TECHNICAL FIELD

The present invention generally relates to packaging products, and in particular to methods and apparatuses for manufacturing folded packaging products.

BACKGROUND

With growing awareness for the environment and humanly induced climate change, the use of single use plastic items and products has come more and more into question. However, despite this concern the use of these items and products has grown vastly with new trends in lifestyles and consumer habits of the last decade. One reason for this is that more and more goods are transported around the globe and these goods need protection against impact or shock. A common way of protecting the goods is to include cushioning and/or insulating elements or products, such as inserts of suitable form into the packaging. These can be made from different materials but are typically made from a foamed polymer, of which expanded polystyrene (EPS) is by far cheapest and most common. In some cases, the entire packaging can be made out of EPS. EPS is, however, one of the most questioned plastic materials and many brand owners are looking for more sustainable solutions for these packaging applications. Many countries have also begun to take legislative actions against single use plastic items and products, which increases the pressure to find alternative solutions.

More sustainable alternatives to polymer products exist today, such as inserts made by a process known as pulp molding, where a fiber suspension is sucked against a wire mold by vacuum. Another technique for forming such inserts are described in U.S. patent application no. 2010/0190020, European patent no. 1 446 286 and International application no. 2014/142714, which concern hot pressing of porous fiber mats produced by the process called air-laying into structures with matched rigid molds or by membrane molding.

There is still a need for efficient methods and apparatuses for manufacturing packaging products, and in particular folded packaging products designed to protect goods and articles from impacts and shock during transport and/or storage. SUMMARY

It is a general objective to provide methods and apparatuses for manufacturing folded packaging products designed to protect goods and articles from impacts and shock during transport and/or storage.

This and other objectives are met by embodiments of the present invention.

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

An aspect of the invention relates to a method for manufacturing a folded packaging product. The method comprises folding a section of an air-laid blank against a male mold. The air-laid blank is transported in a transport direction on a conveyor and the male mold is moving in the transport direction. The method also comprises compacting the folded section of the air-laid blank against the male mold to form at least one depression in at least one inner surface of the folded section of the airlaid blank. The at least one inner surface faces the male mold. The method further comprises cutting the folded section of the air-laid blank from a remainder of the air-laid blank to form a folded packing product having a cavity in at least one inner surface formed by the at least one depression. The cavity is designed to house a packaged article or at least a portion thereof.

Another aspect of the invention relates to an apparatus for manufacturing a folded packaging product. The apparatus comprises a conveyor arranged to transport an air-laid blank. The apparatus also comprises a male mold movable in a transport direction of the conveyor. The apparatus further comprises folding means arranged to fold a section of the air-laid blank against the male mold movable in the transport direction of the conveyor. The apparatus additionally comprises compacting means arranged to compact the folded section of the air-laid blank around the male mold to form at least one depression in at least one inner surface of the folded section of the air-laid blank. The at least one inner surface faces the male mold. The apparatus also comprises cutting means arranged to cut the folded section of the air-laid blank from a remainder of the air-laid blank to form a folded packing product having a cavity in at least one inner surface. The cavity is designed to house a packaged article or at least a portion thereof.

The method and apparatus of the present invention enable production of folded packaging products from air-laid blanks in a time efficient and automated way requiring little, if any, manual labor to produce folded packaging products designed to protect articles and goods from impacts and shock during transport and/or storage.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments, together with further objects and advantages thereof, may best be understood by making reference to the following description taken together with the accompanying drawings, in which:

Fig. 1 is a flow chart illustrating a method for manufacturing a folded packaging product according to an embodiment;

Fig. 2 is a flow chart illustrating an embodiment of the folding step in Fig. 1 ;

Fig. 3 is a flow chart illustrating another embodiment of the folding step in Fig. 1 ;

Fig. 4 is a flow chart illustrating an embodiment of the compacting step in Fig. 1 ;

Fig. 5 is a flow chart illustrating an additional, optional step of the method in Fig. 1 according to an embodiment;

Fig. 6 is a flow chart illustrating additional, optional steps of the method in Fig. 1 according to an embodiment;

Fig. 7 is a schematic illustration of an apparatus for manufacturing a folded packaging product according to an embodiment;

Fig. 8 is a schematic illustration of an apparatus for manufacturing a folded packaging product according to an embodiment together with an apparatus for producing an air-laid blank;

Fig. 9 is a schematic illustration of an apparatus for manufacturing a folded packaging product according to an embodiment during a compacting operation;

Fig. 10 is a schematic illustration of an apparatus for manufacturing a folded packaging product according to an embodiment during a cutting operation; Fig. 11 is schematic illustration of a portion of an apparatus for manufacturing a folded packaging product according to an embodiment capable of pre-forming at least one crease;

Figs. 12A and 12B are schematic illustrations of an apparatus for manufacturing a folded packaging product according to an embodiment capable of compacting the cut and folded section of the air-laid blank;

Figs. 13A to 13C are schematic illustrations of cross-sectional views of air-laid blanks following a compacting operation;

Fig. 14 is a schematic illustration of a folded packing product according to an embodiment; and

Fig. 15 is a schematic illustration of a cross-sectional view of the folded packing product in Fig. 14.

DETAILED DESCRIPTION

The present invention generally relates to packaging products, and in particular to methods and apparatuses for manufacturing folded packaging products.

Folded packaging products manufactured according to the present invention are useful as environmentally more friendly replacements to corresponding packaging products made of or from foamed polymers, for instance expanded polystyrene (EPS). The folded packaging products are manufactured from an air-laid blank. An air-laid blank, sometimes also referred to as dry-laid blank, airlaid mat, dry-laid mat, air-laid web or dry-laid web, is formed by a process known as air-laying, in which natural fibers and optionally binders are mixed with air to form a porous fiber mixture deposited onto a support and consolidated or bonded by heating or thermoforming. This air-laid blank is characterized by being porous, having the character of an open cell foam and being produced in a so-called dry forming method, i.e., generally without addition of water. The air-laying process was initially described in U.S. patent no. 3,575,749.

The folded packaging products as manufactured according to the present invention at least partly maintain properties of the air-laid blank, from which it is produced, such as the porosity and open cell foam structure. As a consequence, the folded packaging products provide excellent shock absorption or damping and/or thermal insulation. This means that the folded packaging products are well designed to protect articles packed in the folded packaging products from, among others, impacts during transport and storage. The folded packaging products could, hence, be used as inserts or other forms of packaging products. The good thermal insulating properties of the folded packaging products further imply that the folded packaging products could be used to enclose temperature sensitive or tempered articles, such as food or beverages, which should be kept within defined temperature ranges.

Furthermore, the packaging products as manufactured according to the present invention are folded packaging products that may protect multiple sides of packaged articles or goods and even fully enclose such packaged articles. As a consequence, the packaged articles are more effectively protected against shocks and high or low temperatures as compared to traditional packaging products that may only protect a portion of the packaged articles, thereby requiring multiple packaging products to fully protect the packaged articles. Furthermore, by folding the packaging product around the packaged articles it is possible to protect larger packaged articles that are too large to fit into cavities pressed into packaging products or that can be protected by deep drawn packaging products.

The traditional approach of manufacturing folded packaging products from air-laid blanks and other environmentally friendly materials, such as cellulose substrates, is generally slow and demanding a lot of manual labor. Typically, a starting air-laid blank or cellulose substrate is first produced in a dedicated machine and then manually transported to a cutting machine to produce several cut air-laid blank or cellulose substrate pieces. These pieces are then manually transported to a press that presses and optionally forms the pieces into packing products or folded packaging products in one or more press and fold operations. The present invention relates to methods and apparatuses that can produce folded packaging products from air-laid blanks in a more automated way, in a shorter period of time and requiring less manual labor. The apparatuses of the present invention may in fact be connected in line with an apparatus for manufacturing the air-laid blank that is used as starting material for producing the folded packaging products.

An aspect of the invention relates to a method of manufacturing a folded packaging product 20, see Figs. 1 and 7. The method comprises folding, in step S1 , a section 19 of an air-laid blank 10 against a male mold 120. The air-laid blank 10 is transported in a transport direction 115 on a conveyor 110 and the male mold 120 is moving in the transport direction 115. The method also comprises compacting, in step S2, the folded section 19 of the air-laid blank 10 against the male mold 120 to form at least one depression 17, 18, see Figs. 13A to 13C, in at least one inner surface 11 , 12, 16 of the folded section 19 of the air-laid blank 10. The at least one inner surface 11, 12, 16 faces the male mold 120. The folded section 19 of the air-laid blank 10 is cut in step S3 from a remainder of the air-laid blank 10 to form a folded packaging product 20 having a cavity 27, 28, see Fig. 14, in at least one inner surface 21 , 22 formed by the at least one depression 17, 18. This cavity 27, 28 is designed to house a packaged article or goods or at least a portion thereof.

The method of the invention and as disclosed in Fig. 1 thereby takes a fundamentally different approach from the previous manual processes in manufacturing folded packaging products 20 from airlaid blanks 10. In more detail, the present invention folds and compacts a section 19 of the air-laid blank 10 prior to cutting this section or portion 19 from a remainder of the air-laid blank 10. This is possible by having a movable male mold 120 that is moving together with the air-laid blank 10 and then folding and compacting a section 19 of the air-laid blank 10 against this movable male mold 120. Hence, the male mold 120 moves in the transport direction 115 of the conveyor 110 in synchrony with the portion of the air-laid blank 10 on the conveyor 110, i.e., together with and at a same speed as the air-laid blank 10 on the conveyor 110. The section 19 of the air-laid blank 10 is thereby folded in the direction of and into contact with the male mold 120 in step S1 .

In an embodiment, step S1 in Fig. 1 comprises folding the section 19 of the air-laid blank 10 against the male mold 120 to form at least one fold F, F1 , F2 substantially parallel with the transport direction 115. Hence, the section 19 of the air-laid blank 10 is folded against the male mold 120 to form one fold F, see Figs. 13A and 13C, or multiple, such as two, folds F1, F2, see Fig. 13B, in the section 19 of the airlaid blank 10. If the male mold 120 is comparatively thin the section 19 of the air-laid blank 10 can be folded in step S1 so that the opposite inner surfaces 11 , 12 of the section 19 of the air-laid blank 10 are close to each other, thereby leaving merely a small gap as shown in Figs. 13A and 13C. In such a case, a single fold F is formed at the junction of the two inner surfaces 11 , 12. However, if the male mold 120 is thicker, the section 19 of the air-laid blank 10, will be folded in step S1 so that the two inner surfaces 11 , 12 are spaced apart as shown in Fig. 13B and are interconnected by an inner intermediate surface 16. In such a case, two folds F1 and F2 are formed, one fold F1 at the junction of a first inner surface 11 and the inner intermediate surface 16 and another fold F2 at the junction of a second inner surface 12 and the inner intermediate surface 16.

The one or more folds F, F1 , F2 in the section 19 of the air-laid blank 10 is substantially parallel with transport direction 115. Hence, by folding edge portions 19A, 19B of the section 19 of the air-laid blank 10, see Figs. 8-10, against the male mold 120, the section 19 will be folded, in step S1, along one or more folds F, F1 , F2 in the main longitudinal extension of the air-laid blank 10 as positioned on the conveyor 110 and thereby in the transport direction 115. The one or more folds F, F1 , F2 do not necessarily need to be present in the middle of the width W of air-laid blank 10, see Fig. 9, or be symmetrical relative to this middle W. Fig. 13C illustrates an example of such a situation, in which the fold F is not present in the middle W of the air-laid blank 10 but rather closer to one of its edges. As a consequence, lengths L1 , L2 of the two outer surfaces 13, 14 and of the two inner surfaces 11 , 12 need not be the same. In such an embodiment, the longer side in the resulting folded packing product 20 could then optionally be folded or bent as a lid towards the edge of the shorter side.

In an embodiment, step S1 comprises folding the section 19 of the air-laid blank 10 against the male mold 120 along at least one crease C substantially parallel with the transport direction 115 of the conveyor, see Fig. 11 . Hence, in this embodiment, at least one crease C or folding line is formed in the air-laid blank 10 to facilitate folding of the section 19 of the air-laid blank 10 along the at least one crease C. As mentioned above, the section 19 could be folded along one or more folds F, F1 , F2 in step S1. Accordingly, one or more creases C could be formed in the air-laid blank 10, preferably one such crease C per fold F, F1 , F2. The at least one crease C could be formed according to various embodiments. In an embodiment, a die is pushed into at least one main surface 30, 31 of the air-laid blank 10, preferably prior to folding the section 19 of the air-laid blank 10. This die could, as an example, be pushed into an upper main surface 30 of the air-laid blank 10. Alternatively, the die could be pushed into a lower main surface 31 of the air-laid blank 10 or a first die is pushed into the upper main surface 30 and a second die is pushed into the lower main surface 31. The at least one die could then be designed to form one or more, such as two, creases C in the main surface(s) 30, 31. In another embodiment, one or more roller wheels 155 could be arranged to push into at least one of the main surfaces 30, 31 of the air-laid blank 10 to form one or more creases C in the at least one main surface 30, 31 . The at least roller wheel 155 or the at least one die is positioned relative to the edges of the airlaid blank 10 to produce the at least one crease C at a position where the section 19 of the air-laid blank 10 is to be folded in step S1 , i.e., where the at least one fold F, F1 , F2 is desired.

The at least one crease C is substantially parallel with the longitudinal extension of the air-laid blank 10 and thereby with transport direction 115. Such a crease C simplifies folding of the section 19 of the airlaid blank 10 in step S1 , in particular for quite thick air-laid blanks 10. In addition, the at least one crease C guides the folding of the section 19 to form the at least one fold F, F1, F2 at the intended position or positions in the section 19. As is shown in Fig. 7, the section 19 of the air-laid blank 10 folded against the male mold 120 in step S1 may be present on the conveyor 110 when folding against the male mold 120. However, the section 19 of the air-laid blank 10 folded against the male mold 120 in step S1 does not necessarily have to be present on the conveyor 110 when folding against the male mold 120 as is schematically shown in Fig. 8. For instance, the conveyor 110 could end slightly upstream of the apparatus 100 as shown in this Fig. 8. In such a case, a portion of the air-laid blank 10 upstream of this section 19 of the air-laid blank 10, such as closer to a roll 190 of air-laid blank 10 as schematically shown in Fig. 7 or the apparatus 200 for forming an air-laid blank as shown in Fig. 8, is transported on the conveyor 110, whereas the portion of the air-laid blank 10 processed by the apparatus 100 for manufacturing a folded packaging product, including the section 19 of the air-laid blank 10, does not need to be positioned on the conveyor 110. Alternatively, or in addition, the section 19 of the air-laid blank 10 could be lifted slightly from the conveyor 110 during or prior to the folding step S1 . This lifting could, for instance, by achieved by folding guides 135 to be described further below.

Fig. 2 is a flow chart illustrating an embodiment of the folding step in Fig. 1. In this embodiment, the section 19 of the air-laid blank 10 is transported in step S10 over folding guides 135 arranged to guide edge portions 19A, 19B of the section 19 of the air-laid blank 10 away from the conveyor 110 and towards the male mold 120, see Figs. 11 , 12A and 12B. These folding guides 135 thereby lift the edge portions 19A, 19B of the section 19 from the conveyor 110 and towards each other and with the male mold 120 positioned between these edge portions 19A, 19B. The method then continues to step S2 in Fig. 1.

The folding guides 135 could be in the form of various structures arranged relative to the conveyor 110 to guide and lift the edge portions 19A, 19B towards each other and the male mold 120. Illustrative, but non-limiting, examples of such structures include sheets arranged in connection with and preferably slightly above the conveyor 1 10 and at peripheral positions relative to the conveyor 110. These edge portions 19A, 19B will then slide onto the sheets when the air-laid blank 10 is transported on the conveyor 110 thereby causing these edge portions 19A, 19B to be lifted towards the male mold 120. Another illustrative example of folding guides 135 are rollers arranged to engage and fold the edge portions 19A, 19B of the section 19 of the air-laid blank 10. These rollers could then be arranged with an axis substantially perpendicular to the main surfaces 30, 31 of the air-laid blank 10 positioned on the conveyor 110 or at least angled with an angle larger than 0° (non-zero angle), and typically not larger than 90°, relative to the main surfaces 30, 31 of the air-laid blank 10. These rollers could be substantially as the rollers 140A, 140B shown in Figs. 8 to 10 and employed, in these figures, as part of the compacting means 140. Yet another illustrative example of folding guides 135 include rails arranged to guide the edge portions 19A, 19B towards each other and the male mold 120 as the air-laid blank 10 is transported on the conveyor 110.

In an embodiment, step S1 is performed as shown in Fig. 3. In this embodiment, edge portions 19A, 19B of the section 19 of the air-laid blank 10 are pushed towards each other with the male mold 120 positioned in between the edge portions 19A, 19B in step S20. The method then continues to step S2 in Fig. 1. In such an embodiment, a press could be arranged to engage the outer surfaces 13, 14 of the section 19 of the air-laid blank 10 and apply pressure onto these surfaces 13, 14 to push the edge portions 19A, 19B towards each other and towards the male mold 120. This press could be implemented substantially as the press 140C illustrated in Figs. 8 to 10 and forming part of the compacting means 140.

It is also possible to use a combination of folding guides 135 and a press to fold the section 19 of the air-laid blank 10.

The inner surfaces 11 , 12 of the folded section 19 of the air-laid blank 10 are substantially perpendicular to or angled with a non-zero angle relative to the main surfaces 30, 31 of the non-folded air-laid blank 10 transported on the conveyor 1 10 as schematically shown in Figs. 8-10. This is achieved by folding the edges 19A, 19B of the air-laid blank 10 towards each other.

In an embodiment, step S1 comprises folding the section 19 of the air-laid blank 10 transported on a conveyor belt 112 of a belt conveyor 110 against the male mold 120 moving in the transport direction 115 of the belt conveyor 110. Hence, in this particular embodiment, the conveyor 110 is a belt conveyor 110 with a conveyor belt 112 running and taut between drive rollers 111 , 113. The embodiments are, however, not limited to the usage of belt conveyors 110. In clear contrast, any conveyor system that can transport an air-laid blank 10 could be used according to the embodiments including, but not limited to, lineshaft roller conveyor, roller conveyor, chain conveyor, etc.

The air-laid blank 10 could be transported through the apparatus 100 for manufacturing a folded packaging product 20 in a substantially continuous movement or in an intermittent movement. In this latter case, the movement may optionally be stopped or slowed down in connection with folding, compacting and cutting operations and then resumed or speeded up once these operations have been performed.

In an embodiment, step S2 in Fig. 1 comprises compacting the folded section 19 of the air-laid blank 10 against the male mold 120 with the male mold 120 positioned between first and second inner surfaces 11 , 12 of the folded section 19 of the air-laid blank 10. Thus, the compacting of the folded section 19 in step S2 is conducted with the male mold 120 positioned between the inner surfaces 11 , 12 to thereby form at least one depression 17, 18 in at least one of the inner surfaces 11 , 12. In an embodiment, one such depression 18 is formed in one inner surface 12, see Fig. 13C. In another embodiment, multiple, i.e. , at least two, depressions are formed in one inner surface. In a further embodiment, one or multiple depressions 17 is or are formed in the first inner surface 11 and one or multiple depressions 18 is or are formed in the second inner surface 12. The number of, the placement of and the shape and size of the depressions 17, 18 are dependent on and preferably adapted for the particular article(s) or goods to be packaged in the manufactured folded packaging product 20.

It is also possible for the male mold 120 to form at least one depression in the inner intermediate surface 16 in addition to, or instead of, forming at least one depression in the first inner surface 11 and/or the second inner surface 12. Hence, in an embodiment, the male mold 120 could be employed to form one or more depressions 17 in the first inner surface 11 , one or more depressions 18 in the second inner surface 12 and one or more depressions in the inner intermediate surface 16. In another embodiment, the male mold 120 is employed to form depressions 17, 18 in two inner surfaces 11 , 12, 16. The male mold 120 could be employed to form one or more depressions 17 in the first inner surface 11 and one or more depressions 18 in the second inner surface 12, or one or more depressions 17 in the first inner surface 11 and one or more depressions in the inner intermediate surface 16, or one or more depressions 18 in the second inner surface 12 and one or more depressions in the inner intermediate surface 16. In a further embodiment, the male mold 120 is employed to form one or more depressions 17, 18 in only one of the inner surfaces 11 , 12, 16. In such an embodiment, the male mold 120 is employed to form one or more depressions 17 in the first inner surface 11 , or one or more depressions 18 in the second inner surface 12, or one or more depressions in the inner intermediate surface 16.

The compacting of the folded section 19 of the air-laid blank 10 against the male mold 120 in step S2 could be performed by compacting the complete folded section 19 against the male mold 120. In another embodiment, merely a portion of the folded section 19 is compacted against the male mold 120 in step S2. In this latter embodiment, the compacting is mainly applied to the portion of the folded section 19 aligned with the portion of the inner surfaces 11 , 12 where the at least one depression 17, 18 is to be formed. Hence, in such case, compacting of the folded section 19 takes place at the portion of the folded section 19 aligned with the at least one depression 17, 18, whereas remaining portions of the folded section 19 might not be compacted at all or compacted to a lesser degree than this portion.

The male tool 120 comprises one or more protrusions that engage and protrude into at least one inner surface 11 , 12 of the folded section 19 to form the at least one depression 17, 18 in the at least one inner surface 11 , 12 during the compaction. The shape, size and position of the at least one protrusion in the male tool 120 define the shape, size and position of the at least one depression 17, 18 in the at least one inner surface 11, 12 and are preferably selected based on the particular article(s) or goods to be packaged into the folded packing product 20.

In an embodiment, step S2 comprises compacting the folded section 19 of the air-laid blank 10 against the male mold 120 while transporting the air-laid blank 10 on the conveyor 110. Hence, the compacting step S2 is preferably conducted while the air-laid blank 10 is transported on the conveyor 110 and while the male mold 120 is correspondingly moved in synchrony with the air-laid blank 10.

In a particular embodiment, step S2 comprises compacting the folded section 19 of the air-laid blank 10 against the male mold 120 by applying pressure onto outer surfaces 13, 14 of the folded section 19 of the air-laid blank to press the outer surfaces 13, 14 of the folded section of the air-laid blank 10 towards each other. These outer surfaces 13, 14 face away from the male mold 120 and are, hence, opposite to the inner surfaces 11 , 12 as shown in Figs. 13A-13C. Figs. 8 and 9 schematically illustrate such a pressing operation. In Fig. 9, one or multiple pairs of presses 140C are spaced apart from the outer surfaces 13, 14 of the folded section 19 prior to the compacting operation in step S2. In Fig. 8, the one or more pairs of presses 140C are pressed towards the outer surfaces 13, 14 and thereby apply pressure to these outer surfaces 13, 14 of the folded section 19 to press them towards each other and with the male mold 120 positioned between the inner surfaces 11 , 12 of the folded section 19.

In an embodiment, the compacting step S2 may also comprise compacting an outer intermediate surface 15 of the folded section 19 of the air-laid blank 10. This outer intermediate surface 15 is positioned intermediate and between the outer surfaces 13, 14 of the folded section 19 of the air-laid blank 10 and where these outer surfaces 13, 14 face away from the male mold 120. Hence, also the outer intermediate surface 15 connecting the two outer surfaces 13, 14 could be compacted, such as by a roller 140D arranged to engage and press against the outer intermediate surface 15 of the folded section 19.

In addition, or alternatively, the surfaces of the folded section 19 of the air-laid blank 10 opposite to the outer intermediate surface 15, i.e., the end surfaces of the folded section 19 of the air-laid blank 10 may be compacted by applying pressure.

The compacting step S2 in Fig. 1 preferably comprises compacting the folded section 19 of the air-laid blank 10 against the male mold 120 while applying heat to at least a portion of the folded section 19 of the air-laid blank 10. Hence, in a particular embodiment the compacting step S2 is performed as shown in Fig. 4. The method continues from step S1 in Fig. 1. A next step S30 then comprises hot pressing the folded section 19 of the air-laid blank 10 against the male mold 120. In this particular embodiment, the folded section 19 is, thus, pressed and compacted under heat. The method then continues to step S3 in Fig. 1.

The heating of at least a portion of the folded section 19 can be achieved by using a heated compacting tool 140A, 140B, 140C, a heated male mold 120 and/or by applying heat to the air-laid blank 10 prior to compacting the folded section 19, such as by transporting the air-laid blank 10 into an oven prior to folding a section 19 of the air-laid blank 10. The compacting tool 140A, 140B, 140C and/or male mold 120 is, in a particular embodiment, heated to a temperature selected within an interval of from 120°C up to 210°C, preferably within an interval of from 120°C up to 190°C. At these temperatures, many binders, such thermoplastic polymer binders, typically used in air-laid blanks 10 are in a malleable but not melted state.

In an embodiment, compacting the outer intermediate surface 15 may also be performed while applying heat to at least a portion of the folded section 19 of the air-laid blank 10. For instance, a roller 140D arranged to compact this outer intermediate surface 15 could be heated.

The compacting and optional, but preferable heating, in step S3 or S30 compacts the folded section 19 of the air-laid blank 10 and forms the at least one depression 17, 18 in at least one inner surface 11, 12 by pressing the outer surfaces 13, 14 towards each other with the male mold 120 positioned between the inner surfaces 11 , 12. As a result, a folded packing product 20 is formed once the compacted and folded section 19 of the air-laid blank 10 is cut from the remainder of the air-laid blank 10. This folded packaging product 20 thereby comprises at least one cavity 27, 28 in at least one inner surface 21 , 22 and where this at least one cavity 27, 28 is formed by the at least one depression 17, 18.

In an embodiment, the folded section 19 of the air-laid blank 10 could be cut in a plane substantially perpendicular to or angled at a non-zero angle relative to the main surfaces 30, 31 of the non-folded air-laid blank 10 transported on the conveyor 110 as shown in Fig. 10.

The cutting of the folded section 19 in step S3 in Fig. 1 thereby releases the folded packing product 20 from a remainder of the air-laid blank 10. The so obtained folded packaging product 20 could then be used as it is to package and protect one or more articles or goods, which could at least partly be fitted in the at least one cavity 27, 28 in at least one inner surface 21, 22 of the folded packaging product 20, see Figs. 13 and 14.

In an embodiment, the method comprises an additional step S40 as shown in Fig. 5. The method continues from step S3 in Fig. 1. A next step S40 comprises compacting the cut and folded section 19 of the air-laid blank 10 by applying pressure, and optionally heat, onto cut edges of the cut and folded section 19 of the air-laid blank 10 to form the folded packing product 20, see Figs. 12A and 12B. Hence, in this embodiment, also the cut edges of the cut and folded section 19 could be compacted and optionally heat treated, such as by hot pressing.

In this embodiment, step S2 of Fig. 1 thereby compacts the folded section 19 of the air-laid blank 10 against the male mold 120 along a first compaction axis substantially perpendicular to the transport direction 115, whereas step S40 in Fig. 5 compacts the cut and folded section 19 of the air-laid blank 10 along a second compaction axis substantially perpendicular to the first compaction axis and thereby substantially parallel to the transport direction 115.

In an embodiment, the method also comprises an additional step S50 as shown in Fig. 6. The method then continues from step S3 in Fig. 1 and to step S50, which comprises releasing the folded packaging product 20 from the male mold 120. Hence, the male mold 120 is removed from the folded packing product 20 to thereby obtain the folded packaging product 20 with at least one cavity 27, 28.

In a particular embodiment, step S1 in Fig. 1 comprises folding the section 19 of the air-laid blank 10 against the male mold 120 at a folding section 114 of an apparatus 100 for manufacturing the folded packaging product 20. In such a particular embodiment, step S50 in Fig. 6 comprises releasing the folded packaging product 20 from the male mold 120 at a releasing section 116 of the apparatus 100. The method then preferably comprises an additional step S51 as shown in Fig. 6. This step S51 comprises transporting the male mold 120 from the releasing section 116 to the folding section 114.

Hence, in a particular embodiment, the male mold 120 initially engages the folded section 19 of the airlaid blank 10 at a folding section 114 and is then transported together with the folded section 19 while performing the compacting and cutting steps S2 and S3 in Fig. 1. Once the folded packaging product 20 has been cut free from the remainder of the air-laid blank 10 and the male mold 120 has been released from the folded packaging product 20 at the releasing section 116, the male mold 120 can be moved back to the folding section 114 to thereby engage a new section 19 of the air-laid blank 10. As a consequence, the male mold 120 is preferably moved from the folding section 114 to the releasing section 116 and then back once more, such as by circulating between the folding section 114 and the releasing section 116. This movement of the male mold 120 could be performed by a robotic having a robotic arm, to which the male mold 120 is attached. The robotic could then move the male mold 120 initially in synchrony with the air-laid blank 10 from the folding section 114 to the releasing section 116 and then back to the folding section 114 once the folded packaging product 20 has been released from the male mold 120. In another embodiment, the male mold 120 is attached to a mold conveyor arrangement or system 170 as schematically shown in Figs. 7-11 and further described herein.

The air-laid blank 10 comprises natural fibers. In an embodiment, the natural fibers of the air-laid blank 10 are wood fibers. In a particular embodiment, the natural fibers are cellulose and/or lignocellulose fibers. Hence, in an embodiment, the natural fibers contain cellulose, such as in the form of cellulose and/or lignocellulose, i.e., a mixture of cellulose and lignin. The natural fibers may also contain lignin, such as in the form of lignocellulose. The natural fibers may additionally contain hemicellulose. In a particular embodiment, the natural fibers are cellulose and/or lignocellulose pulp fibers produced by chemical, mechanical and/or chemi-mechanical pulping of softwood and/or hardwood. For instance, the cellulose and/or lignocellulose pulp fibers are in a form selected from the group consisting of sulfate pulp, sulfite pulp, dissolving pulp, thermomechanical pulp (TMP), high temperature thermomechanical pulp (HTMP), mechanical fiber intended for medium density fiberboard (MDF-fiber), chemi- thermomechanical pulp (CTMP), high temperature chemi-thermomechanical pulp (HTCTMP), and a combination thereof. The natural fibers can also be produced by other pulping methods and/or from other cellulosic or lignocellulosic raw materials, such as flax, jute, hemp, kenaf, bagasse, cotton, bamboo, straw or rice husk.

In an embodiment, the air-laid blank 10 comprises the natural fibers in a concentration of at least 70 % by weight of the air-laid blank 10. In a preferred embodiment, the air-laid blank 10 comprises the natural fibers in a concentration of at least 72.5 %, more preferably at least 75 %, such as at least 77.5 %, at least 80 %, at least 82.5 %, at least 85 % by weight of the air-laid blank 10. In some applications, even higher concentrations of the natural fibers may be used, such as at least 87.5 %, at least 90 %, at least 92.5 %, at least 95 % or at least 96 % by weight of the air-laid blank 10.

In an embodiment, the air-laid blank 10 also comprises a binder included in the air-laid blank 10 to bind the air-laid blank 10 together and preserve its form and structure. In an embodiment, the binder may also assist in building up the foam-like structure of the air-laid blank 10. The binder is, in such an embodiment, intermingled with the natural fibers during an air-lying process forming a fiber mixture. The binder may be added in the form of a powder, but is more often added in the form of fibers that are intermingled with the natural fibers in the air-laying process. Alternatively, or in addition, the binder may be added as powder, solution, emulsion or dispersion during and/or after the air-laying process.

In an embodiment, the binder, or at least a portion thereof, has a softening point not exceeding a degradation temperature of the natural fibers. Hence, the binder, or at least a portion thereof, thereby becomes softened at a process temperature during heating that does not exceed the degradation temperature of the natural fibers. This means that at least a portion of the binder becomes malleable but preferably not melted, which enables hot processing while maintaining the porous structure of the air-laid blank 10 and where the hot processing is performed at a temperature that does not degrade the natural fibers in the air-laid blank 10.

The binder could be a natural or synthetic binder, or a mixture of natural binders, a mixture of synthetic binders, or a mixture of natural and synthetic binders. In a preferred embodiment, the binder is a polymer binder and more preferably a thermoplastic polymer binder.

In an embodiment, the polymer binder is or comprises polymer fibers cut at a fixed length, which is typically referred to as staple fibers. It is generally preferred for the mixing in the air-laying process and, thereby, for the properties of the formed air-laid blank 10 if the length of the polymer fibers is of the same order of magnitude as the length of the natural fibers or longer. Length of the polymer fibers and the natural fibers as referred to herein is length weighted average fiber length. Length weighted average fiber length is calculated as the sum of individual fiber lengths squared divided by the sum of the individual fiber lengths.

In an embodiment, the polymer binder is or comprises polymer fibers having a length weighted average fiber length that is selected within an interval of from 100 up to 600 %, preferably from 125 up to 500 %, and more preferably from 150 up to 450 % of a length weighted average fiber length of the natural fibers. In a particular embodiment, the polymer binder is or comprises polymer fibers having a length weighted average fiber length that is selected within an interval of from 200 up to 400 %, preferably within an interval of from 250 up to 350 % of a length weighted average fiber length of the natural fibers. In a particular embodiment, the polymer fibers have a length weighted average fiber length within an interval of from 1 up to 12 mm, such as within an interval of from 1 up to 10 mm, preferably within an interval of from 2 up to 8 mm and more preferably within an interval of from 2 up to 6 mm.

The length weighted average fiber length of the natural fibers is dependent on the source of the natural fibers, such as tree species they are derived from, and the pulping process. A typical interval of length weighted average fiber length of natural fibers is from about 0.8 mm up to about 5 mm.

In an embodiment, the polymer binder is or comprises, such as consists of, mono-component and/or bicomponent polymer fibers. Bi-component polymer fibers, also known as bico fibers, comprise a core and sheath structure, where the core is made from a first polymer, copolymer and/or polymer mixture and the sheath is made from a second, different polymer, copolymer and/or polymer mixture.

In an embodiment, the polymer binder is or comprises, such as consists of, bi-component polymer fibers comprising a core component made of a material having a melting temperature above a temperature at which the air-laid blank 10 is heated during hot pressing of the air-laid blank 10. The bi- component polymer fibers also comprise a sheath component made of a material having a melting temperature below the temperature at which the air-laid blank 10 is heated.

In this embodiment, the core component of the bi-component polymer fibers has a melting temperature that is higher than the melting temperature of the sheath component of the bi-component polymer fibers. In addition, the melting temperature of the core component is above the process temperature at which the air-laid blank 10 is heated during the hot processing, whereas the melting temperature of the sheath component is below this process temperature. This means that the core component will not melt but advantageously becomes malleable during the hot processing, whereas the sheath component will melt or at least be significantly tackified. The sheath component will thereby adhere to natural fibers while the non-melted but malleable core component provides structural support. Such bi-component polymer fibers achieve both good attachment to the natural fibers and simultaneously maintaining the porous structure of the air-laid blank 10 even during hot processing, such as hot pressing.

In an embodiment, the polymer binder is or comprises, such as consists of, mono-component thermoplastic polymer fibers 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), polybutylene adipate terephthalate (PBAT), polybutylene succinate (PBS), polylactic acid (PLA), polyethylene terephthalate (PET), polycaprolactone (PCL), copolymers thereof and mixtures thereof, and ii) optionally one or more additives.

Hence, in an embodiment, the polymer fibers are made of a material selected from the above mentioned group. In another embodiment, the polymer fibers are made of a material selected from the above mentioned group and one or more additives.

In another embodiment, the polymer binder is or comprises, such as consists of, bi-component thermoplastic polymer fibers having a core and/or sheath made from i) a material or materials selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives. In a further embodiment, the polymer binder is or comprises, such as consists of, a combination or mixture of mono-component polymer fibers made from i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives, and bi-component polymer fibers having a core and/or sheath made from i) a material or materials selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.

The polymer binder could be made of a single type of polymer fibers, i.e., made of a same material in the case of mono-component polymer fibers or made of the same material or materials in the case of bi-component polymer fibers. However, it is also possible to use a polymer binder made of one or multiple, i.e., at least two, different mono-component polymer fibers made of different materials and/or one or multiple different bi-component polymer fibers made of different materials. In an embodiment, the binder is or comprises a powder, preferably a polymer powder and more preferably a thermoplastic polymer powder made of i) a material selected from the group consisting of PE, EAA, EVA, PP, PS, PBAT, PBS, PLA, PET, PCL, copolymers thereof and mixtures thereof, and ii) optionally one or more additives.

It is also, as mentioned in the foregoing, possible to use a polymer binder that is a combination of polymer fibers and polymer powder.

Another aspect of the invention relates to an apparatus 100 for manufacturing a folded packing product 20. The apparatus 100 comprises a conveyor 110 arranged to transport an air-laid blank 10 and a male mold 120 movable in a transport direction 115 of the conveyor 110. The apparatus 100 also comprises folding means 130 arranged to fold a section 19 of the air-laid blank 10 against the male mold 120 movable in the transport direction of the conveyor 110. The apparatus 100 further comprises compacting means 140 arranged to compact the folded section 19 of the air-laid blank 10 against the male mold 120 to form at least one depression 17, 18 in at least one inner surface 11 , 12 of the folded section 19 of the air-laid blank 10. The at least one inner surface 1 1 , 12 faces the male mold 120. The apparatus 100 additionally comprises cutting means 150 arranged to cut the folded section 19 of the air-laid blank 10 from a remainder of the air-laid blank 10 to form a folded packing product 20 having a cavity 27, 28 in at least one inner surface 21, 22. The cavity 27, 28 is designed to house a packaged article or at least a portion thereof.

As previously discussed herein, the conveyor 1 10 could be in the form of a belt conveyor 110 comprising a conveyor belt 112, on which the air-laid blank 10 is transported. The conveyor belt 112 is typically running between drive rollers 1 11 , 113. Also other types of conveyors 110 could be used for the apparatus 100 including, but not limited to, lineshaft roller conveyor, roller conveyor, chain conveyor, etc.

The conveyor 110 could be arranged in the apparatus 100 to extend substantially along the whole length of the apparatus 100, i.e., from the folding section 114 up to the releasing section 116 as shown in Fig. 7. The conveyor 110 typically additionally also extend upstream of the apparatus 100, such as from the roll 190 of air-laid blank 10 as schematically shown in Fig. 7. In another embodiment, the conveyor 110 could extend to merely a portion of the length of the apparatus 100 or indeed end upstream of the apparatus as shown in Fig. 8. This means that the conveyor 110 could be arranged solely upstream of the apparatus 100, arranged upstream of the apparatus 100 and additionally extend along at least a portion of the length of the apparatus 100 or indeed along the full length of the apparatus, i.e., to the releasing section 116. It is also possible to have a conveyor 110 that is substantially arranged from the folding section 114 up to the releasing section 116 of the apparatus 100 or at least along a portion of the distance between the folding section 114 and the releasing section 116 but does not necessary have to extend upstream of the apparatus 100.

In an embodiment, the folding means 130 is configured to fold the section 19 of the air-laid blank 10 against the male mold 120 to form at least one fold F, F1 , F2 substantially parallel with the transport direction 115.

In an embodiment, the folding means 130 is arranged to fold the section 19 of the air-laid blank 10 against the male mold 120 along at least one crease C substantially parallel with the transport direction 115 of the conveyor 110. In such an embodiment, the apparatus 100 preferably comprises a creasing means 155 arranged to form the at least one crease C in the air-laid blank 10, preferably in one or both of the main surfaces 30, 31 of the air-laid blank 10. In an embodiment, the creasing means 155 comprises at least one die configured to be pressed into the main surface(s) 30, 31 of the air-laid blank 10 to produce the at least one crease C. Alternatively, or in addition, the creasing means 155 comprises at least one roller wheel 155 arranged to push into at least one of the main surfaces 30, 31 of the air-laid blank 10 to form one or more creases C in the at least one main surface 30, 31 .

In an embodiment, the folding means 130 comprises folding guides 135, such as sheets, rollers and/or racks, arranged to guide edge portions 19A, 19B of the section 19 of the air-laid blank 10 away from the conveyor 110 and towards the male mold 120. In another embodiment, the folding means 130, alternatively or in addition, comprises a press tool arranged to push edge portions 19A, 19B of the section 19 of the air-laid blank 10 towards each other with the male mold 120 positioned in between the edge portions 19A, 19B.

In an embodiment, the compacting means 140 is arranged in the apparatus 100 to compact the folded section 19 of the air-laid blank 10 against the male mold 120 with male mold 120 positioned between first and second inner surfaces 11, 12 of the folded section 19 of the air-laid blank 10. In a particular embodiment, the compacting means 140 is arranged to compact the folded section 19 of the air-laid blank 10 against the male mold 120 by applying pressure onto outer surfaces 13, 14 of the folded section 19 of the air-laid blank 10 to press the outer surfaces 13, 14 of the folded section 19 of the airlaid blank 10 towards each other.

The compacting means 140 is preferably arranged to compact the folded section 19 of the air-laid blank 10 against the male mold 120 while transporting the air-laid blank 10 on the conveyor 110. For instance, the compacting means 140 could comprise two rollers 140A, 140B arranged to compact the folded section 19 of the air-laid blank 10 around the male mold 120. The male mold 120 and the air-laid blank 10 can then be moved relative to the two rollers 140A, 140B by the conveyor 110 and a mold transport arrangement or system 170. As the folded section 19 of the air-laid blank 10 is moved in between the rollers 140A, 140B, the rollers 140A, 140B exert a pressure onto the outer surfaces 13, 14 of the folded section 19 to press these outer surfaces 13, 14 towards each other so that the inner surfaces 11 , 12 of the folded section 19 are pressed against the male mold 120. In an alternative or additional embodiment, the compacting means 140 comprises a press 140C arranged to compact the folded section 19 of the air-laid blank 10 against the male mold 120. The press 140C then comprises at least two press elements arranged on either side of the folded section 19 to be pressed against each other with the folded section 19 of the air-laid blank 10 and the male mold 120 positioned between these press elements. The press 140C could comprise one pair of such press elements or multiple successive pairs of press elements as schematically shown in Fig. 9 with three such pairs shown in an open position spaced apart from the outer surfaces 13, 14 of the folded section 19.

In an embodiment, the compacting means 140 is arranged to compact the folded section 19 of the airlaid blank 10 against the male mold 120 while applying heat to at least a portion of the folded section 19 of the air-laid blank 10. In such an embodiment, the compacting means 140 is arranged to hot press the folded section 19 of the air-laid blank 10 against the male mold 120. For instance, the compacting means 140 could comprise at least one heating element, preferably at least one controllable heating element. Such a heating element could then be arranged in the above mentioned rollers 140A, 140B and/or press 140C. Alternatively, or in addition, the male mold 120 comprises at least one heating element, such as at least one controllable heating element.

In these embodiments, the compacting means 140 and/or the male mold 120 is preferably heated to a temperature selected within an interval of from 120°C up to 210°C, preferably within an interval of from 120°C up to 190°C. At these temperatures, many binders, such thermoplastic polymer binders, typically used in air-laid blanks 10 are in a malleable but not melted state. The cutting means 150 of the apparatus 100 could be any means capable of cutting the folded and compacted section 19 of the air-laid blank 10 to release the folded packaging product 20. Illustrative, but non-limiting examples, of such cutting means 150 include a saw, a punch, a knife, etc.

In an embodiment, the cutting means 150 is arranged to cut the folded section 19 of the air-laid blank 10 in a plane substantially perpendicular to or angled at a non-zero angle to the main surfaces 30, 31 of the non-folded air-laid blank 10 transported on the conveyor 110.

The compacting means 140 and/or the cutting means 150 of the apparatus 100 for manufacturing a folded packing product 20 could be movable to perform compacting and/or cutting operations while the male mold 120 and the folded section 19 of the air-laid blank 10 are transported relative to the apparatus 100. For instance, the compacting means 140 and/or cutting means 150 could be movable back and forth between a start position and a stop position. The compacting operation could thereby be performed at least partly while the compacting means 140 is moving together with the male mold 120 and the folded section 19 of the air-laid blank 10. Alternatively, or in addition, the cutting operation could be performed at least partly while the cutting means 150 is moving together with the male mold 120 and the compacted folded section 19 of the air-laid blank 10.

In an embodiment, the compacting means 140 is a first compacting means 140. In such an embodiment, the apparatus 100 further comprises a second compacting means 160 arranged to compact the cut and folded section 19 of the air-laid blank 10 by applying pressure onto cut edges of the cut and folded section 19 of the air-laid blank 10 to form the folded packing product 20.

The first compacting means 140 is then arranged to compact the folded section 19 of the air-laid blank 10 against the male mold 120 along a first compaction axis substantially perpendicular to the transport direction 115, whereas the second compacting means 160 is arranged to compact the cut and folded section 19 of the air-laid blank 10 along a second compaction axis substantially perpendicular to the first compaction axis and thereby substantially parallel to the transport direction 115.

In an alternative, or additional, embodiment, the compacting means 140 is a first compacting means 140. In this embodiment, the apparatus 100 further comprises a third compacting means 140D arranged to compact the outer intermediate surface 15 of the folded section 19 of the air-laid blank 10. This third compacting means 140D could be in the form of a roller 140D or a press element configured to engage and press against this outer intermediate surface 15 of the folded section 19.

The apparatus 100 may optionally comprise an additional (fourth) compacting means to compact the edges or sides of the folded section 19 of the air-laid blank 10 opposite to the outer intermediate surface 15.

The optional second compacting means 160, optional third compacting means 140D and/or optional fourth compacting means could comprise at least one heating element, such as at least one controllable heating element, in correspondence to the first compacting means 140.

In an embodiment, the apparatus 100 further comprises a mold transport arrangement or system 170 arranged to move the male mold 120 from a folding section 114 of the apparatus 100 at which the folding means 140 is arranged to fold the section 19 of the air-laid blank 10 against the male mold 120 up to a releasing section 116 of the apparatus 100 at which the folded packing product 20 is released from the male mold 120 and then move the male mold 120 from the releasing section 116 back to the folding section 114.

As mentioned in the foregoing, the mold transport arrangement 170 could comprise a robotic having a robotic arm, to which the male mold 120 is attached. The robotic could then move the male mold 120 initially in synchrony with the air-laid blank 10 from the folding section 114 to the releasing section 116 and then back to the folding section 114 once the folded packaging product 20 has been released from the male mold 120. In another embodiment, the mold transport arrangement 170 comprises a mold conveyor 171, 172, 173 comprising multiple male molds 120 movable by the mold conveyor 171 , 172, 173 relative to the conveyor 110 arranged to transport the air-laid blank 10.

The mold conveyor 171 , 172, 173 could be any type of conveyor capable of transporting multiple male molds 172 back and forth, preferably in a circular manner, between the folding section 114 and the releasing section 116. The mold conveyor may comprise a conveyor belt or other structure 172 with the attached male molds 120 and running between drive rollers 171 , 173.

The multiple male molds 120 attached to the mold conveyor 171 , 172, 173 could be identical and thereby produce the same at least one depression 17, 18 in the folded sections 19 of the air-laid blank 10. Alternatively, different male molds 120 having different shape, size and/or position of at least one protrusion could be attached to the mold conveyor 171 , 172, 173. In such an embodiment, folded packaging products 20 having different internal cavities 27, 28 can be produced in line by the apparatus 100.

The air-laid blank 10 input into the apparatus 100 could be a pre-manufactured air-laid blank 10, such as in the form of a roll 190 of air-laid blank 10 as schematically shown in Fig. 7. In such an embodiment, the air-laid blank 10 is manufactured at a separate apparatus and then transported, such as in the form of a roll 190, to the apparatus 100 of the invention.

In another embodiment, the apparatus 100 of the invention could be arranged in line with an apparatus 200 for forming an air-laid blank 10 as shown in Fig. 8.

The apparatus 200 used for producing an air-laid blank 10 comprises a forming head, also referred to as forming chamber in the art. The natural fibers and the binder are input into the forming head as one or more discrete input streams and/or as one or more mixed input streams. In these illustrative examples, the natural fibers and the binder or the mixture of natural fibers and binder are mixed and blended during the transport through the forming head ultimately depositing the mixture 40 of natural fibers and the binder onto a collector belt 210, typically in the form of an air-permeable collector belt 210. Alternatively, or in addition, the binder may be added as powder, solution, emulsion or dispersion during and/or after, i.e., downstream of, the apparatus 200.

The natural fibers and the binder and/or the mixture thereof is transported through the forming head by a vacuum, i.e., an air suction or under pressure, applied over the collector belt 210 that is disposed in connection with a lower end of the forming head. The vacuum applied over the collector belt 210, thus, draws the natural fibers and the binder and/or the mixture thereof towards the lower end of the forming head and down onto the collector belt 210. The vacuum may also contribute to the mixing of natural fibers and the binder during the transport through the forming head and compact the fibrous mixture 40 on the collector belt 210.

The fibrous mixture 40 of natural fibers and binder is then heated in an oven 220 to form an air-laid blank 10. The fibrous mixture 40 is preferably heated to a temperature where the binder is in a malleable state or in a melted state, preferably in a malleable but not melted state. For most binders used in air-laying processes this temperature is within an interval of from 80°C up to 180°C, such as from 100°C up to 180°C or from 120°C up to 160°C. The air-laid blank 10 output from the oven 220 may then be input into the apparatus 100 of the present invention as shown in Fig. 8. One or more optional compacting or pressing tools may be arranged upstream of the oven 220, i.e., between the forming head and the oven 220, and/or downstream of the oven 220 but upstream of the apparatus 100 of the present invention.

The embodiments described above are to be understood as a few illustrative examples of the present invention. It will be understood by those skilled in the art that various modifications, combinations and changes may be made to the embodiments without departing from the scope of the present invention. In particular, different part solutions in the different embodiments can be combined in other configurations, where technically possible.