Air-laid blanks and cushioning inserts

Abstract

An air-laid blank (10) comprises natural fibers and a polymer binder. The air-laid blank (10) comprises a cushioning portion (14) comprising a plurality of cavities (13) extending into the air-laid blank (10). The air-laid blank (10) also comprises a frame portion (15) lacking any cavities extending into the air-laid blank (10). The frame portion (15) encircles the cushioning portion (14). The air-laid blank (10) is used to produce cushioning inserts (60A, 60B) configured to be inserted into packaging boxes (50) to protect goods or products (70) packaged in the packaging boxed (50).

1 . An air-laid blank comprising:
 natural fibers; and   a polymer binder, wherein   the air-laid blank comprises:
 a cushioning portion comprising a plurality of cavities extending into the air-laid blank; and 
 a frame portion lacking any cavities extending into the air-laid blank, wherein the frame portion encircles the cushioning portion. 
   
     
     
         2 . The air-laid blank according to  claim 1 , wherein the plurality of cavities extends through a portion of a thickness of the air-laid blank from a first major surface of the air-laid blank towards a second, opposite major surface of the air-laid blank but not through an entirety of the thickness of the air-laid blank. 
     
     
         3 . The air-laid blank according to  claim 1 , wherein a distance between adjacent cavities in the cushioning portion is less than twice a largest side length or a diameter of the adjacent cavities. 
     
     
         4 . The air-laid blank according to  claim 1 , wherein a distance between adjacent cavities in the cushioning portion is less than twice an average side length or an average diameter of the plurality of cavities. 
     
     
         5 . The air-laid blank according to  claim 1 , wherein each cavity of at least a portion of the plurality of cavities overlaps with another cavity of at least the portion of the plurality of cavities. 
     
     
         6 . The air-laid blank according to  claim 1 , wherein the cushioning portion further comprises:
 a bottom comprising the natural fibers and the polymer binder; and   a plurality of protruding structures comprising the natural fibers and the polymer binder and extending from the bottom.   
     
     
         7 . The air-laid blank according to  claim 1 , wherein an average density of air-laid material in the frame portion is higher than an average density of air-laid material in the cushioning portion. 
     
     
         8 . (canceled) 
     
     
         9 . The air-laid blank according to  claim 1 , wherein the air-laid blank comprises:
 at least 70% by weight of the natural fibers; and   from 2.5 up to 30% by weight of the polymer binder.   
     
     
         10 . The air-laid blank according to  claim 1 , wherein the natural fibers comprise wood fibers. 
     
     
         11 . (canceled) 
     
     
         12 . The air-laid blank according to  claim 1 , wherein the polymer binder is selected from a group consisting of: a polymer powder, polymer fibers, and a combination thereof. 
     
     
         13 . The air-laid blank according to  claim 12 , wherein the thermoplastic polymer fibers are selected from a group consisting of: mono-component thermoplastic polymer fibers, bi-component thermoplastic polymer fibers, and a mixture thereof. 
     
     
         14 . The air-laid blank according to  claim 1 , wherein the polymer binder is made from i) a material selected from a group consisting of: polyethylene (PE), ethylene acrylic acid copolymer (EAA), ethylene-vinyl acetate (EVA), polypropylene (PP), polystyrene (PS), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), polyvinyl alcohol (PVA), polyethylene glycol (PEG), poly (2-ethyl-2-oxazoline) (PEOX), polyvinyl ether (PVE), polyvinylpyrrolidone (PVP), polyacrylic acid (PAA), polymethacrylic acid (PMAA), polyvinyl acetate (PVAc), polyurethane (PU), copolymers thereof and mixtures thereof, and ii) optionally one or more additives. 
     
     
         15 . A method of producing an air-laid blank, the method comprising:
 introducing natural fibers and a polymer binder, or a mixture thereof, or both, into at least one inlet of a forming head;   transporting the natural fibers and the polymer binder, or the mixture thereof, or both to an outlet of the forming head;   capturing the natural fibers and the polymer binder, or the mixture thereof, or both, as an unbound air-laid web on a collector arranged in connection with the outlet of the forming head;   applying gas pulses onto the unbound air-laid web to form a cushioning portion comprising a plurality of cavities extending into the unbound air-laid web, wherein the cushioning portion is encircled by a frame portion of the unbound air-laid web and the frame portion lacks any cavities extending into the unbound air-laid web; and   heat treating the unbound air-laid web to at least partly melt the polymer binder and form an air-laid blank.   
     
     
         16 . The method according to  claim 15 , wherein the heat treating comprises heat treating the unbound air-laid web to at least partly melt the polymer binder and form the air-laid blank with the cushioning portion comprising the plurality of cavities extending into the air-laid blank and the frame portion lacking any cavities extending into the air-laid blank, and wherein the frame portion encircles the cushioning portion. 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . A cushioning insert made of an air-laid blank comprising natural fibers and a polymer binder, wherein the cushioning insert comprises:
 a cushioning portion comprising a plurality of cavities extending into the cushioning insert; and   a frame portion lacking any cavities extending into the cushioning insert, wherein the frame portion encircles the cushioning portion.   
     
     
         21 . The cushioning insert according to  claim 20 , wherein the plurality of cavities extend through a portion of a thickness of the cushioning insert from a first major surface of the cushioning insert towards a second, opposite major surface of the cushioning insert but not through an entirety of the thickness of the cushioning insert. 
     
     
         22 . The cushioning insert according to  claim 20 , wherein a distance between adjacent cavities in the cushioning portion is less than twice a largest side length or a diameter of the adjacent cavities. 
     
     
         23 . The cushioning insert according to  claim 20 , wherein a distance between adjacent cavities in the cushioning portion is less than twice an average side length or an average diameter of the plurality of cavities. 
     
     
         24 . The cushioning insert according to  claim 20 , wherein each cavity of at least a portion of the plurality of cavities overlaps with another cavity of at least the portion of the plurality of cavities. 
     
     
         25 . The cushioning insert according to  claim 20 , wherein the cushioning portion further comprises:
 a bottom; and   a plurality of protruding structures extending from the bottom.   
     
     
         26 . (canceled) 
     
     
         27 . A packaging assembly comprising:
 a packaging box having a bottom and at least one side wall attached to the bottom, wherein the bottom and the at least one side wall define a packaging volume; and   a first cushioning insert according to  claim 20  arranged on the bottom of the packaging box with the plurality of cavities facing away from the bottom of the packaging box.   
     
     
         28 . (canceled)