Patent Publication Number: US-2007119122-A1

Title: Environmentally sustainable packaging and method of making thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
      Not Applicable.  
     BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention relates generally to packaging and more specifically to environmentally sustainable packaging used to ship or transport articles.  
      2. Description of Related Art  
      In today&#39;s global manufacturing environment, many parts, components or workpieces, especially those used in automotive manufacturing, are obtained from worldwide sources. That is, the part or component manufacturer may not be located geographically near the assembly facility. Thus, the parts or components are packaged and shipped to the assembly facility where there are assembled to form a finished product. An assembly facility can literally receive thousands of parts from various manufacturers located all across the globe, with the parts or components arriving at the assembly facility in various types of packaging and/or shipping containers. Ultimately, the assembly facility is tasked with handling or disposing of the packaging and/or shipping containers once the part or component has been removed. Thus, in many cases, the packaging and/or shipping containers are carted off and discarded as waste, creating further environmental issues when they end up in a landfill.  
      Various types of materials are used for packaging or shipping containers, one of the primary materials being cardboard. Cardboard packaging or shipping containers have drawbacks; specifically, depending upon the particular part or component being shipped they can be a source of part contamination. In some cases, cardboard packaging increases overall shipping costs since in some instances the part must be removed from the cardboard packaging and repacked in a different container prior to reaching its final destination. Cardboard also has poor environmental sustainability. While cardboard is recyclable, it is not typically used by the end manufacture or assembly plant and thus must be stored and ultimately removed from the assembly facility. In many instances, it is simply discarded after use. Thus, the overall cost to make and recycle or dispose of cardboard packaging impacts the environment and increases energy costs.  
      Wood packaging, such as pallets and boxes, is also used to transport parts or components. Wood packaging is typically expensive to make and maintain. The wood may be a source of part contamination, may deteriorate due to adverse weather and may be subject to insect infestation. Finally, wood packaging or shipping containers also have issues with recyclability and disposal. As with cardboard, the overall cost to make and recycle or dispose of wood packaging impacts the environment and increases energy costs.  
      Plastic or polymer packaging, such as plastic pallets and boxes are also used for shipping parts or components. Plastic packaging may also result in part contamination. In addition, the initial cost of plastic packaging typically requires that the packaging be returned to the initial manufacturer for reuse. Returning the packaging incurs additional costs associated with storing sorting and returning plastic packaging or shipping materials to the component manufacturer. In many cases, the packaging is part or component specific and thus must be returned to specific component manufacturers. Accordingly, the cost of returning the plastic packaging or shipping materials may outweigh any benefits obtained over other packaging materials.  
      Accordingly, it is desirable to have an environmentally sustainable packaging wherein the material used for the packaging can also be recycled or used by the end user or assembly facility thereby eliminating the need to discard or return the packaging or shipping materials to the component manufacturer.  
     SUMMARY OF THE INVENTION  
      Accordingly, the present invention is sustainable packaging and method of designing such packaging. In general, the sustainable packaging is designed by taking into account or determining a need for a particular raw material used to manufacture a first product. The method includes determining packaging requirements for a second product. Accordingly, the packaging for the second product is designed such that it includes or is formed of the raw material needed for the first product. Thus, upon removal of the second product from the packaging, at least a portion of the packaging can be used to manufacture the first product. Designing and using sustainable packaging according to the present invention saves on overall costs, reduces energy consumption and conserves resources.  
      The present invention also includes sustainable packaging for transporting a part or component wherein at least a portion of the packaging is intended for use to manufacture a predetermined article or product. Accordingly, the packaging supplies the recipient of the packaging with a raw material with which to manufacture the predetermined article or product. The packaging includes a top and bottom layer formed of a material used to form the predetermined article or product. The top and bottom layer are configured to hold the transported part or component. First and second sheet layers positioned or sandwiched between the top layer and the part and between the bottom layer and the part help protect the transported part or component during shipment. A predetermined amount of layers are stacked upon one another and sandwiched between a bottom tray and the lid. A sleeve extending between the bottom tray and the related surrounds the layers and forms an outer wall to complete the packaging.  
      One advantage of the present invention is that the packaging is designed with a predetermined end use; specifically, providing raw material used to manufacture a part or component. Thus, the packaging has a twofold function; it transports a part or component after which it is formed into a predetermined article or product. Accordingly, the packaging eliminates material from the waste stream and adds value to the packaging.  
      These and other features and advantages of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       FIG. 1  is a block diagram illustrating the overall method of one embodiment of the present invention.  
       FIG. 2  is a block diagram illustrating a plurality of steps for reviewing current packaging according to the present invention.  
       FIG. 3  is a block diagram illustrating a plurality of steps for designing packaging according to the present invention.  
       FIG. 4  is an exploded perspective view of sustainable packaging according to the present invention.  
       FIG. 5  is a cross-sectional view of the sustainable packaging illustrated in  FIG. 4  shown in an assembled condition. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
      Referring to the drawings and more particularly to  FIG. 1  thereof, a block diagram of a method  10  for developing sustainable packaging based on a predetermined material selection according to one embodiment of the present invention is illustrated. In this embodiment, the method  10  is used to develop packaging, seen generally at  50  in  FIG. 4 , for powertrain components  14  wherein at least a portion of the packaging  50  is reused to manufacture a second part or product.  
      In operation, the method  10  begins with block  16 , wherein the need for materials to manufacture a first part or product, such as a splash shield for a motor vehicle is assessed. Specifically, the method contemplates beginning with a particular part or component manufactured from a predetermined material. Once the material needs are determined for the first part or product, as illustrated in block  18 , the method includes reviewing packaging currently used for transporting a second part or product, illustrated in the present embodiment as a powertrain component. The review may include determining packaging requirements for the second part or product such as ergonomic requirements, corrosion requirements, contamination prevention requirements and part support.  
      Block  20  illustrates that the method includes determining whether the predetermined material will satisfy the packaging needs or specifications determined in the previous step, block  18 . Once it is determined that the predetermined material will meet the packaging needs of the second part or product, as illustrated in block  22 , the next step is to design packaging for the second part or product. The packaging is designed such that at least a part of the packaging will be constructed from the predetermined material used to manufacture the first part or product.  
      Upon completing the design, the proposed packaging then, as illustrated in block  24 , undergoes a variety of tests. For example, a finite element analysis is performed on the design concept to establish the viability of the proposed packaging. Continued testing includes manufacturing a prototype and subjecting it to a shake test and a load test. Upon successful completion of the testing phase, as illustrated in block  26 , packaging is manufactured and used to transport the second part or product from a manufacturing facility to a final destination, often an assembly facility. As illustrated in block  28 , removal of the second part or product from the packaging enables use of that portion of the packaging formed from the predetermined material in a process to manufacture the first product.  
      Accordingly, the overall method of the present invention is comprised of three interrelated parts: first, determining an end use or need for a particular or predetermined material used to manufacture a first product, typically a polymer material; second, defining packaging criteria for transporting a second product; and third designing packaging for the second product using the predetermined material.  
      Turning now to  FIG. 2 , block  18  is shown in detail and includes blocks  30 - 36 . Block  30  includes the step of evaluating contamination issues associated with the current packaging. For example, with cardboard packaging, cardboard fibers may contaminate the part. Additionally, open rack containers also allow for part contamination. Block  32  includes the step of evaluating environmental waste; specifically, cardboard containers and wood pallets are typically treated as waste material that must be disposed once the second part or product reaches its end destination.  
      Block  34  includes the step of evaluating non-value added steps. It may be necessary to remove the part or product from the original packaging and repack it prior to the part or product reaching its final destination. For example, when cardboard is used as packaging, cardboard fibers can create contamination issues. Accordingly, prior to transporting the part or product to its final destination to prevent contamination at the final destination, the part or product is removed from the cardboard container and repacked in a different container. Finally, block  36  includes the step of evaluating the quality issues including part-to-part contact, corrosion issues and other packaging concerns that may result in damage to the part or product.  
      Turning now to  FIG. 3 , block  22  is shown in detail and includes blocks  38 - 46 . Block  38  includes evaluating international packaging requirements, including standards for sea-containers. Block  40  includes evaluating the requirements for intermodal shipping including transferring the packaging through various types of shipping including ocean, rail and truck. Block  42  includes evaluating the corrosion protection needs of the part or product. Block  44  includes evaluating any potential contamination issues associated with the part or product. Block  46  includes evaluating any ergonomic requirements, including loading and unloading the second part or product from the packaging.  
      It should be understood that the above-identified steps are not inclusive of all steps taken to create packaging according to the present invention. Nor must every step be taken in order to create sustainable packaging according to the present invention. One aspect of the present invention is a method for use in designing packaging from a predetermined end use material, whereby at least a portion of the packaging is formed of the predetermined end use material. Accordingly, at least a portion of the packaging is recycled and formed into a first product made from the end use material after removal of the second part or product from the packaging.  
       FIGS. 4-5  illustrate packaging  50  formed in accordance with the method of the present invention. As illustrated herein, the packaging is used for transporting or shipping a powertrain component  14 . The packaging  50  includes a bottom spacer pad  52  and a top spacer pad  54 . The bottom and top spacer pads  52 ,  54  may include a shaped receptacle or cutout  56  that receives the part, in the present embodiment the powertrain component  14 . The bottom and top spacer pads  52 ,  54  may be molded with the shaped receptacle or cutout  56 . In addition, each spacer pad  52 ,  54  may be made up of any plurality of individual layers, wherein one or more of the layers is die cut with the shaped receptacle or cutout  56  prior to assembling the individual layers to form the spacer pads  52 ,  54 .  
      The packaging further includes protection sheets or layers  58  dispersed between the powertrain components  14  and the bottom and top spacer pads  52 ,  54 . Depending upon the material used for the bottom and top spacer pads  52 ,  54  the sheets  58  perform several functions. Initially, the sheets  58  prevent direct contact between the bottom and top spacer pads  52 ,  54  and the powertrain components  14  to eliminate any wear between the two. Specifically, if the powertrain components  14  rub on the bottom and top spacer pads  52 ,  54  a small amount of material from the bottom and top spacer pads  52 ,  54  may be removed and cause part contamination.  
      In addition, the sheets  58  may include a volatile corrosion inhibitor impregnated therein. Accordingly, the volatile corrosion inhibitor in the sheets  58  will vaporize and attach to the powertrain components  14  and form a protection layer that prevents humidity, salt, dirt and other contaminants from depositing on and causing corrosion of the powertrain components  14 .  
      The packaging  50  further includes a bottom tray  60  having legs  62  arranged in a pallet configuration. A sleeve  64  surrounds the bottom and top spacer pads  52 ,  54  and forms an outer wall of the packaging  50 . A lid  66  fits over and on top of the sleeve  64  to complete the packaging. In accordance with the present invention, the bottom and top spacer pads  52 ,  54 , bottom tray  60 , sleeve  64  and lid  66  are all made from a predetermined polymer, such as polypropylene, suitable for use as a raw material to manufacture a preselected part or product.  
      The packaging is used as follows, the sleeve  64  is placed into the bottom tray  60  after which a bottom spacer pad  52  is placed in the tray  60 . One of the protective sheets  58  is placed on the bottom spacer pad  52 . A part, illustrated herein a powertrain component  14 , is placed on top of protective sheet  58  such that it sits in one of the shaped receptacle or cutout areas  56  of the bottom spacer pad  52 . A second protective sheet  58  is then placed on top of the powertrain component  14  layer after which a top spacer pad  54  is placed on the top protective sheet  58  and over the powertrain component  14  layer. The process is continued in a layer-by-layer manner until reaching the top of the sleeve  64  at which time the lid  66  is placed on the sleeve  64 . The entire packaging  50  may be secured with bands or straps extending around the bottom tray  60 , sleeve  64  and lid  66 .  
      One advantage of the present packaging  50  is that the spacer pads  52 ,  54  forming each layer operate to separate the parts or products, shown herein as powertrain components  14 . Since the powertrain components  14  are stacked on top of each other, they bear their own weight and support one another rather than the packaging being designed to support the weight of the powertrain components  14 . Further, while shown with top and bottom spacer pads  54 ,  52 , depending upon the part or product being transported, the packaging  50  may use a single pad between each layer of parts. For example, if the part or product has a relatively simple configuration, a single layer between the parts may suffice. In addition, the shaped receptacle or cutout  56  may be located on both sides of a single spacer pad.  
      In accordance with the present invention, prior to designing the packaging for the powertrain components  14 , it was determined that polypropylene was a needed material to manufacture a first product, for example a vehicle splash shield. Accordingly, knowing that there is a predetermined need for polypropylene material to manufacture a first product, current packaging designs for transporting other products; i.e., a second part or product, are reviewed to determine if polypropylene can be used for packaging the second part or product.  
      In the present example, currently cardboard containers are used to transport the powertrain components  14 . Cardboard containers contribute to part contamination. Cardboard fibers can cause serious contamination problems with powertrain components. To prevent contamination the components are sometimes inserted in a plastic bag prior to placement in the cardboard container. In addition, cardboard containers require a repack step as powertrain assembly plants typically restrict the use of cardboard shipping materials to prevent part contamination. Accordingly, this increases costs of using cardboard containers to ship powertrain components. By using polypropylene as the base material for the packaging  50 , the materials may be reused thereby eliminating costly waste and repack costs. Accordingly, once the powertrain components  14  are removed from the packaging  50 , the polypropylene components, specifically the bottom and top spacer pads  52 ,  54 , bottom tray  60 , sleeve  64  and lid  66  are subjected to a regrind process to transform them into raw material used to form the first part or product, disclosed herein as a vehicle splash shield.  
      Accordingly, using packaging made from a predetermined material having a known end use to transport parts or products has dual savings; first, it eliminates problems associated with non-value added repackaging and second, it supplies raw material for manufacturing a second part or product. Thus, the present invention provides sustainable packaging designed to transport a second part or product. Once the second product is delivered to its end destination, the packaging is then recycled as a raw material to form a first part or product.  
      The description of the invention is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention.