A 3D shaped product (20) is formed by hot pressing of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank and a thermoplastic polymer binder at a concentration selected within an interval of from 2.5 up to 30% by weight of the air-laid blank. The 3D shaped product (20) is recyclable in a repulping process. At least a part of the thermoplastic polymer binder is water soluble at a repulping temperature of the repulping process. The 3D shaped product (20) are environmentally friendly alternatives to plastic 3D shaped products made by foamed polymers and can be recycled in existing recycling schemes.

A 3D shaped product (20) is formed by hot pressing of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank and a thermoplastic polymer binder at a concentration selected within an interval of from 2.5 up to 30% by weight of the air-laid blank. The 3D shaped product (20) is recyclable in a repulping process. At least a part of the thermoplastic polymer binder is water soluble at a repulping temperature of the repulping process. The 3D shaped product (20) are environmentally friendly alternatives to plastic 3D shaped products made by foamed polymers and can be recycled in existing recycling schemes.

A fibrous structure is disclosed. The fibrous structure exhibits a plurality of discrete knuckles arranged in a pattern of repeat units. The repeat units can include a plurality of rows arranged orthogonally in an X-Y plane, each row having a portion of the discrete knuckles, and each discrete knuckle separated from adjacent discrete knuckles in a row by a distance. Each of the discrete knuckles within the repeat unit can have substantially the same shape and size; and wherein the distance between at least two adjacent discrete knuckles in each row are non-uniform such that the repeat unit exhibits varying pillow width distances along the rows in both the X and Y axes.

A fibrous structure is disclosed. The fibrous structure exhibits a plurality of discrete knuckles arranged in a pattern of repeat units. The repeat units can include a plurality of rows arranged orthogonally in an X-Y plane, each row having a portion of the discrete knuckles, and each discrete knuckle separated from adjacent discrete knuckles in a row by a distance. Each of the discrete knuckles within the repeat unit can have substantially the same shape and size; and wherein the distance between at least two adjacent discrete knuckles in each row are non-uniform such that the repeat unit exhibits varying pillow width distances along the rows in both the X and Y axes.

A 3D shaped packaging product (20) for cushioning and/or thermal insulation of packaged goods is formed by hot pressing at an average pressure equal to or below 200 kPa of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank (10) and a thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30% by weight of the air-laid blank (10). The 3D shaped packaging product (20) has a density that is less than four times a density of the air-laid blank (10) and the density of the 3D shaped packaging product (20) is selected within an interval of from 15 to 240 kg/m.sup.3. The 3D shaped packaging product (20) maintains at least a significant portion of the porosity of the air-laid blank (10) even after hot pressing and therefore provides excellent shock absorbing and damping properties and thermal insulation.

A folded 3D shaped packaging product (30) is folded at at least one crease (22A, 22B, 22C, 22D, 22E) constituting a folding line in a 3D shaped product (20) formed by hot pressing of an air-laid blank (10) comprising natural fibers at a concentration of at least 70% by weight of the air-laid blank (10) and a thermoplastic polymer binder at a concentration selected within an interval of from 4 up to 30% by weight of the air-laid blank (10). The folded 3D shaped packaging product (30) is useful for cushioning and/or thermal insulation of packaged goods and can protect multiple sides of the packaged goods.

The invention relates to a method of making a paper product 10, 10.01 to 10.14, wherein the method includes the step of adding natural reinforcing material (31, 31.1, 51, 51.1, 61, 61.1, 71, 71.1) to one of: a) a layer of pulp as it exits or after it exits from a layer formation process or apparatus; or b) a tank 20, 20.1, 20.2 of pulp prior to it exiting from a layer formation process or apparatus; or c) a combination of a) and b). Additionally, the invention relates to paper products made by this process. The present invention also provides a multi-layered material 2.10, 2.10″, 2.10.1, 2.100 to 2.1600, and 100 to 1900, and a layer treatment of a layer or layers of a multilayered material, and a multilayered material which has had such a layer or layers treated by such a layer treatment.

The invention relates to a method of making a paper product 10, 10.01 to 10.14, wherein the method includes the step of adding natural reinforcing material (31, 31.1, 51, 51.1, 61, 61.1, 71, 71.1) to one of: a) a layer of pulp as it exits or after it exits from a layer formation process or apparatus; or b) a tank 20, 20.1, 20.2 of pulp prior to it exiting from a layer formation process or apparatus; or c) a combination of a) and b). Additionally, the invention relates to paper products made by this process. The present invention also provides a multi-layered material 2.10, 2.10″, 2.10.1, 2.100 to 2.1600, and 100 to 1900, and a layer treatment of a layer or layers of a multilayered material, and a multilayered material which has had such a layer or layers treated by such a layer treatment.

A nonwoven web, containing at least one first homogeneous layer consisting of a blend of at least one of defibrated natural plant based fibers, individualized natural plant based fibers and staple fibers is provided. The nonwoven web contains no binder, adhesive or thermal bonding fibers and a basis weight of the at least one homogeneous layer is from 20 g/m.sup.2 to 100 g/m.sup.2. When a weighted average fiber length of the blend is greater than about 4.0 mm, the nonwoven web is a non-dispersible product which does not meet the requirement for dispersibility in accordance with INDA/EDANA GD4, and when a weighted average fiber length of the blend is less than about 4.0 mm, the nonwoven web is a dispersible product as defined in accordance with INDA/EDANA GD4. Methods to prepare the nonwoven web are provided.

A nonwoven web, containing at least one first homogeneous layer consisting of a blend of at least one of defibrated natural plant based fibers, individualized natural plant based fibers and staple fibers is provided. The nonwoven web contains no binder, adhesive or thermal bonding fibers and a basis weight of the at least one homogeneous layer is from 20 g/m.sup.2 to 100 g/m.sup.2. When a weighted average fiber length of the blend is greater than about 4.0 mm, the nonwoven web is a non-dispersible product which does not meet the requirement for dispersibility in accordance with INDA/EDANA GD4, and when a weighted average fiber length of the blend is less than about 4.0 mm, the nonwoven web is a dispersible product as defined in accordance with INDA/EDANA GD4. Methods to prepare the nonwoven web are provided.