CN113584941B - 制造隔热材料和隔热封套的方法 - Google Patents

制造隔热材料和隔热封套的方法 Download PDF

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Publication number
CN113584941B
CN113584941B CN202110728997.2A CN202110728997A CN113584941B CN 113584941 B CN113584941 B CN 113584941B CN 202110728997 A CN202110728997 A CN 202110728997A CN 113584941 B CN113584941 B CN 113584941B
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Prior art keywords
paper
fibers
paper layer
fiber
binder fibers
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CN113584941A (zh
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A·B·克里森
R·伯格曼
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Pratt Retail Monopoly Co ltd
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Pratt Retail Monopoly Co ltd
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Abstract

一种用于生产隔热封套的方法和系统以及具有隔热纸纤维垫子结构的隔热盒，其中所述隔热纸纤维垫的密度为小于约10磅/立方英尺。隔热纸纤维垫具有缠绕的增强纤维。本发明提供了一种使用再循环相容性或水溶性黏结剂和纸层形成隔热纸纤维垫的方法。

Description

制造隔热材料和隔热封套的方法
本发明申请是2017年11月7日提交的、申请号为201780081689.7、发明名称为“制造隔热材料和隔热封套的方法”(基于PCT国际申请No.PCT/US2017/060403)发明专利申请的分案申请。
技术领域
本发明涉及一种用于生产隔热材料和使用该隔热材料的容器的方法和系统，以及该隔热材料和使用该隔热材料的容器，并且更具体地，涉及一种生产可再浆化的隔热材料的方法和系统，以及使用该可再浆化的隔热材料的可再循环容器。
背景技术
隔热盒广泛用于许多运输应用中。当运输材料需要在降低或升高的温度下运输并需要有助于缓冲冲击时，则需要隔热盒。类似地，当运输材料需要避免大的温度波动时，需要隔热盒。这种盒子还可以减轻对产品的冲击应力，从而延长所运输产品的寿命和/或使产品看起来更耐用并且质量更高。遗憾的是，隔热材料通常由与用于形成盒子的材料不同材料制成，从而不能够进行再循环。
发明内容
该部分提供了对本发明的总体概述，并未全面公开其全部范围或其所有特征。
根据本发明的教导，公开了一种形成运输容器的方法。该方法包括将纸纤维与再循环相容性纤维混合以形成材料混合物。将混合物置于表面上以形成混合物层。将热与热和压力中的至少一种施用于混合物层上，形成纸纤维絮(fiber batt)。然后修剪纸纤维絮，使其具有固定的宽度和固定的长度。纸纤维絮定位于与瓦楞盒相邻，并且运输容器具有大于85％的可再浆化性。
根据另一种教导，上述或下述方法包括将纸纤维与可熔性聚乙烯和聚丙烯(“PE/PP”)双组分热塑性纤维混合。
根据本发明的教导，公开了一种用于制造隔热材料的方法。该方法包括将纸增强纤维与以重量计约0.5％至约25％、长度小于约16mm的可熔性PE/PP双组分热塑性粘合纤维混合。PE/PP双组分热塑性粘合纤维在纸增强纤维内基本上无规分布以形成混合物。对混合物施加热以熔化PE/PP双组分热塑性粘合纤维，以将PE/PP双组分热塑性粘合纤维粘合至纸增强纤维以形成絮。隔热材料具有可再浆化速率大于85％的物理性质。
根据另一种教导，在上述或下述方法中，所述方法包括将可再浆化纸层与絮连接以形成隔热絮组件。
根据另一种教导，在上述或下述方法中，所述方法包括形成可再浆化的纸纤维垫，其在压缩约25％至约50％下具有约0.3psi至约1.4psi的抗压缩性。
根据另一种教导，在上述或下述方法中，所述方法包括形成可再浆化的纸纤维垫，其在压缩约25％下具有约5％至约18％的压缩变定。
根据另一种教导，在上述或下述方法中，所述方法包括在纸纤维垫和第一纸层之间形成设置水溶性黏结剂层。
根据本发明的教导，公开了一种用于制造隔热材料的方法。形成纸纤维与在纸纤维内基本上无规分布的0.5％至25％的热塑性粘合纤维的混合物。加热混合物使热塑性粘合纤维高于纤维的玻璃化转变温度或熔点，从而将热塑性粘合纤维粘合至纸纤维，形成密度为小于5磅/立方英尺的絮。纸纤维的纤维网与热塑性粘合纤维紧密连接，随后使絮达到低于热塑性纤维的玻璃化转变温度的温度，以形成可再浆化性大于85％的隔热垫。该垫设置在可再浆化的瓦楞纸板盒或可再浆化的外裹物的内表面之一内，以形成可再浆化性大于85％的组件。
根据另一种教导，在上述或下述方法中，形成纸纤维和热塑性粘合剂的混合物是形成纸纤维与约0.5％至约25％、长度小于约24mm的PE/PP双组分热塑性纤维的混合物。
根据另一种教导，在上述或下述方法中，形成纸纤维与热塑性粘合纤维的混合物是形成纸纤维与约5％至约10％、长度不一且平均长度为小于约16mm的PE/PP双组分热塑性粘合纤维的混合物。
根据本发明的教导，上述或下述或使用上述和下述方法生产的容器、运输容器、隔热材料和隔热结构的可再浆化性为大于85％，并且具有可再浆化的纸层和与所述纸层连结的可再浆化的纸纤维垫。纸纤维垫具有纸增强纤维，其与在其中基本上无规分布的以重量计约2％至约25％的可熔性PE/PP双组分热塑性粘合纤维紧密连接。
根据本发明的教导，在上述或下述或使用上述或下述的方法生产的容器、运输容器、隔热材料和隔热结构中，可熔性热塑性纤维是长度为约0.5mm至约16mm的短切纤维。
根据本发明的教导，在上述或下述或使用上述或下述的方法生产的容器、运输容器、隔热材料和隔热结构中，可熔性热塑性纤维可以是长度为约0.5mm至约16mm的短切纤维PE/PP双组分。
根据本发明的教导，上述或下述或使用上述或下述的方法生产的容器、运输容器、隔热材料和隔热结构还具有与纸层相邻放置的可再浆化的瓦楞纸板。
根据本发明的教导，上述或下述或使用上述或下述的方法生产的容器、运输容器、隔热材料和隔热结构还具有设置在纸层和瓦楞纸板之间的再循环相容性或水溶性黏结剂层。
根据另一种教导，在上述或下述的方法中，该方法包括将松软的(lose)磨碎的纤维状纤维素纸或磨碎的纸板材料放置在移动的传送带上。可以通过诸如针刺的方法或通过使用熔化的粘合纤维、生物可吸收的黏结剂、再循环相容性水溶性黏结剂、植物基(糖或果胶)黏结剂(来自例如甜菜、玉米、或甘蔗、或淀粉)来使纤维纸或纤维素材料中的纤维紧密连接。通过使连续的材料层在一对锥形边缘板之间通过而将磨碎的纤维素纸或纸板材料形成为板坯或絮，所述锥形边缘板形成未压缩絮的絮宽度和厚度。该材料可以具有使用能够施加热的压辊调节的厚度和密度。
根据另一种教导，在上述或下述方法中，所述方法包括在压缩之后使用切刀将絮切割成单独的片。任选地，可以使用移动切刀或刀片将絮沿其厚度切成两半。一旦絮形成为矩形形状和厚度，则该材料准备好连结至内瓦楞盒或封套或放置在内瓦楞盒或外裹物中。
根据另一种教导，在上述或下述方法中，该方法包括从一卷合适的材料取下瓦楞盒的内表面。瓦楞盒的内表面材料被切割成特定的长度和宽度。例如，纸板盒的内表面材料的宽度和长度可以大于纤维絮的宽度和长度。
根据本发明的教导，上述或下述的或使用上述或下述的方法生产的容器、运输容器、隔热材料和隔热结构包括可以布置在絮上方、在所有四个侧面下方与絮的扩展部分重叠的纸层。纸层的端部可以包裹并塞在絮的端部下面。可以施加热或再循环相容性或水溶性黏结剂以将内纸层固定到絮上。
根据另一种教导，在上述或下述方法中，所述方法包括在内纸层的外表面上将内纸层粘合至絮，所述内纸层可以折叠以形成袋。然后，将经折叠的絮放置通过端部封闭装置以封闭内层纸的侧面，从而形成袋。可以使用工业缝纫机缝合经折叠的絮边缘。
根据另一种教导，在上述或下述方法中，所述方法包括将另一纸层放置在经折叠的絮的外侧周围。外纸层可以以形成可封闭折页的方式包围内纸层上的絮放置。该可封闭折页可以包括双面胶带形式的再循环相容性或水溶性黏结剂。
根据另一种教导，在上述或下述方法中，所述方法包括在内纸层和外纸层之间封装隔热絮材料。在这种情况下，可以使用热或再循环相容性或水溶性黏结剂或缝合来将外纸层的边缘与内纸层连结。边缘的多余材料可以被移除。
根据本发明的教导，上述或下述或使用上述或下述的方法制造的隔热材料和隔热结构可以包括通过使再循环的纸板通过锤磨机来形成纤维素纤维。这些纤维与纸和一种再循环相容性纤维混合。再循环相容性纤维可以是可熔性热塑性纤维。由再循环纸纤维形成具有第一宽度和第一长度的隔热纸纤维絮。第一纸层与纸纤维絮连结。纸纤维絮连结至瓦楞盒。
根据本文提供的描述，其他适用领域将变得显而易见。本发明内容中的描述和具体实例仅用于说明的目的，并不旨在限制本发明的范围。
附图说明
这里描述的附图仅用于所选实施方案而不是所有可能的实施方式的说明性目的，并且不旨在限制本发明的范围。
图1表示用于隔热封套的隔热絮或垫的形成；
图2表示将可再循环纸层置于图1所示的隔热垫上；
图3表示切割如图2所示的位于垫上的可再循环纸层；
图4表示将纸层包围垫的边缘；
图5表示施加热以将纸层粘合至垫；
图6表示将图5的结构折叠成袋；
图7表示缝合图6结构的侧面以形成袋；
图8表示黏结剂的应用；
图9表示包围图8结构的外纸层的应用；
图10表示热密封和切割图9结构的内纸层和外纸层；
图11表示使用图1至图10的方法和系统形成的封套；
图12表示根据本发明另一教导来形成盒的衬里的系统；
图13A至图13B表示隔热絮或垫的切割和形成；
图14A至图14C表示根据本发明的教导的上纸层的应用；
图15A至图15B表示任选的底纸层的应用；
图16A和图16B表示纸层包围隔热构件的侧面密封；
图17表示根据本发明的教导用于形成隔热构件的热通道；和
图18A至图18B表示连结到瓦楞盒的隔热絮。
在附图的几种视图中，相应的附图标记表示相应的部件。
具体实施方式
现在将参考附图更全面地描述示例性实施方案。
将在图1-图12的描述中描述隔热材料和隔热封套或运输容器的形成。如图1所示，将纤维纸或纤维素材料2放置在移动的传送带4上。可以通过诸如针刺或使用熔融的粘合剂的方法来使纤维紧密连接，其中，所述熔融的粘合剂占纤维的约2％至约25％(以重量计)，在纤维纸或纤维素材料中混合。或者，可以使用再循环相容性或水溶性黏结剂来粘合纤维。通过使连续的材料层2在形成絮宽度的一对锥形边缘板11(仅示出一个)之间通过来将纤维纸或纤维素材料4形成为板坯10。可以由上耙或块14限定未压缩板坯10的厚度。该材料然后可以具有使用压缩辊16调节的厚度和密度(图3)。
在压缩之后，将板10转变成纸纤维隔热絮22(图2)，其可以是通过使再循环纸板通过研磨机如锤磨机而形成的经制造的纤维组合物。絮22可以含有少量水溶性黏结剂或可熔性纤维，如聚丙烯纤维。任选地，使用无规分布的天然纤维如长度为约1/16英寸至约1.5英寸并且旦尼尔(denier)为约5至约12的棉和粘合纤维形成纸纤维絮22，其中，纸纤维絮22被加工以形成隔热垫46(图3)。
另外，粘合纤维可以是水溶性PVOH纤维，其旦尼尔可以为约0.02至约3.0，水温为大于约100℃并且切割长度为约2mm至约8mm。粘合纤维可以是例如KURALON(tm)牌短切纤维。作为粘合纤维，用于隔热的可再循环PVOH纤维可以是约0.4旦尼尔至约1.0旦尼尔的纤维，其长度为约3.0mm至约4.0mm。
在一对侧引导件之间的传送带上连续地进料隔热材料22，所述侧引导件限定了用于隔热材料的连续条带的一对侧面。侧引导件限定了垫的预定宽度。一旦对齐，材料的连续条带位于切割机构下面，该切割机构将连续的絮22切割成预定长度，从而形成隔热垫46。
如图2所示，通过传送带4将絮22输送到第二位置，在第二位置，内纸层25覆盖在垫46上。内纸层25的长度和宽度大于垫46的长度和宽度。内纸层25的第一端部和第二端部26可以塞在垫46的第一端部和第二端部28下面。
如图3所示，然后可以使用切刀12将絮22切割成单独的片，切刀12可以是旋转刀片或圆形刀片。任选地，可以使用切刀12将絮22沿其厚度切成两半。一旦絮22形成为矩形形状和厚度，则该材料即可与内瓦楞盒的内表面连结或放置为与内瓦楞盒的内表面相邻。
将内纸层25从一卷适合的材料中取出，该材料例如可以是预穿孔的或防水的。如图3和图4所示，纸盒的内表面材料位于隔热层上方并被切割成特定的长度和宽度。例如，纸盒的内表面材料的宽度和长度可以大于纤维垫46的宽度和长度。
如图4所示，将内纸层25置于垫46上，在全部四个侧面上与垫46重叠。内纸层25的端部26包裹并塞在垫46的端部28下。如图5所示，可以施加热或再循环相容性或水溶性黏结剂以将内纸层25固定至垫46。然后将内纸层25对折，将垫46放在相对其自身配置的内纸层25的外表面上，从而形成子组件。
如图6所示，然后，使经折叠的垫46通过封闭内纸层25的侧面的端部封闭装置，从而形成袋31。如图7所示，边缘可以使用工业缝纫机80缝合或者可以视情况进行热熔。一排较小的针脚84从子组件的顶部到底部沿其每一侧延伸，并且与垫46的横向边缘82相邻并置。针脚84在空间上略微向内的是第二排较大的针脚86，其包围垫46和垫46内侧上的纸层25，并包括垫46的外侧上的部分78。第二排针脚86仅从子组件的顶部向下纵向延伸并且终止于部分78。
图8表示再循环相容性或水溶性黏结剂的应用，以帮助将外纸片或外纸层32粘合至内纸层25。如图9所示，然后外纸层32可以定位为包围经折叠的垫46的外侧。外纸层32可以以形成可封闭折页56的方式定位为包围内纸层25上的垫46。该可封闭折页56可以采用双面胶带形式的再循环相容性或水溶性的黏结剂36。
然后将外纸层32连结至内纸层25，将隔热材料或垫46封装在内纸层25和外纸层32之间以形成运输容器或封套40(图11)。在这方面，可以使用热、再循环相容性或水溶性黏结剂或缝合来将外纸层32的边缘连结到内纸层25。可以移除边缘的多余材料。
形成封套或运输容器40的外表面的外纸层32可以是可再循环的，并且可以加工成防水或耐水的。任选地，外纸层32横向延伸，从而使得其横向边缘或边缘44可以热密封在一起，如图10所示。在封套40的底部，在52处折叠纸层32。在封套40的顶部，正面顶部边缘58终止于封套的开口54处，并且背面继续向上以形成折页(flap)56，从而通过使折页56折叠在封套40的正面顶部边缘58上以封闭开口54来密封封套40。折页56具有可再循环的或再循环相容性的或水溶性黏结剂30的横向条带，其覆盖有可移除的保护纸62。
从上面的描述中可以明显看出，垫46在内侧被内纸层25覆盖，内纸层25横向延伸超过垫46，与外纸层32的边缘44共同延伸，因此可以一起热密封所有边缘。内纸层25包围垫46的纵向末端延伸，从而使得当垫46位于封套40中时，内纸层25的端部82位于垫46和外纸层32之间。这些部分82使内纸层25能够与外纸层32一起包围封套开口54热密封，从而包裹垫46。开口54的与折页56相对的部分具有压敏的、可生物降解的带59(用保护条64覆盖)，以便在将折页56密封到封套40的正面之前将内纸层25的顶部边缘密封在一起。除了外纸层32至内纸层25的针脚和热密封之外，垫46并不附接于外纸层32。
垫46的纤维可以是例如重量为约1600克/平方(GSM)的约75％的可再循环纸板和纸纤维以及约25％的粘合纤维，即(75/25)。另外的纤维材料构造可以是约1500GSM的约80/20可再循环纸板/纸纤维和粘合纤维；约1400GSM的约80/20可再循环纸板/纸纤维和粘合纤维；约为1600GSM的约85/15再循环纸板/纸纤维和粘合纤维；约1500GSM的约85/15可再循环纸板/纸纤维和粘合纤维；约1400GSM的约85/15可再循环纸板/纸纤维和粘合纤维；约1500GSM的约90/10可再循环纸板/纸纤维和粘合纤维，第一个数字是纸板纤维的分数，第二个数字是双组分粘合纤维的分数(80/20是约80％的纸纤维和约20％的双组分)。纸板/纸纤维组分由约50/50纤维化纸板/纸至最高约75/25纤维化纸板/纸混合制成。
絮材料可以具有约25克/立方米至约40克/立方米(kg/m3)的密度，约12.5mm至约75mm的厚度，并且具有的旦尼尔范围为约1den到约3den的纤维(纸板和粘合剂)。垫46的密度与絮22的压缩量和粘合纤维的百分比有关。
优选地，该材料可以由约10％的双组分纤维和约90％的再循环纸板纤维形成。双组分纤维可以是短切的并且长度小于约24mm、小于约16mm，或者长度为约0.5mm至约16mm，并且可以是两种或更多种长度的混合物，优选为约1mm至约16mm。两种或更多种长度的混合物中一种纤维长度与另一种纤维长度的比率可以为约10％至约90％，并且平均长度可以小于约16mm。
结果发现，对于约1300GSM、约90％纸板与约10％粘合剂的絮样品(约50％的1mm长的双组分纤维和约50％的6mm长的双组分纤维)，超过93％的材料是可再浆化的，并且因此是可再循环的。应该注意的是，大于85％的可再浆化性是可再循环性的“合格等级”。双组分纤维可以是约0.5mm至约16mm的聚乙烯和聚丙烯(“PE/PP”)双组分；并且可由约65％/35％的PE/PP混合物形成。任选地，PE/PP比率可以为约65/35至约50/50。作为非限制性实例，这些纤维可以是ES聚乙烯/聚丙烯纤维，包括EAC、EPS、ESC、ESE、EDC、Herculon T426和Herculon T457型纤维。
已经发现，当测试可再浆化性时，根据本发明的教导的隔热材料样品是可再浆化的并因此是可再循环的。根据2013年8月16日由Fibre Box Association of Elk GroveVillage,IL提供的“Voluntary Standard For Repulping and Recycling CorrugatedFiberboard Treated to Improve Its Performance in the Presence of Water andWater Vapor”修订版本(其全部内容并入本文)的要求，所述隔热材料是可再浆化的。在本方面，根据2013年8月16日由Fibre Box Association of Elk Grove Village,IL提供的“Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treatedto Improve Its Performance in the Presence of Water and Water Vapor”修订版本的要求，所述隔热材料是可再循环的。包括隔热材料的容器可以是单流可再循环的，其中容器所包含的所有材料可以通过单个处理系统再循环，而不需要分离容器的任何材料或部件。可再浆化性测试结果如下：
结果发现，对于约1300GSM的絮样品(约90％的纸板与约为10％的1mm的双组分纤维的粘合剂)，超过约98％的材料是可再浆化的，并因此是可再循环的。本发明教导的隔热材料容器和运输容器是超过85％可再浆化的，85％的可再浆化性是可再循环性的“合格等级”。可再浆化性测试结果如下：
提供的热塑性粘合纤维的重量小于约0.2磅/平方英尺，更特别地，优选为约0.1875磅/平方英尺。剩余的增强纤维大于约0.8磅/平方英尺，优选为约1.0625磅/平方英尺。粘合纤维优选是通过锤磨机的纤维和纸组分的混合物。
根据本发明的教导的材料对于约25％至约50％的压缩厚度可以具有约0.3psi至约1.4psi的抗压缩性。例如，1/8”隔热垫在约25％的压缩厚度下具有约0.451psi的抗压缩性。相同的1/8”垫在约30％的压缩厚度下具有约0.564psi的抗压缩性。相同的1/8”垫在约50％的压缩厚度下具有约1.81psi的抗压缩性。1/4”垫在约25％的压缩厚度下具有约0.425psi的抗压缩性。相同的1/4”垫在约30％的压缩厚度下具有约0.547psi的抗压缩性。相同的1/4”垫在约50％的压缩厚度下具有约1.566psi的抗压缩性。1/2”垫在约25％的压缩厚度下具有约0.356psi的抗压缩性。相同的1/2”垫在约30％的压缩厚度下具有约0.458psi的抗压缩性。相同的1/2”垫在约50％的压缩厚度下具有约1.36psi的抗压缩性。相同的1/2”隔热垫可以具有约8.4磅至约8.8磅的抗撕裂性。
当根据ASTM规范C518-15在约50％的相对湿度下测试本发明的隔热垫时，该材料具有约2.64psi的弹性模量。在约0.020psi的载荷下，可以观察到约5％的应变。在约0.29psi的载荷下，可以观察到约10％的应变，并且在约0.4psi的载荷下，可以观察到约15％的应变。材料的密度可以小于约5磅/立方英尺，并且优选约3.5磅/立方英尺。材料的导热率可以是约0.254(BTU in/h ft^2Temp F)，热阻可以是约1.577(Temp F Ft^2H/BTU)，并且热阻可以是约3.943(Temp F Ft^2h/BTU in)。当根据ASTM规范C518-15测试时，所测试的垫的R值也为约1.577。
通过在烘箱中将纸纤维絮22加热到大于约350°F的温度，并且更优选地，加热到约362°F的温度，来形成隔热垫46。这种加热使粘合纤维熔化并与非粘合纤维连结，从而使纤维彼此粘合并在冷却过程中固化。一旦冷却，粘合纤维固化并起到与非粘合增强纤维连结在一起的作用，并且本身起到增强作用。
隔热纸纤维絮22被加热以形成隔热垫46，因此其密度小于约10磅/立方英尺。隔热垫46的密度优选为小于约10磅/立方英尺，并且更优选为约8.3磅/立方英尺，厚度为约1/4英寸。
图12表示根据本发明的另一教导形成用于折叠盒的隔热衬里142的系统140。通常，该系统140利用多个连接的输送带144通过一系列过程移动如上所述的隔热垫46，以形成隔热衬里142。系统140使用切割装置150从连续的絮22分离出隔热垫4。然后使用一系列辊152将上纸层154和下纸层156定位包围隔热垫46。第二切割装置185可以用于将上纸层154和下纸层156与连续的纸层供应分离。另外的或择一的，密封和切割装置186可以用于切割和密封上纸层和下纸层的包围隔热垫46的边缘。热通道可以定位为包围输送带，以将包围隔热垫46连结纸层154、156，以形成隔热衬里142。
图13A至图13B表示从连续的絮22切割并形成隔热垫46。如图所示，沿多个连接的输送带144输送絮22和垫46。切割装置150可以是圆形刀片。另外，切割装置150可以是带状刀片。
任选地，可以横切垫46以形成具有部分厚度垫的两个絮，其可以具有相等的厚度(即，织物隔热垫被分成两半)或者可以具有不相等的厚度。本发明能够形成约1/16英寸或更厚的部分厚度的絮。可以纵向分开初始隔热垫以提供两个、三个或更多个部分厚度的絮。
在本发明中，已经发现，如果进料辊位于距切割刀的预定距离内，则可以可控地且精确地分开隔热垫46。由于隔热垫的可压缩性和柔韧性，该距离很重要。在优选实施方案中，预定距离为约0至约2毫米。
热塑性粘合纤维和增强纤维在x-y-z轴上无规且一致地铺设。增强纤维通常通过将粘合纤维加热到高于其玻璃化转变温度而被粘合在一起。通常，使用小于约20％(以重量计)的粘合纤维，并且优选使用约10％的粘合纤维来形成隔热垫。
提供的热塑性粘合纤维的重量小于约0.2磅/平方英尺，更特别地，优选为约0.1875磅/平方英尺。剩余的增强纤维大于约0.8磅/平方英尺，优选为约1.0625磅/平方英尺。粘合纤维优选地是热塑性聚合物的混合物，该热塑性聚合物包括聚乙烯/聚酯或聚丙烯/聚酯或其组合。
图14A至图14C表示根据本发明的教导的上纸层的应用。然后使用一系列辊152使上纸层154和下纸层156包围隔热垫46放置。如图所示，辊152可以以不垂直于移动输送带的方向的角度定位。优选地，该角度可以与输送带的流动方向成约45度。
图15A至图15B表示底纸层156的应用；一旦上纸层154位于垫46上方，辊152就可以在两个输送带144的交叉处将下纸层156定位于垫46下方。第二切割装置185用于将上纸层154和下纸层156与连续纸层供应分离。
图16A和图16B表示包围隔热构件的纸层154、156的侧面密封。在这方面，一系列切割和密封辊186均切割并使用再循环相容性或水溶性黏合剂来密封纸层154、156的侧面。使用载荷如弹簧将切割和密封辊186偏压到纸层154、156上。
图17表示根据本发明教导的任选地用于形成盒隔热构件或隔热絮的热通道110，应该使用热敏再循环相容性或水溶性黏结剂。一旦在所有侧面上对该结构进行了密封，子组件就通过热通道110，该热通道将上纸层154和下纸层156包围隔热垫46密封。
如图18A和图18B所示，隔热絮22连结至瓦楞盒158。任选地，在将盒子切割成瓦楞盒158的形式之前，隔热絮22可以直接连结至该盒或中间纸层160。当用于形成垫46时，再循环相容性或水溶性黏结剂或可熔性纤维形式的粘合材料可以优选地是可再循环的或可生物降解的，并且可以优选地选自包含聚乙烯、聚酯、聚丙烯及其混合物的组。
隔热絮22可以用于具有用于容纳液体或储存气体的聚合物囊状物的容器中，或用于光敏或类似材料的包装盒中。在这方面，隔热絮22可以用于保持上述材料高于或低于环境温度的温度。
任选地，该盒158可以是例如顶面和底面隔热的扁平盒(例如披萨盒)。设想容器可以用于调节盒内的温度变化。例如，容器可以包含装置如可再循环冷包，其利用隔热材料为内容物提供特定的环境，例如，高于或低于环境温度的温度。在这方面，冷包可以是可再循环构件，其是穿孔的并且容纳有例如干冰。可以通过折叠或竖立纸坯来形成容器。装入容器中的可以是可拆卸或非永久固定的封闭构件。容器可以包括具有减震性能的隔热层。
使用根据本发明的教导的隔热材料的容器、包装元件或包装可以用于保护具有特定运输环境挑战的生物体、物品或材料。在这方面，隔热盒可以用于运输活的植物或动物。容器可以包括整体连结或分配特性，以允许将携带的材料填充或分配到隔热容器中。
纸、隔热结构特别适用于保护内容物免受机械损坏。在这方面，容器可以具有多边形横截面，该横截面设置有用于内容物的内部保护层。容器或包装可以具有特殊的机构，例如可折叠构件或用于分配内容物的漏斗(包括形成的倾倒口)，或者合并在可移除或非永久固定的容器封闭件中的分配装置。
根据本发明的教导，提出了一种形成隔热盒的方法。该方法包括：通过使再循环纸板通过锤磨机形成纸纤维，以及将纸纤维与可再循环相容性粘合纤维混合，以形成2％至25％的再循环相容性纤维、余量为纸和纸板纤维的混合物。然后将该材料由再循环纸纤维形成纸纤维絮，其具有第一宽度和第一长度，其重量为1000gsm至1600gsm。任选地，可再循环的第一纸层在絮的第一面上与纸纤维絮连结。纤维絮可以放置在瓦楞盒内或与瓦楞盒连结。纸层可以连结至瓦楞纸元件，或者絮可以直接连结至纸板的表面层。任选地，可再循环的第二纸层可以在絮的第二面上与纸纤维絮连结。
可以通过熔化上述粘合纤维来形成絮。第一纸层可以通过加热纸层或在第一纸层和絮之间设置再循环相容性或水溶性黏合剂之一而与纸纤维絮连结。可以包围隔热材料设置第一层和第二层可再循环纸以形成袋。第一层和第二层可以通过缝合或用再循环相容性或水溶性黏合剂之一来粘合一对相对面而连结到纤维纸层的相对面。粘合纤维选自由PVOH、聚乙烯、聚酯、聚丙烯、双组分及其混合物构成的组。隔热垫的厚度为约1/4英寸至约1英寸。
隔热封套可以通过以下步骤来形成：切割第一纸页，并将具有基本上无规分布的纸纤维的纤维网的纸纤维垫的第一面连结到第一纸页上。纸纤维的纤维网可以与第一纸页紧密连接。隔热垫连结至瓦楞板盒的内表面的一部分。在将纤维网连结到盒的内表面之后，该过程包括冲压盒的外围并折叠瓦楞盒。可以利用通过辊或蒸汽辐射的热量将纤维与纸和纸板纤维紧密连接，以具有小于约10磅/立方英尺的密度。
为了再循环根据本发明的教导的隔热容器，收集清洁的、用过的隔热瓦楞容器，在许多情况下作为混合的可再循环流(如单流再循环)的一部分。为了优化可再循环性，容器应不含污染物，如食品、金属箔、蜡等。将收集的隔热瓦楞容器分类、压实并与非隔热瓦楞容器打包，以便用于节省空间的存储和处理，无论是在最终用途(商店或商业)处还是在再循环中心处。打开捆包，并将隔热瓦楞容器放入再浆化器中。再浆化器是具有可搅动构件的巨型桶，所述可搅动构件搅动具有热水的容器。水可以优选具有高于约100华氏度的温度。将它们搅拌以形成纤维和水的液体浆(浆料)。
再浆化器可以具有垂入材料旋转桶中并且随后可以从再浆化器中取出的链条或绳索，所述链条或绳索用于去除将会缠绕该链条的较大的污染物如缠绕的长的粗绳、细绳或条带、塑料和金属带。剩余的液体浆通过不同的过滤器(其中额外的金属落到底部以便移除)、筛网、旋风分离器、甚至大罐(其中污染物漂浮到顶部并且可以被刮掉)。然后将清洁过的纸浆送到造纸机。
在典型的造纸机中，高度稀释的纤维溶液被倾倒于移动的筛网上，其使得能够排尽水，从而形成连续的纤维垫。在辊之间压制连续的纤维垫以除去更多的水。然后将湿的连续纤维网通过干燥器，其中网的顶部和底部交替地接触烘干桶的加热表面，除去纸上剩余的水分。在造纸机的末端，将纸在大卷轴上卷起。
瓦楞板由这种材料使用三片或更多片纸质盒纸板制成。外表面是挂面纸板，内部的有凹槽的纸称为介质。可以用蒸汽软化将成为瓦楞介质的纸片，然后使其进料通过称为单面机的机器。介质在两个带齿的巨大金属辊之间通过，使其具有波浪状的脊或“凹槽”。将淀粉黏结剂施加到凹槽状介质上，然后将其夹在两张平坦的纸片(挂面纸板)之间。如上所述，隔热材料可以连结至纸板以形成再循环隔热结构。在这方面，隔热材料可以直接连结至盒或者包围隔热结构设置的可再循环纸。
然后将具有相关隔热材料的经组合的3±层板通过连续网中的固化部分，然后刻痕，切成适当尺寸的坯(片)并堆叠。为了制造新盒，瓦楞片通过打印、刻痕、模切和折叠的机器。通过胶粘、胶带粘接或缝合固定盒的侧缝(制造商的接合处)。
本发明提供了示例性实施方案，从而使得透彻地理解本发明，并且将向本领域技术人员充分地传达本发明的范围。本发明提出了许多特定细节，例如特定组件、设备和方法的实例，以提供对本发明的实施方案的透彻理解。对于本领域技术人员显而易见的是，不需要采用特定细节，示例性实施方案可以以许多不同的方式实施，并且两者都不应被解释为限制本发明的范围。在一些示例性实施方案中，没有详细描述众所周知的过程，众所周知的设备结构和众所周知的技术。
本文使用的术语是仅出于描述特定的示例性实施方案的目的，而并非旨在限制本发明。如本文所使用的，指代物前不含数量词可以旨在包括了一个或者多个指代物的情况，除非上下文中另有明确规定。术语“包含”、“包含有”、“包括”和“具有”是包含性的，并且因此具体指明所述特征、整数、步骤、操作、要素和/或组件的存在，但不排除存在或添加一个或多个其他特征、整数、步骤、操作、要素、组件和/或其组。除非特别明确为实施的顺序，否则本文描述的方法步骤、过程和操作不应被解释为必须要求它们以所讨论或说明的特定顺序来实施。还应理解，可以采用另外的或替代的步骤。
当元件或层被称为“位于……上”、“接合至”、“连接至”或“连结至”另一要素或层时，它可以直接位于……上、接合、连接或连结至另一要素或层，或可以存在中间要素或层。相反，当要素被称为“直接位于……上”、“直接接合至”、“直接连接至”或“直接连结至”另一要素或层时，可以不存在中间要素或层。用于描述要素之间的关系的其他词语应以类似的方式解释(例如，“在……之间”与“直接在……之间”，“相邻”与“直接相邻”等)。如这里所使用的，术语“和/或”包括一个或多个相关所列项目的任意和所有组合。
尽管这里可以使用术语第一、第二、第三等来描述各种要素、组件、区域、层和/或部分，但是这些要素、组件、区域、层和/或部分不应受这些术语的限制。这些术语可以仅用于将一个要素、组件、区域、层或部分与另一区域、层或部分区分开。除非上下文明确指出，否则本文使用的诸如“第一”、“第二”和其他数字术语的术语并不指序列或顺序。因此，在不脱离示例性实施方案的教导的情况下，下面讨论的第一要素、组件、区域、层或部分可以被称为第二要素、组件、区域、层或部分。
如图所示，为了便于描述，在此可以使用空间相对术语，诸如“内部”、“外部”、“在……之下”、“在……下方”、“下部”、“在……上方”、“上部”等，以描述一个要素或特征与另一个要素或特征的关系。除了图中所示的方位之外，空间相对术语可以旨在涵盖设备在使用或操作中的不同方位。例如，如果图中的设备被翻转，则被描述为在其他要素或特征“下方”或“之下”的要素将被定向为在其他要素或特征“上方”。因此，示例性术语“在……下方”可以包括在……上方和在……下方的方位。设备可以以其他方式定向(旋转90度或在其他方位)，并且本文使用的空间相对描述符可以同样地作出相应地解释。
已经出于说明和描述的目的提供了实施方案的前述描述。其并非旨在穷举或限制本发明。特定实施方案的各个要素或特征通常不限于该特定实施方案，而是在适用的情况下是可互换的并且可以在所选实施方案中使用，即使没有具体示出或描述。同样也可以以多种方式变化。不应将这些变化视为脱离本发明，并且所有这些修改旨在包括在本发明的范围内。

Claims (73)

1.一种可再浆化的运输容器，包括：
第一纸层；和
与所述第一纸层连结的纤维素纤维垫，所述纤维素纤维垫具有纤维素增强纤维，所述纤维素增强纤维与以重量计2％至25％的无规分布的可熔性PE/PP双组分热塑性粘合纤维紧密连接，其中，使所述纤维素纤维垫经历可再浆化性测试产生大于85％的纤维产率。
2.根据权利要求1所述的运输容器，其中，所述可熔性PE/PP双组分热塑性粘合纤维包括长度为0.5mm至16mm的短切纤维。
3.根据权利要求1所述的运输容器，其中，所述可再浆化的运输容器还包括设置为与所述第一纸层相邻的可再浆化的瓦楞纸板；以及所述纤维素纤维垫与所述第一纸层连结；并且所述第一纸层设置于所述纤维素纤维垫和所述瓦楞纸板之间。
4.根据权利要求3所述的运输容器，其中，所述可再浆化的运输容器还包括设置在所述第一纸层和所述瓦楞纸板之间的再循环相容性或水溶性黏结剂层之一。
5.根据权利要求1所述的运输容器，其中，所述可再浆化的运输容器还包括与所述纤维素纤维垫和所述第一纸层中的至少一个连结的第二纸层。
6.根据权利要求5所述的运输容器，其中，所述第二纸层与所述第一纸层连结；并且所述纤维素纤维垫封装于所述第一纸层和所述第二纸层之间。
7.根据权利要求5所述的运输容器，其中，所述第一纸层、所述纤维素纤维垫和所述第二纸层经折叠以沿折线限定所述可再浆化的运输容器的底部并且还限定所述可再浆化的运输容器的正面、背面、横向边缘和顶部；并且所述第一纸层的至少两个横向边缘密封，使得所述第一纸层限定所述可再浆化的运输容器的内侧，且所述第二纸层限定所述可再浆化的运输容器的外侧，所述顶部限定开口。
8.根据权利要求7所述的运输容器，其中，所述正面终止于所述开口，且所述背面延伸以形成折页以覆盖所述开口。
9.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
纸纤维絮，其位于所述盒的所述内部且连结至由瓦楞纸板形成的至少一个表面，所述纸纤维絮包括通过热塑性粘合纤维粘合在一起的纸纤维，其中，所述热塑性粘合纤维具有0.5mm至16mm的长度，其中，所述纸纤维絮由以重量计最高达10％的所述热塑性粘合纤维形成，并且其中，所述纸纤维絮的重量为1300GSM至1600GSM；
所述热塑性粘合纤维是可熔性PE/PP双组分热塑性粘合纤维；使所述纸纤维絮经历可再浆化性测试产生大于85％的纤维产率。
10.根据权利要求9所述的运输容器，其中，所述纸纤维絮连结至所述盒的至少一个表面并且直接连结至由瓦楞纸板形成的至少一个表面。
11.根据权利要求9所述的运输容器，其中，所述运输容器还包括设置于所述纸纤维絮和所述瓦楞纸板之间的中间纸层，其中，所述纸纤维絮连结至所述中间纸层。
12.根据权利要求9所述的运输容器，其中，所述热塑性粘合纤维组成以重量计10％的所述纸纤维絮。
13.根据权利要求9所述的运输容器，其中，所述热塑性粘合纤维具有多种不同的长度，所述热塑性粘合纤维的第一部分的长度为1mm，且所述热塑性粘合纤维的第二部分的长度为6mm。
14.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
可再浆化的嵌件，其位于所述盒的内部，并由以下形成：
第一纸层；和
纤维素纤维垫，其连结至所述第一纸层，所述纤维素纤维垫具有纤维素增强纤维，所述纤维素增强纤维与以重量计5％至10％的无规分布的双组分热塑性粘合纤维紧密连接，其中，使所述纤维素纤维垫经历可再浆化性测试产生大于85％的纤维产率；所述热塑性粘合纤维是可熔性PE/PP双组分热塑性粘合纤维。
15.根据权利要求14所述的运输容器，其中，所述第一纸层包括纸板。
16.根据权利要求15所述的运输容器，其中，所述纸板包括可再循环纸。
17.根据权利要求14所述的运输容器，其中，所述热塑性粘合纤维组成以重量计10％的所述纤维素纤维垫。
18.根据权利要求14所述的运输容器，其中，所述纤维素纤维垫的重量为1300GSM至1600GSM。
19.根据权利要求14所述的运输容器，其中，所述热塑性粘合纤维具有多种不同的长度，所述热塑性粘合纤维的第一部分的长度为1mm，且所述热塑性粘合纤维的第二部分的长度为6mm。
20.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
隔热衬里，其位于所述盒的内部，并由以下形成：
第一纸层；
第二纸层，所述第二纸层与所述第一纸层连结形成外裹物；和
纤维素纤维絮，所述纤维素纤维絮封装在所述第一纸层和所述第二纸层之间，并且所述第一纸层和所述第二纸层的边缘在所述纤维素纤维絮的全部四个侧面上连接在一起，所述纤维素纤维絮包括由热塑性粘合纤维粘合在一起的纤维素纤维，其中，使所述纤维素纤维絮经历可再浆化性测试产生大于85％的纤维产率；所述热塑性粘合纤维组成以重量计低于10％或10％的所述纤维素纤维絮；并且所述热塑性粘合纤维是可熔性PE/PP双组分热塑性粘合纤维。
21.根据权利要求20所述的运输容器，其中，所述纤维素纤维絮连结至所述第一纸层；并且所述纤维素纤维絮不直接连结至所述第二纸层，而是经由所述第一纸层和所述第二纸层之间的连结和所述第一纸层和所述纤维素纤维絮之间的连结而邻接所述第二纸层。
22.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
纤维素纤维垫，其连结至或位于所述盒的内部，所述纤维素纤维垫具有纤维素增强纤维，所述纤维素增强纤维与无规分布于所述纤维素增强纤维内的热塑性粘合纤维紧密连接，所述热塑性粘合纤维组成以重量计0.5％至25％的所述纤维素纤维垫，所述纤维素纤维垫的厚度为至少1/16英寸，其中，使所述纤维素纤维垫经历可再浆化性测试产生大于85％的纤维产率；
所述热塑性粘合纤维是可熔性PE/PP双组分热塑性粘合纤维。
23.根据权利要求22所述的运输容器，其中，所述纤维素增强纤维包括纸纤维和纸板纤维中的至少一者。
24.根据权利要求22所述的运输容器，其中，所述热塑性粘合纤维的长度小于24mm或重量为1000GSM至1600GSM范围。
25.根据权利要求22所述的运输容器，其中，所述纤维素纤维垫连结至所述盒的至少一个表面。
26.根据权利要求25所述的运输容器，其中，所述纤维素纤维垫直接连结至所述瓦楞纸板的至少一个表面。
27.根据权利要求22所述的运输容器，其中，所述运输容器还包括设置于所述纤维素纤维垫和所述瓦楞纸板之间的中间纸层，其中，所述纤维素纤维垫连结至所述中间纸层。
28.根据权利要求27所述的运输容器，其中，所述运输容器还包括设置于所述中间纸层和所述纤维素纤维垫之间的黏结剂层，其中，所述黏结剂层是再循环相容性和水溶性黏结剂层中的至少一者。
29.根据权利要求27所述的运输容器，其中，所述运输容器还包括与所述纤维素纤维垫和所述中间纸层中的至少一者连结的第二纸层；以及所述纤维素纤维垫封装于所述中间纸层和所述第二纸层之间；或者，所述中间纸层在所述纤维素纤维垫的第一侧上连结至所述纤维素纤维垫，以及所述第二纸层在所述纤维素纤维垫的与所述第一侧相反的第二侧上连结至所述纤维素纤维垫。
30.根据权利要求29所述的运输容器，其中，所述第二纸层连结至所述中间纸层。
31.根据权利要求22所述的运输容器，其中，所述热塑性粘合纤维组成以重量计10％的所述纤维素纤维垫。
32.根据权利要求22所述的运输容器，其中，所述热塑性粘合纤维具有多种不同的长度，所述热塑性粘合纤维的第一部分的长度为1mm，且所述热塑性粘合纤维的第二部分的长度为6mm。
33.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
可再浆化的嵌件，其位于所述盒的内部，并由以下形成：
第一纸层；和
纤维素纤维垫，其连结至所述第一纸层，所述纤维素纤维垫具有纤维素增强纤维，所述纤维素增强纤维与无规分布于所述纤维素增强纤维内的热塑性粘合纤维紧密连接，所述热塑性粘合纤维组成以重量计0.5％至25％的所述纤维素纤维垫，所述纤维素纤维垫的厚度为至少1/16英寸，其中，使所述可再浆化的嵌件经历可再浆化性测试产生大于85％的纤维产率；
所述热塑性粘合纤维是可熔性PE/PP双组分热塑性粘合纤维。
34.根据权利要求33所述的运输容器，其中，所述第一纸层包括纸板或可再循环纸。
35.根据权利要求33所述的运输容器，其中，所述热塑性粘合纤维组成以重量计10％的所述纤维素纤维垫。
36.根据权利要求33所述的运输容器，其中，所述纤维素纤维垫的重量为1300GSM至1600GSM。
37.根据权利要求33所述的运输容器，其中，所述热塑性粘合纤维具有多种不同的长度，所述热塑性粘合纤维的第一部分的长度为1mm，且所述热塑性粘合纤维的第二部分的长度为6mm。
38.一种运输容器，包括：
盒，其由瓦楞纸板形成并限定内部，以及
隔热衬里，其位于所述盒的所述内部，并由以下形成：
第一纸层；
第二纸层，所述第二纸层与所述第一纸层连结形成外裹物；和
纤维素纤维垫，其连结至所述第一纸层，所述纤维素纤维垫具有纤维素增强纤维，所述纤维素增强纤维与无规分布于所述纤维素增强纤维内的可熔性PE/PP双组分热塑性粘合纤维紧密连接，所述热塑性粘合纤维组成以重量计0.5％至25％的所述纤维素纤维垫，所述纤维素纤维垫的厚度为至少1/16英寸，其中，使所述隔热衬里经历可再浆化性测试产生大于85％的纤维产率。
39.根据权利要求38所述的运输容器，其中，所述纤维素纤维垫连结至所述第一纸层。
40.根据权利要求39所述的运输容器，其中，所述纤维素纤维垫不直接连结至所述第二纸层，而是经由所述第一纸层和所述第二纸层之间的连结和所述第一纸层和所述纤维素纤维垫之间的连结而邻接所述第二纸层。
41.根据权利要求38所述的运输容器，其中，所述热塑性粘合纤维组成以重量计低于10％或10％的所述纤维素纤维垫。
42.一种用于形成运输容器的方法，所述方法包括：
将纸纤维与以重量计0.5％至25％的可熔性PE/PP双组分粘合纤维混合，以形成混合物，其中，所述粘合纤维的长度小于24mm；
将所述混合物置于表面上以形成混合物层，所述混合物的密度为1300GSM至1600GSM；
施加热以由所述混合物形成具有固定宽度和固定长度的纸纤维絮；
由纸介质形成运输容器，所述运输容器限定内部；
将纸层固定至所述纸纤维絮；以及
用所述纸纤维絮围绕所述运输容器的所述内部，
其中，使所述运输容器经历可再浆化性测试产生大于85％的纤维产率。
43.根据权利要求42所述的方法，其中，所述粘合纤维的长度为0.5mm至16mm。
44.根据权利要求42所述的方法，其中，所述将纸层固定至所述纸纤维絮的步骤包括将所述纸纤维絮封装于所述纸层中。
45.根据权利要求42所述的方法，其中，所述由纸介质形成运输容器的步骤包括将经封装的所述纸纤维絮折叠以沿折线形成所述运输容器的底部，并且还限定邻接所述底部的横向边缘和与所述底部相对设置的顶部，所述顶部限定开口。
46.根据权利要求42所述的方法，其中，所述由纸介质形成运输容器的步骤包括形成瓦楞盒，并且其中，所述将纸层固定至所述纸纤维絮的步骤包括将所述纸纤维絮连结至所述瓦楞盒。
47.根据权利要求42所述的方法，其中，所述PE/PP双组分粘合纤维组成以重量计低于10％的所述纸纤维絮。
48.根据权利要求42所述的方法，其中，50％的所述PE/PP双组分粘合纤维的长度为1mm，且50％的所述PE/PP双组分粘合纤维的长度为6mm。
49.根据权利要求42所述的方法，其中，所述施加热以形成纸纤维絮的步骤还包括施加压力与热以形成纸纤维絮。
50.根据权利要求42所述的方法，其中，所述方法还包括密封所述纸层的至少两个横向边缘的步骤。
51.根据权利要求50所述的方法，其中，所述横向边缘通过热密封来密封。
52.一种用于形成运输容器的方法，所述方法包括：
将纸纤维与以重量计0.5％至25％的可熔性热塑性粘合纤维混合，以形成混合物，其中，所述可熔性热塑性粘合纤维的长度为0.5mm至16mm；
将所述混合物置于表面上以形成混合物层；
施加热以由所述混合物形成具有固定宽度和固定长度的纸纤维絮；以及
将所述纸纤维絮连结至瓦楞盒；
其中，使所述运输容器经历可再浆化性测试产生大于85％的纤维产率。
53.根据权利要求52所述的方法，其中，所述将纸纤维与粘合纤维混合的步骤包括将所述纸纤维与可熔性PE/PP双组分热塑性粘合纤维混合。
54.根据权利要求52所述的方法，其中，所述热塑性粘合纤维组成以重量计低于10％的所述纸纤维絮。
55.根据权利要求52所述的方法，其中，所述施加热以形成纸纤维絮的步骤还包括施加压力与热以形成纸纤维絮。
56.根据权利要求52所述的方法，其中，所述将所述纸纤维絮连结至瓦楞盒的步骤包括将所述纸纤维絮插入所述盒的内部。
57.一种用于形成运输容器的方法，所述方法包括：
将纸纤维与以重量计0.5％至25％的可熔性PE/PP双组分热塑性粘合纤维混合，以形成混合物，其中，所述热塑性粘合纤维的长度为0.5mm至16mm；
将所述混合物置于表面上以形成混合物层；
施加热以由所述混合物形成具有固定宽度和固定长度的纸纤维絮；以及
将所述纸纤维絮插入瓦楞盒的内部；
所述方法还包括使所述运输容器经历可再浆化性测试产生大于85％的纤维产率。
58.根据权利要求57所述的方法，其中，所述热塑性粘合纤维组成以重量计低于10％的所述纸纤维絮。
59.根据权利要求57所述的方法，其中，所述施加热以形成纸纤维絮的步骤还包括施加压力与热以形成所述纸纤维絮。
60.根据权利要求57所述的方法，其中，所述方法还包括将所述纸纤维絮封装在纸层中的步骤。
61.根据权利要求57所述的方法，其中，所述方法还包括将第一纸层与第二纸层连接以形成封装所述纸纤维絮的所述纸层的步骤。
62.一种用于形成运输容器的方法，所述方法包括：
将纸纤维与以重量计0.5％至25％的可熔性热塑性粘合纤维混合，以形成混合物；
将所述混合物置于表面上以形成混合物层，所述混合物的密度为1300GSM至1600GSM；
施加热以由所述混合物形成具有固定宽度和固定长度的纸纤维絮；
将所述纸纤维絮封装在纸层中；以及
将经封装的纸纤维絮折叠以沿折线形成所述运输容器的底部，并且还限定邻接所述底部的横向边缘和与所述底部相对设置的顶部，所述顶部限定开口，其中，使所述运输容器经历可再浆化性测试产生大于85％的纤维产率。
63.根据权利要求62所述的方法，其中，所述方法还包括密封所述纸层的至少两个横向边缘的步骤。
64.根据权利要求63所述的方法，其中，所述横向边缘通过热密封来密封。
65.根据权利要求62所述的方法，其中，所述将所述纸纤维絮封装在纸层中的步骤包括将第一纸层固定于第二纸层，其中所述纸纤维絮位于所述第一纸层和所述第二纸层之间。
66.根据权利要求62所述的方法，其中，所述热塑性粘合纤维组成以重量计低于10％的所述纸纤维絮。
67.一种用于形成运输容器的方法，所述方法包括：
将纸纤维与以重量计0.5％至25％的可熔性PE/PP双组分粘合纤维混合，以形成混合物，其中，所述粘合纤维的长度为小于24mm；
施加热以由所述混合物形成具有固定宽度和固定长度的纸纤维絮；
由纸介质形成运输容器，所述运输容器限定内部；
将纸层固定于所述纸纤维絮；以及
用所述纸纤维絮围绕所述运输容器的内部，
其中，使所述运输容器经历可再浆化性测试产生大于85％的纤维产率。
68.根据权利要求67所述的方法，其中，所述粘合纤维的长度为0.5mm至16mm。
69.根据权利要求67所述的方法，其中，所述将纸层固定于所述纸纤维絮的步骤包括将所述纸纤维絮封装于所述纸层内。
70.根据权利要求67所述的方法，其中，所述由纸介质形成运输容器的步骤包括将经封装的纸纤维絮折叠以沿折线形成所述运输容器的底部，并且还限定邻接所述底部的横向边缘和与所述底部相对设置的顶部，所述顶部限定开口。
71.根据权利要求67所述的方法，其中，所述由纸介质形成运输容器的步骤包括形成瓦楞盒，并且其中，所述将纸层固定于所述纸纤维絮的步骤包括将所述纸纤维絮连结至所述瓦楞盒。
72.根据权利要求67所述的方法，其中，所述PE/PP双组分粘合纤维组成以重量计低于10％的所述纸纤维絮。
73.根据权利要求67所述的方法，其中，50％的所述PE/PP双组分粘合纤维的长度为1mm，且50％的所述PE/PP双组分粘合纤维的长度为6mm。
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