 40 may be multi-layer or laminate paper-based sheets.

[0058] The first and second paper-based sheets 30, 40 not only hold the multiple cellulose-based airlaid or solid foam substrates 20 together but also form at least one hinge section 50. The first and second paper-based sheets 30, 40 also provide surface covering for the first and second major sides 22, 24 of the multiple cellulose-based airlaid or solid foam substrates 20, as shown in FIG. 3 , and optionally also provide surface covering for the end sides. This surface covering alleviates the need for surface treatment of the multiple cellulose-based airlaid or solid foam substrates 20 to reduce shedding of cellulose-based particles or fibers from the multiple cellulose-based airlaid or solid foam substrates 20. Furthermore, the first and second paper-based sheets 30, 40 can protect the multiple cellulose-based airlaid or solid foam substrates 20 and the merchandise protected by the package insert 10 from moisture, oils, grease, or other liquids that may penetrate the cellulose-based airlaid or solid foam substrates 20.

[0059] Airlaid or solid foam substrate 20 is cellulose-based when it comprises cellulose and / or lignocellulosic materials as a major portion or component. Cellulosic and / or lignocellulosic materials may be included in cellulose-based airlaid or solid foam substrate 20, including, but not limited to, cellulose and / or lignocellulosic fibers, cellulose and / or lignocellulosic particles, and / or cellulose and / or lignocellulosic fibrils.

[0060] In one embodiment, the multiple cellulose-based airlaid or solid foam substrate 20 comprises cellulose and / or lignocellulose fibers. As used herein, lignocellulose refers to a mixture of cellulose and lignin. The cellulose and / or lignocellulose fibers may further comprise hemicellulose. In certain embodiments, the cellulose and / or lignocellulose fibers are cellulose pulp fibers and / or lignocellulose pulp fibers produced by chemical, mechanical, and / or chemi-mechanical pulping of softwoods and / or hardwoods. For example, the cellulose pulp fibers and / or lignocellulose pulp fibers are in a form selected from the group consisting of sulfate pulp, sulfite pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), medium-density fiberboard fiber (MDF fiber), chemi-thermomechanical pulp (CTMP), high-temperature chemi-thermomechanical pulp (HTCTMP), and combinations thereof.

[0061] The cellulosic and / or lignocellulosic pulp fibers may be bleached or unbleached.

[0062] Cellulosic and / or lignocellulosic fibers can also be produced by other pulping methods and / or from cellulosic or lignocellulosic materials other than wood, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw, or rice husks. Natural fibers that are mixtures of fibers from different sources can also be used, such as mixtures of wood and any of the above materials.

[0063] Many cellulose-based airlaid or solid foam substrates 20 may include one or more additives in addition to the cellulosic and / or lignocellulosic materials. Illustrative examples of such additives include, but are not limited to, blowing agents, also referred to in the art as foaming agents, thickeners, conductive or semiconductive fillers, coupling agents, flame retardants, dyes, impact modifiers, and the like.

[0064] In one embodiment, the average density of the multiple cellulose-based airlaid or solid foam substrates 20 is preferably between 10 and 60 kg / m 3 In certain embodiments, the average density of the multiple cellulose-based airlaid or solid foam substrates 20 is selected within the range of 15 to 60 kg / m 3 It is preferably in the range of 15 to 50 kg / m 3 is within the range.

[0065] In one embodiment, the plurality of cellulose-based airlaid or solid foam substrates 20 are a plurality of cellulose-based airlaid substrates 20. Airlaid substrates (also called airlaid panels) are formed from airlaid materials by a process called airlaid, in which cellulose and / or lignocellulosic fibers and a polymeric binder are mixed with air to form a porous fibrous mixture, which is deposited on a support and solidified or bonded by heating. This airlaid substrate is characterized by its porosity, its open-cell foam properties, and its dry-formed nature, i.e., it is generally produced without the addition of water. The airlaid process was first described in U.S. Pat. No. 3,575,749. Thus, airlaid substrates can be formed from airlaid blanks, drylaid blanks, airlaid mats, drylaid blanks, airlaid webs, or drylaid webs.

[0066] In one embodiment, each cellulose-based airlaid substrate 20 comprises cellulose and / or lignocellulosic fibers at a concentration of at least 70% by weight of the cellulose-based airlaid substrate 20 and a polymeric binder at a concentration selected within the interval of 2.5 to 30% by weight of the cellulose-based airlaid substrate 20.

[0067] In preferred embodiments, each cellulose-based airlaid substrate 20 comprises cellulose and / or lignocellulosic fibers at a concentration of at least 72.5%, more preferably at least 75%, e.g., at least 77.5%, at least 80%, at least 82.5%, or at least 85% by weight of the cellulose-based airlaid substrate 20. In some applications, even higher concentrations of cellulose and / or lignocellulosic fibers may be used, e.g., at least 87.5%, or at least 90%, at least 92.5%, at least 95%, or at least 97.5% by weight of the cellulose-based airlaid substrate 20.

[0068] In some embodiments, each cellulose-based airlaid substrate 20 comprises a polymer binder at a concentration selected from the range of 5-30% by weight of the cellulose-based airlaid substrate 20, preferably from the range of 10-25% by weight of the cellulose-based airlaid substrate 20, e.g., from 12.5-22.5%, or from 15-20% by weight of the cellulose-based airlaid substrate 20.

[0069] Many cellulose-based airlaid substrates 20 may contain small amounts of synthetic materials or fibers mixed with the cellulose and / or lignocellulosic fibers. Synthetic materials or fibers that can be mixed with the cellulose and / or lignocellulosic fibers include, for example, glass or mineral wool and / or carbon fibers. Such synthetic materials or fibers can be added in amounts of 10% (w / w) or less of the cellulose-based airlaid substrate 20, preferably 8% (w / w) or less, such as 6% (w / w) or less, or preferably 4% (w / w) or less of the cellulose-based airlaid substrate 20.

[0070] Many cellulose-based airlaid substrates 20 may contain small amounts of synthetic materials or fibers mixed with the cellulose and / or lignocellulosic fibers. Synthetic materials or fibers that can be mixed with the cellulose and / or lignocellulosic fibers include, for example, glass or mineral wool and / or carbon fibers. Such synthetic materials or fibers can be added in amounts of 10% (w / w) or less of the cellulose-based airlaid substrate 20, preferably 8% (w / w) or less, such as 6% (w / w) or less, or preferably 4% (w / w) or less of the cellulose-based airlaid substrate 20.

[0071] The lengths of fibers, such as cellulosic and / or lignocellulosic fibers, referred to herein are length-weighted average fiber lengths, calculated as the sum of the squares of the individual fiber lengths divided by the sum of the individual fiber lengths, such as described in ISO 16065-1 or ISO 16065-2.

[0072] In one embodiment, the cellulose and / or lignocellulose fibers have a length-weighted average fiber length of at most 10 mm, preferably at most 8 mm, more preferably at most 6 mm, and most preferably at most 5 mm. In a particular embodiment, the cellulose and / or lignocellulose fibers have a length-weighted average fiber length selected in the range of 1 mm to 10 mm, preferably selected in the range of 1 mm to 8 mm, more preferably selected in the range of 1 mm to 6 mm, and most preferably selected in the range of 1 mm to 5 mm.

[0073] It is also possible to include small amounts of longer fibers having a length-weighted average fiber length of 10 mm or greater.

[0074] A polymeric binder is included in the multiple cellulose-based airlaid substrates 20 to bind the multiple cellulose-based airlaid substrates 20 together and preserve their shape and structure during use, handling, and storage. In one embodiment, the polymeric binder can also assist in establishing the foam-like structure of the multiple cellulose-based airlaid substrates 20. In such an embodiment, the polymeric binder is mixed with the cellulosic and / or lignocellulosic fibers during the manufacture of the multiple cellulose-based airlaid substrates 20. The polymeric binder may be added in the form of a powder, but more often is added in the form of polymer fibers that are mixed with the cellulosic and / or lignocellulosic fibers during manufacture. Alternatively, or additionally, the polymeric binder may be added as a solution, emulsion, or dispersion in or on the cellulosic and / or lignocellulosic fibers during the manufacturing process.

[0075] In certain embodiments, the polymer binder is selected from the group consisting of polymer powders, polymer fibers, and combinations thereof.

[0076] The polymer binder may be a natural or synthetic polymer binder, or a mixture of natural polymer binders, a mixture of synthetic polymer binders, or a mixture of natural and synthetic polymer binders, but is preferably a thermoplastic polymer binder.

[0077] In one embodiment, the polymer binder is made from i) a material selected from the group consisting of 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 acetate (PVAc), polyurethane (PU), copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0078] In another embodiment, the polymeric binder is a polymeric binder that is water-soluble at the repulping temperatures of the repulping process. Such a water-soluble polymeric binder means that the package insert 10 is recyclable in the repulping process. In such an embodiment, the polymeric binder is made from i) a material selected from the group consisting of polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly(2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0079] Thus, in one embodiment, the polymer binder is made from a material selected from the group described above, hi another embodiment, the polymer binder is made from a material selected from the group described above and one or more additives.

[0080] In one embodiment, the polymer binder is or comprises (e.g., consists of) monocomponent and / or bicomponent polymer fibers. Bicomponent polymer fibers, also called bico fibers, are composed of a first polymer, copolymer, and / or polymer blend and a second, different polymer, copolymer, and / or polymer blend. In most cases, bicomponent polymer fibers are composed of a core made from a first polymer, copolymer, and / or polymer blend and a sheath made from a second polymer, copolymer, and / or polymer blend, although other combinations of two or more polymers, copolymers, and / or polymer blends are possible.

[0081] In certain embodiments, the polymer binder is, comprises, etc., a monocomponent polymer fiber made from i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives. In another particular embodiment, the polymeric binder is, comprises, e.g., consists of, a bicomponent polymer fiber having i) a first material such as a core consisting of a first material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives, and i) a second material such as a sheath, typically a different material, selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives. In further embodiments, the polymer binder is, comprises, or e.g., consists of a combination or blend of i) monocomponent polymer fibers consisting of a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives, and i) bicomponent polymer fibers having a material such as a core and / or sheath selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0082] The polymeric binder can be made from a single type of polymeric fiber, i.e., the same material in the case of monocomponent polymeric fibers, or the same material in the case of bicomponent polymeric fibers, however, polymeric binders made from one or more, i.e., two or more, different monocomponent polymeric fibers made from different materials and / or one or more different bicomponent polymeric fibers made from different materials can also be used.

[0083] In one embodiment, the polymer binder is a polymer powder made from i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, PVAc, PU, ​​PVA, PEG, PEOX, PVE, PVP, PAA, PMAA, copolymers thereof, and mixtures thereof, and ii) optionally one or more additives.

[0084] Many cellulose-based airlaid substrates 20 may include one or more additives in addition to the natural fibers and polymeric binder described above. The one or more additives may be added to the polymeric binder and / or may be added during the manufacture of the polymeric binder. Alternatively, or additionally, the one or more additives may be added to the cellulosic and / or lignocellulosic fibers. Alternatively, or additionally, the one or more additives may be added to the cellulosic and / or lignocellulosic fibers.

[0085] 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 (e.g., fibrillar, microfibrillar, or nanofibrillar cellulose).

[0086] In one embodiment, the polymeric binder may be in the form of an aqueous (water) solution, emulsion, suspension, or dispersion of the polymeric binder.

[0087] In another embodiment, the plurality of cellulose-based airlaid or solid foam substrates 20 are a plurality of cellulose-based solid foam substrates 20. Such cellulose-based solid foam substrates 20 may be formed from cellulose particles and / or lignocellulose particles, cellulose fibrils and / or lignocellulose fibrils, and / or cellulose fibers and / or lignocellulose fibers. A cellulose-based solid foam substrate 20 comprising cellulose fibers and / or lignocellulose fibers is also referred to herein as a cellulose-based fibrous foam substrate 20.

[0088] Examples of cellulosic and / or lignocellulosic fibers that can be used in the cellulosic solid foam substrate 20 are described above.

[0089] Cellulose fibrils and / or lignocellulose fibrils can be produced by longitudinal fibrillation of cellulose and / or lignocellulose fibers. Such cellulose and / or lignocellulose fibrils may be in the form of so-called microfibrillated cellulose (MFC). MFC refers to cellulose particles, fibers, or fibrils with a width or diameter of 20 nm to 1000 nm.

[0090] There are various methods for producing MFC, including one or more purification steps, prehydrolysis followed by purification, high-shear degradation, or fibril release. To combine energy efficiency and sustainability in MFC production, one or more pretreatment steps are typically required. Thus, the cellulose fibers of the pulp used to produce MFC can be natural or enzymatically or chemically pretreated, for example, to reduce the amount of hemicellulose and / or lignin. Cellulose fibers can be chemically modified before fibrillation, in which case the cellulose molecules contain functional groups other than (or more than) those found in the original cellulose. Such groups include, among others, carboxymethyl (CM), aldehyde and / or carboxyl groups (cellulose obtained by N-oxyl-mediated oxidation, e.g., "TEMPO"), or quaternary ammonium (cationic cellulose). After being modified or oxidized by one of the above methods, the fibers are easily fibrillated by MFC.

[0091] MFCs can be made from wood cellulose fibers from hardwoods and softwoods. They can also be made from microbial sources, agricultural fibers such as straw pulp, bamboo, bagasse, or other non-wood fiber sources. They can be made from pulp, including pulp from virgin fibers, such as mechanical, chemical, and / or thermomechanical pulps. They can also be made from waste or recycled paper.

[0092] Cellulose and / or lignocellulose particles can be produced by grinding cellulose and / or lignocellulose fibers and / or fibrils into particles, such cellulose and / or lignocellulose particles generally having dimensions in the micrometer or nanometer range.

[0093] As used herein, the term "foam" refers to a material created by entrapping air or gas bubbles within a solid or liquid. Typically, the volume of the gas is much greater than the volume of the liquid or solid, and the gas pockets are separated by thin membranes. Mechanical work is performed during foam formation to increase the surface area. This occurs by agitation, dispersing a large amount of gas into a liquid, or injecting gas into a liquid. To reduce surface tension, a blowing agent, usually an amphiphile, surfactant, or surface-active component, is present. The foam generally results in a liquid foam or a solid foam. The cellulose-based solid foam substrate 20 of the package insert 10 is a solid foam.

[0094] The term "solid" as used herein with respect to foams refers to foams that are not liquid or fluid, but are rigid and stable in shape. A solid is a sample of matter that maintains its shape and density when unconfined. A solid may be rigid or susceptible to plastic and / or elastic deformation. The adjective "solid" describes the state or condition of a material that possesses this property. Cellulose-based solid foam substrates are porous.

[0095] 5 and 6, the present invention also relates to a package assembly 70 including a package 80 including a bottom 82 and a plurality of sidewalls 86, 88 that define a cavity 85. The package assembly 70 also includes a package insert 10 according to the present invention and disposed within the cavity 85 as described herein.

[0096] The package 80 can be made from a variety of materials. In one embodiment, the package 80 includes, consists of, or is made from a paper-based material. Illustrative, non-limiting examples of such paper-based materials include cardboard. The paper-based material can also be optionally coated with a barrier coating to limit the ingress of, for example, moisture or grease.

[0097] The package insert 10 of the embodiment can be used to protect various products in different types of packages, including, but not limited to, boxes and containers. The bottom 82 of the package 80 is preferably a quadratic or rectangular bottom 82. In such cases, the package 80 includes four side walls 86, 88 connected to the bottom 82. The package 80 may also include a lid 84. However, embodiments are not limited thereto. The package 80 may include fewer than four side walls 86, 88, such as three side walls 86, 88 with a triangular bottom 82, or may include more than four side walls 86, 88, such as five, six, seven, eight, or more side walls 86, 88 with a pentagonal, hexagonal, heptagonal, or octagonal bottom 82.

[0098] In one embodiment, the package insert 10 is folded at at least one hinge section 50A, 50B to form at least one corner 12A, 12B, which is preferably a 90-degree corner.

[0099] In such a case, the package insert 10 is preferably folded at at least one hinge section 50A, 50B so that the upper portions 26A', 26B', 28B', 28C' (see FIG. 2) of the beveled edges 26A, 26B, 28B, 28C of the continuous cellulose-based airlaid or solid foam substrates 20A, 20B, 20C are adjacent to or adjacent to one another, and preferably contact one another (see FIG. 7). These upper portions 26A', 26B', 28B', 28C' of the beveled edges 26A, 26B, 28B, 28C are adjacent to or adjacent to the first paper-based sheet 30.

[0100] Therefore, by cutting the beveled edges 26A, 26B, 28B, 28C at an angle β<45° so that the beveled edges 26A, 26B, 28B, 28C face each other to form an angle α<90°, the second paper-based sheet 40 facing the walls 86, 88 and / or bottom 82 of the package 80 will be slightly too short, while the first paper-based sheet 30 facing the cavity 85 of the package 80 will be temporarily fastened in the gaps between the successive beveled edges 26A, 26B, 28B, 28C of the corners 12A, 12B. This means that force F1 acts on the upper portions 26A', 26B', 28B', 28C' of beveled edges 26A, 26B, 28B, 28C, pushing the upper portions 26A', 26B', 28B', 28C' toward each other, while force F2, extending along the length of the continuous cellulose-based airlaid or solid foam substrate 20A, 20B, 20C, acts on the opposite lower portions of the beveled edges 26A, 26B, 28B, 28C, as shown in Figure 7. This positions the continuous cellulose-based airlaid or solid foam substrates 20A, 20B, 20C next to each other, minimizing gaps between the cellulose-based airlaid or solid foam substrates 20A, 20B, 20C. As a result, the folded package insert 10 provides good insulation and protection even at the folded points of the package insert 10 by reducing the gaps between the cellulose-based airlaid or solid foam substrates 20A, 20B, 20C.

[0101] 5 and 6, the package insert 10 is folded at first and second hinge sections 50A, 50B to form a U-shaped package insert 10. Correspondingly, the package insert 10 as shown in FIG. 1 is folded to form a generally L-shape.

[0102] The package 80 may contain a single package insert 10 within its cavity 85. However, it is typically preferable to include multiple package inserts 10 within the cavity 85 to protect the product from all sides, including the bottom and top. For example, two package inserts 10, as shown in FIGS. 2 and 3, may be positioned within the package 80 to provide protection and insulation to all four side walls 86, 88, the bottom 82, and the lid 84. It is also possible to include different types of package inserts 10 within a single package 80, such as one or more package inserts 10 including two sandwich sections 52 as shown in FIG. 1, or one or more package inserts 10 including three sandwich sections 52A, 52B, and 52C as shown in FIGS. 2 and 3.

[0103] The package insert 10 of the present invention effectively protects goods and items from impacts and shocks. The package insert 10 also has excellent thermal insulation properties and can be used for thermal insulation, i.e., for insulating heated or cold items.

[0104] A further aspect of the present invention relates to a method for producing a package insert 10, as shown in Figures 4A-4D and 8. The method includes, in step S1, cutting a cellulose-based airlaid substrate or solid foam substrate blank 20' at a first angle β less than 45° relative to a normal 1' to a major side 22' of the cellulose-based airlaid substrate or solid foam substrate blank 20' and at a second angle β equal to but opposite in sign to the first angle β to obtain at least a first cellulose-based airlaid substrate or solid foam substrate 20A including a beveled edge 26A, a second cellulose-based airlaid substrate or solid foam substrate 20B including two beveled edges 26B, 28B, and a third cellulose-based airlaid substrate or solid foam substrate 20C including a beveled edge 28C, as shown in Figure 4B. The method then includes turning second cellulose-based airlaid or solid foam substrate 20B upside down so that beveled edge 26A of first cellulose-based airlaid or solid foam substrate 20A faces first beveled edge 28B of second cellulose-based airlaid or solid foam substrate 20B, and beveled edge 28C of third cellulose-based airlaid or solid foam substrate blank 20C faces second beveled edge 26B of second cellulose-based airlaid or solid foam substrate blank 20B, as shown in FIG. 4C. Beveled edge 26A of first cellulose-based airlaid or solid foam substrate 20A and first beveled edge 28B of second cellulose-based airlaid or solid foam substrate 20B form an angle α of less than 90° between beveled edges 26A, 26B; correspondingly, beveled edge 28C of third cellulose-based airlaid or solid foam substrate 20B and second beveled edge 26B of second cellulose-based airlaid or solid foam substrate 20B form an angle α of less than 90° between beveled edges 26B, 28C.The next step S3 includes attaching a first paper-based sheet 30 to first major sides 22A, 22B, 22C of at least first, second, and third cellulose-based airlaid or solid foam substrates 20A, 20B, 20C and attaching a second paper-based sheet 40 to second major sides 24A, 24B, 24C of at least first, second, and third cellulose-based airlaid or solid foam substrates 20A, 20B, 20C to form package insert 10. Referring to FIG. 2 , package insert 10 includes a first hinge section 50A interposed between beveled edge 26A of first cellulose-based airlaid or solid foam substrate 20A and first beveled edge 28B of second cellulose-based airlaid or solid foam substrate 20B. The package insert 10 also includes a second hinge section 50B interposed between the second beveled edge 26B of the second cellulose-based airlaid or solid foam substrate 20B and the beveled edge 28C of the third cellulose-based airlaid or solid foam substrate 20C.

[0105] In one embodiment, first hinge section 50A includes a wedge-shaped channel 51 defined by beveled edge 26A of first cellulose-based airlaid or solid foam substrate 20A, first beveled edge 28B of second cellulose-based airlaid or solid foam substrate 20B, and first and second paper-based sheets 30, 40. In this embodiment, second hinge section 50B includes a wedge-shaped channel 51 defined by second beveled edge 26B of second cellulose-based airlaid or solid foam substrate 20B, beveled edge 28C of third cellulose-based airlaid or solid foam substrate 20C, and first and second paper-based sheets 30, 40.

[0106] In one embodiment, the method also includes attaching an edge 38 of the first paper-based sheet 30 that extends beyond the third cellulose-based airlaid or solid foam substrate 20C to an edge 48 of the second paper-based sheet 40 that extends beyond the third cellulose-based airlaid or solid foam substrate 20C.

[0107] In one embodiment, the method further includes attaching a front side 36 of the first paper-based sheet 30 extending beyond the first cellulose-based airlaid or solid foam substrate 20A to a front side 46 of a second paper-based sheet 40 extending beyond the first cellulose-based airlaid or solid foam substrate 20A.

[0108] The above-described embodiments should be understood as a few illustrative examples of the present invention. Those skilled in the art will understand that various modifications, combinations, and changes can be made to the embodiments without departing from the scope of the present invention. In particular, different partial solutions in different embodiments can be combined in other configurations, where technically possible.

Claims

1. Package insert (10), A plurality of cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) each having a first main surface (22, 22A, 22B, 22C) and a second main surface (24, 24A, 24B, 24C) opposite to the first main surface (22, 22A, 22B, 22C), A first paper-based sheet (30) attached to the first main side surface (22, 22A, 22B, 22C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), A second paper-based sheet (40) attached to the second main side surface (24, 24A, 24B, 24C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) and Includes, The edges (26, 26A, 26B, 28, 28B, 28C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) that are facing each other are inclined edges (26, 26A, 26B, 28, 28B, 28C), forming an angle (α) of less than 90° between them. At least one hinge section (50, 50A, 50B) is interposed between the inclined edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid substrate or solid foam substrate (20, 20A, 20B, 20C) and Includes, The package insert (10) is foldable in at least one hinge section (50, 50A, 50B). Package insert (10).

2. The package insert according to claim 1, wherein the at least one hinge section (50, 50A, 50B) includes a wedge-shaped channel (51) defined by the inclined edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid substrate or solid foam substrate (20, 20A, 20B, 20C) and the first and second paper-based sheets (30, 40).

3. The package insert according to claim 1, wherein when the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) are successively arranged along the longitudinal axis (A) of the package insert (10), the inclined edges (26, 26A, 26B, 28, 28B, 28C) form an angle (α) of less than 90° between them.

4. The package insert according to claim 1, wherein the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) are sandwiched between the first and second paper-based sheets (30, 40).

5. The package insert according to claim 1, wherein the edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid substrate or solid foam substrate (20, 20A, 20B, 20C) are cut at an angle (β) of less than 45° with respect to the normal (1) of the first and second main surfaces (22, 22A, 22B, 22C, 24, 24A, 24B, 24C).

6. The package insert according to claim 1, wherein the inclined edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid substrate or solid foam substrate (20, 20A, 20B, 20C) form an angle (α) selected within the range of 45° to less than 90°.

7. The package insert (10) It comprises at least a first cellulose-based airlaid substrate or solid foam substrate (20A), a second cellulose-based airlaid substrate or solid foam substrate (20B), and a third cellulose-based airlaid substrate or solid foam substrate (20C), The opposing edges (26A, 28B) of the first and second cellulose-based airlaid substrates or solid foam substrates (20A, 20B) are inclined edges (26A, 28B) and form an angle (α) of less than 90°. The opposing edges (26B, 28C) of the second and third cellulose-based airlaid substrates or solid foam substrates (20B, 20C) are inclined edges (26B, 28C) and form an angle (α) of less than 90°. The package insert according to claim 1.

8. The first cellulose-based airlaid substrate or solid foam substrate (20A) includes a straight edge (28A) and an inclined edge (26A), The second cellulose-based airlaid substrate or solid foam substrate (20B) includes two inclined edges (26B, 28B), The third cellulose-based airlaid substrate or solid foam substrate (20C) includes a straight edge (26C) and an inclined edge (28C), The package insert according to claim 7.

9. The end (38) of the first paper-based sheet (30) extends beyond the last cellulose-based airlaid or solid foam substrate (20C) of the numerous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C), The end (48) of the second paper-based sheet (40) extends beyond the last cellulose-based airlaid or solid foam substrate (20C) of the numerous cellulose-based airlaid or solid foam substrates (20, 20A, 20B, 20C), The package insert according to claim 1, wherein the ends (38, 48) of the first and second paper-based sheets (30, 40) are attached to each other.

10. The front portion (36) of the first paper-based sheet (30) extends beyond the front cellulose-based airlaid substrate or solid foam substrate (20A) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), The front portion (46) of the second paper-based sheet (40) extends beyond the front cellulose-based airlaid substrate or solid foam substrate (20A) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), The package insert according to claim 1, wherein the front portions (36, 46) of the first and second paper-based sheets (30, 40) are attached to each other.

11. The first paper-based sheet (30) includes an adhesive (60) which is coated on at least a portion of the main side surface (32) of the first paper-based sheet (30) and attached to the first main side surface (22, 22A, 22B, 22C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), with the main side surface (32) of the first paper-based sheet (30) facing the first main side surface (22, 22A, 22B, 22C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), and is attached to the first main side surface (22, 22A, 22B, 22C) of the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C). The package insert according to claim 1, wherein the second paper-based sheet (40) includes an adhesive that is coated on at least a portion of the main side surface (42) of the second paper-based sheet (40) and attached to the second main side surfaces (24, 24A, 24B, 24C) of the plurality of cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C), with the main side surface (42) of the second paper-based sheet (40) facing the second main side surfaces (24, 24A, 24B, 24C) of the plurality of cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C).

12. The package insert according to claim 1, wherein the first and second paper-based sheets (30, 40) are selected from the group consisting of paper sheets, cardboard sheets, tissue paper sheets, and nonwoven paper sheets.

13. The package insert according to claim 1, wherein the first and second paper-based sheets (30, 40) are selected from the group consisting of kraft paper sheets, cardboard sheets, carton board sheets, and corrugated cardboard sheets.

14. The package insert according to claim 1, wherein the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) include cellulose fibers and / or lignocellulose fibers.

15. The package insert according to claim 14, wherein the cellulose fibers and / or lignocellulose fibers are cellulose pulp fibers and / or lignocellulose pulp fibers in a form selected from the group consisting of sulfate pulp, sulfite pulp, dissolved pulp, thermomechanical pulp (TMP), high-temperature thermomechanical pulp (HTMP), mechanical fibers for medium-density fiberboard (MDF fibers), chemical thermomechanical pulp (CTMP), high-temperature chemical thermomechanical pulp (HTCTMP), and combinations thereof.

16. The package insert according to claim 1, wherein the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) are a number of cellulose-based airlaid substrates (20, 20A, 20B, 20C).

17. The package insert according to claim 16, wherein the numerous cellulose-based airlaid substrates or solid foam substrates (20, 20A, 20B, 20C) include a polymer binder.

18. Package assembly (70), A package (80) comprising a bottom (82) and numerous side walls (86, 88), defining a cavity (85), A package insert (10) according to any one of claims 1 to 17, positioned within the cavity (85) and A package assembly that includes this.

19. The package assembly according to claim 18, wherein the package insert (10) is bent at at least one hinge section (50, 50A, 50B) to form at least one corner (12A, 12B).

20. The package assembly according to claim 18, wherein the upper parts (26A', 26B', 28B', 28C') of the inclined edges (26, 26A, 26B, 28, 28B, 28C) of the continuous cellulose-based airlaid substrate or solid foam substrate (20, 20A, 20B, 20C) are in contact with each other, and the upper parts (26A', 26B', 28B', 28C') of the inclined edges (26, 26A, 26B, 28, 28B, 28C) are adjacent to the first paper-based sheet (30).

21. The package assembly (70) includes the package insert (10) according to claim 6 or 7, which is positioned within the cavity (85). The package assembly according to claim 18, wherein the package insert (10) is bent at a first hinge section (50A) and a second hinge section (50B) to form a U-shaped package insert (10).

22. A method for manufacturing a package insert (10), To obtain at least a first cellulose-based airlaid substrate or solid foam substrate (20A) including an inclined edge (26A), a second cellulose-based airlaid substrate or solid foam substrate (20B) including two inclined edges (26B, 28B), and a third cellulose-based airlaid substrate or solid foam substrate (20C) including an inclined edge (28C), the cellulose-based airlaid substrate or solid foam substrate blank (20') is cut at a first angle (β) less than 45° with respect to the normal (1') of the main side surface (22') of the cellulose-based airlaid substrate or solid foam substrate blank (20'), and at a second angle (β) equal to the first angle (β) but with the opposite sign (S1), The second cellulose-based airlaid substrate or solid foam substrate (20B) is inverted (S2) such that the inclined edge (26A) of the first cellulose-based airlaid substrate or solid foam substrate (20A) faces the first inclined edge (28B) of the second cellulose-based airlaid substrate or solid foam substrate (20B), and the inclined edge (28C) of the third cellulose-based airlaid substrate or solid foam substrate (20C) faces the second inclined edge (26B) of the second cellulose-based airlaid substrate or solid foam substrate (20B), The inclined edge portion (26A) of the first cellulose-based airlaid substrate or solid foam substrate (20A) and the first inclined edge portion (28B) of the second cellulose-based airlaid substrate or solid foam substrate (20B) form an angle (α) of less than 90° between the inclined edges (26A, 28B). The inclined edge (28C) of the third cellulose-based airlaid substrate or solid foam substrate (20C) and the second inclined edge (26B) of the second cellulose-based airlaid substrate or solid foam substrate (20B) form an angle (α) of less than 90° between the inclined edges (26B, 28C). The second cellulose-based airlaid substrate or solid foam substrate (20B) is inverted (S2), To form the package insert (10), a first paper-based sheet (30) is attached to the first main side surface (22A, 22B, 22C) of at least the first, second, and third cellulose-based airlaid substrates or solid foam substrates (20A, 20B, 20C), and a second paper-based sheet (40) is attached to the second main side surface (24A, 24B, 24C) of at least the first, second, and third cellulose-based airlaid substrates or solid foam substrates (20A, 20B, 20C) (S3), wherein the package insert (10) is, A first hinge section (50A) interposed between the inclined edge (26A) of the first cellulose-based airlaid substrate or solid foam substrate (20A) and the first inclined edge (28B) of the second cellulose-based airlaid substrate or solid foam substrate (20B), and The invention includes a second hinge section (50B) interposed between the second inclined edge (26B) of the second cellulose-based airlaid substrate or solid foam substrate (20B) and the inclined edge (28C) of the third cellulose-based airlaid substrate or solid foam substrate (20C), The above-mentioned installation (S3) A method that includes this.

23. The first hinge section (50A) includes a wedge-shaped channel (51) defined by the inclined edge (26A) of the first cellulose-based airlaid substrate or solid foam substrate (20A), the first inclined edge (28B) of the second cellulose-based airlaid substrate or solid foam substrate (20B), and the first and second paper-based sheets (30, 40). The method according to claim 22, wherein the second hinge section (50B) includes a wedge-shaped channel (51) defined by the second inclined edge (26B) of the second cellulose-based airlaid substrate or solid foam substrate (20B), the inclined edge (28C) of the third cellulose-based airlaid substrate or solid foam substrate (20C), and the first and second paper-based sheets (30, 40).

Images