Patent Publication Number: US-2022219877-A1

Title: Compostable or Recyclable Packaging Wrap

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/519,730, filed Jul. 23, 2019, which claims the benefit of U.S. Provisional Application Ser. No. 62/702,859, filed on Jul. 24, 2018, the disclosure of which is incorporated by reference. 
    
    
     TECHNICAL FIELD 
     This invention relates to a compostable or recyclable packaging wrap used for shipping. 
     BACKGROUND 
     A conventional wrapping material is polyethylene. For example, a packaging material, e.g., a bubble wrap, can be used to surround and cushion an item to be packed in a shipping box and shipped. Alternatively, other packaging materials can be molded to form a particular shape to hold an item being shipped and can be placed in a shipping box. 
     Polyethylene is relatively inexpensive and easily formed into a variety of shapes, but is not compostable. Consequently, disposing of the material of the container can be a problem. 
     SUMMARY 
     A packaging wrap that provides protection to an item to be shipped and that is recyclable or compostable is disclosed. 
     In general, in one aspect, a compostable or recyclable packaging wrap includes: a strip that is primarily formed of starch, wherein the strip is flexible such that the strip can be rolled. 
     The foregoing and other implementations can each optionally include one or more of the following features, alone or in combination. The one or more compostable materials include at least one of a grain starch, a root starch, a vegetable starch, and combinations thereof. A depth of the strip is between ⅛ inches and 2.5 inches. In a state in which the strip is rolled, a radius of the rolled strip is between 1 inch and 20 inches. A density of the strip is within at least one of a first range that is 0.25-4.0 g/cm3, a second range that is 0.6-1.0 g/cm3, a third range that is 0.8-2.0 g/cm3, and a fourth range that is 1.0-3.5 g/cm3. The strip comprises: a plurality of sections, wherein a boundary between two adjacent sections of the plurality of sections is perforated. At least 85% of the strip includes a starch by weight of the packaging wrap. 
     In general, another aspect, a compostable or recyclable packaging wrap that includes: a first film that is primarily formed of one or more compostable or recyclable materials; a second film that is primarily formed of one or more compostable or recyclable materials; a plurality of pads, each pad being are surrounded by the first film and the second film and being primarily formed of one or more compostable or recyclable materials, wherein the packaging wrap is flexible such that the packaging wrap can be rolled. 
     The foregoing and other implementations can each optionally include one or more of the following features, alone or in combination. The one or more compostable or recyclable materials for the first film and the second film include at least one of polylactic acid (PLA), poly(beta-amino) esters (PBAE), polyhydroxyalkanoate (PHA), polycapralactones (PCL), polybutyrate adipate terephthalate (PBAT) polyvinylalcohol (PVA), ethylene vinyl alcohol (EVOH), and combinations thereof. The one or more compostable or recyclable materials for the first film and the second film includes at least one of LDPE, MDPE, HDPE, polyethylene terephthalate, and combinations thereof. The one or more compostable or recyclable materials for the plurality of pads include at least one of a grain starch, a root starch, a vegetable starch, and combinations thereof. A depth of the first film is between 1/16 inches and 1.25 inches. A depth of the second film is between 1/16 and 1.25 inches. A depth of each pad of the plurality of pads is between 1/16 inches and 2 inches. In a state in which the packaging wrap is rolled, a radius of the rolled packaging wrap is between 1 inch and 20 inches. A density of the plurality of pads is within at least one of a first range that is 0.25-4.0 g/cm 3 , a second range that is 0.6-1.0 g/cm 3 , a third range that is 0.8-2.0 g/cm 3 , and a fourth range that is 1.0-3.5 g/cm 3 . The packaging wrap further includes a plurality of sections, wherein a boundary between two adjacent sections of the plurality of sections is perforated. Each section of the plurality of sections include a respective pad of the plurality of pads. The first film and the second film is attached to the plurality of pads using an adhesive. At least 85% of each pad of the plurality of pads includes a starch by weight of the pad. 
     Potential advantages may include (and are not limited to) one or more of the following. The packaging wrap is compostable, so all of the components of the packaging wrap are easily disposable. In certain cases, the packaging wrap can be perforated or scored such that a user can easily detach a section of the packaging wrap. In certain cases, the packaging wrap includes pads that are surrounded by films to provide additional protection to an item being shipped. In these cases, the films surrounding the pads are also compostable or recyclable, and also easily disposed. 
     The details of one or more embodiments are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     
       DESCRIPTION OF DRAWINGS 
         FIGS. 1A and 1B  illustrate a first implementation of a compostable packaging wrap. 
         FIGS. 2A to 2D  illustrate a second implementation of a compostable packaging wrap. 
         FIGS. 3A to 3C  illustrate a third implementation of a compostable or recyclable packaging wrap. 
     
    
    
     Like reference symbols in the various drawings indicate like elements. 
     DETAILED DESCRIPTION 
     Initially, some terminology may be beneficial. “Compostable” indicates both that a product will decompose quickly, e.g., within 180 days, and that the product will decompose into material that can be used as fertilizer (e.g., per ASTM D6400 or EN 13432). “Recyclable” indicates that a product can be reused or treated in order to be made suitable for reuse. 
     Most conventional packaging wraps are not compostable, and some are not recyclable. However, packaging wraps formed primarily of materials such as a starch are compostable as well as providing protection to an item being wrapped. In some implementations, a compostable packaging wrap can be rolled to save the storage space or being moved easily. 
       FIGS. 1A and 1B  illustrate a first implementation of a packaging wrap  100  that is compostable or recyclable.  FIG. 1A  is a perspective view of the first implementation of the packaging wrap  100  in an unrolled form and  FIG. 1B  is a perspective view of the first implementation of the packaging wrap  100  in a rolled form. 
     Referring to  FIG. 1A , in the unrolled stated, the packaging wrap  100  has a flat rectangular-shape, e.g., the wrap is a sheet. In particular, the wrap  100  provides an elongated strip. The strip can sharp edges, but in some implementations, edges of the compostable packaging wrap  100  can be rounded. In some implementations, the compostable packaging wrap  100  can have a particular shape to wrap a particular item. For example, the compostable packaging wrap  100  can have a bottle shape to wrap a wine bottle. 
     The compostable packaging wrap  100  can be primarily composed of compostable material. For example, packaging wrap  100  can be primarily composed of a starch, such as a grain starch (e.g., a corn starch, a wheat starch or sorghum, also known as milo), a root starch (e.g., a potato starch), or a vegetable starch. In some implementations, a combinations of different starches can be used. In some implementations, a starch can be mixed with one or more compostable or recyclable other materials, e.g., a plant fiber. The starch can provide at least 50%, e.g., at least 75%, e.g., at least 85%, e.g., at least or 95-99%, by weight of the packaging wrap  100 . In some implementations, the packaging wrap  100  consists of starch. In some implementations, the packaging wrap  100  can be formed using an extrusion process. 
     In some implementations, other materials that do not interfere with the compostable nature of the packaging wrap  100 , e.g., a softener to improve adhesion of the starch, or a preservative or anti-fungal agent, can be present, but only in small quantities. For example, at least 85%, e.g., at least 90%, e.g., 90-95% or 95-99%, by weight of the compostable packaging wrap  100  is made of starch. Polyvinyl alcohol can be present, e.g., 5-10% by weight. 
     In some implementations, the packaging wrap  100  is entirely compostable, i.e., consists of compostable materials. In some implementations, the packaging wrap  100  is composed of a combination of compostable and recyclable materials For example, in some implementations, additional materials, e.g., a water-retarding materials, are added to the compostable material, e.g., the starch, such that the combination is recyclable. 
     In some implementations, the material of the packaging wrap  100  can be a foam material, e.g., include small pores or voids spread substantially uniformly through the packaging wrap  100 . For example, 10-80% of the volume of the packaging wrap  100  can be pores or voids, e.g., 25-75%, 25-50%, 10-25%, and 50-75%. The maximum size of the pores or voids can be about 1 mm. Although the packaging wrap  100  could be a foam material, it is generally incompressible. 
     The packaging wrap  100 , in unrolled and unused form, can has a length that is greater than its width. For example, a length L 1  of the compostable packaging wrap  100  can be between 10 inches and 500 feet, and a width W 1  of the compostable packaging wrap  100  can be between 6 inches and 48 inches. In this example, the size of the compostable packaging wrap  100  represents the size of the entire unrolled compostable packaging wrap  100 . However, the size of the compostable packaging wrap  100  is not limited to these example numbers. The compostable packaging wrap  100  can have any suitable size to wrap an item. 
     The compostable packaging wrap  100  also has a depth D 1  (i.e., a thickness) that is less than the width W 1 . The depth D 1  of the compostable packaging wrap  100  is such that the compostable packaging wrap  100  can be wrapped around a central post or tube, e.g., as shown in  FIG. 1B . In particular, the depth D 1  of the packaging wrap  100  is within a range such that, in conjunction with the material composition, the packaging wrap is sufficiently flexible so as to wrap around a central post having a particular diameter without breaking or permanent deformation. For example, the diameter of the center pole can be between ⅛ inches and 5 inches. If the depth of the compostable packaging wrap  100  is too large, the compostable packaging wrap  100  cannot be rolled. For example, where the compostable packaging wrap  100  is primarily formed of starch, the depth of the compostable packaging wrap  100  can be between ⅛ inches and 2.5 inches to be rolled. The maximum thickness of the compostable packaging wrap  100  can be different for various types of starch. 
     For some materials, the same material can have different densities depending on the manufacturing process, e.g., the degree of compression of the starch. In such cases, the density of the packaging wrap  100  can be selected, e.g., by selection of an appropriate processing parameters. For many materials, the greater the density (e.g., the higher the degree of compaction), the less flexible the material is. In such cases, the density of the packaging wrap  100  can be selected such that the compostable packaging wrap  100  can have enough flexibility to be rolled as described above. Where the compostable packaging wrap  100  is primarily formed of starch, the density of the compostable packaging wrap  100  can be about 0.25-4.0 g/cm 3 , e.g., 0.6-1.0 g/cm 3 , 0.8-2.0 g/cm 3 , 1.0-3.5 g/cm 3 . 
     In some implementations, the density of the packaging wrap  100  is substantially uniform, e.g., the material lacks pores or pores are distributed substantially uniformly through the sheet, and the degree of compaction of the material is similarly substantially uniform. However, in some implementations, the density of the packaging wrap  100  can vary along the length or width of the sheet, e.g., the degree of compaction of the material can vary. 
     Referring to  FIG. 1B , the compostable packaging wrap  100  is in a rolled form. In some implementations, the packaging wrap  100  is rolled around a center pole  102 . In some implementations, the center pole  102  can be primarily formed of compostable material. For example, the center pole  102  can be primarily formed of starch. The starch for the center pole  102  can be any type of starch described above with reference to  FIG. 1A  or any combination of two or more starches described above with reference to  FIG. 1A . In some implementations, the compostable material for the center pole  102  can be the same as the compostable material of the compostable packaging wrap  100 . In these implementations, the cost to manufacture the center pole  102  can be reduced because the center pole  102  and the compostable packaging wrap  100  are formed of the same compostable material. In some implementations, the compostable material for the center pole  102  can be different from the compostable material of the compostable packaging wrap  100 . In these implementations, the compostable material for the center pole  102  can be harder than the compostable material for the compostable packaging wrap  100  such that the rolled compostable packaging wrap  100  can maintain its shape. In some implementations, the compostable packaging wrap  100  can be rolled without a center pole. 
     The compostable packaging wrap  100  can be wound around the center axis (e.g., the center pole) multiple times. For example, where the compostable packaging wrap  100  is rolled, a radius R 1  of the rolled compostable packaging wrap  100  can be between 1 inch and 20 inches. The radius of the compostable packaging wrap  100  should not be limited to these particular numbers, but can be any suitable number. 
       FIGS. 2A-2D  illustrate a second implementation of a compostable packaging wrap  200 .  FIG. 2A  is a perspective view of the second implementation of the compostable packaging wrap  200  in an unrolled form,  FIG. 2B  is a cross-sectional view of one example of the compostable packaging wrap  200  in an unrolled form,  FIG. 2C  is a cross-sectional view of another example of the compostable packaging wrap  200  in un unrolled form, and  FIG. 2D  is a perspective view of the second implementation of the compostable packaging wrap  200  in a rolled form. The compostable packaging wrap  200  can be the same as or similar to the compostable packaging wrap  100  described above with reference to  FIGS. 1A and 1B  except differences described below. 
     Referring to  FIG. 2A , the compostable packaging wrap  200  includes multiple sections, e.g., a first section  210  and a second section  220 , that are respectively divided by a scored or perforated portion, e.g., a scored or perforated portion  230 , that permits easier manual detachment of one section from an adjacent section. The line of the score or perforation  230  can extend across the width of the strip of the packaging wrap  200 . 
     In some implementations, the size of the each section of the multiple sections can be the same. For example, a length L 2  of the first section  210  can be the same as a length L 2 ′ of the second section  220 . In some implementations, different sections can have different sizes. For example, the length L 2  of the first section  210  can be different from the length L 2 ′ of the second section  220 . In this example, a user can use different sizes of wraps to wrap different sizes of items. That is, a user can use a smaller section to wrap a small item and a larger section to wrap a large item. 
     Referring to  FIG. 2B , the scored or perforated portion  230  includes a first score  230   a  that is formed on a top surface of the compostable packaging wrap  200  and a second score  230   b  that is formed on a bottom surface of the compostable packaging wrap  200 . The scores  230   a  and  230   b  can include multiple grooves formed on surfaces of the compostable packaging wrap  200 . For example, the grooves for the first score  230   a  can have a depth D 2  and the grooves for the second score  230   b  can have a depth D 3 . The depths D 2  and D 3  can be between ⅛ inches and 2.5 inches. In some implementations, the depth D 2  can be the same as the depth D 3 . In some implementations, the depth D 2  can be different from the depth D 3 . 
     In some implementations, where the compostable packaging wrap  200  is primarily formed of a starch, the depths D 2  and D 3  should be determined such that a section is not easily detached from the compostable packaging wrap  200  before a user detaches the section from the compostable packaging wrap  200 . Moreover, when the compostable packaging wrap  200  is rolled, a section can be detached because of the tension between two sections, e.g., the first section  210  and the second section  220 . Thus, the depths D 2  and D 3  should be shallow enough not to be detached by the tension. In these implementations, the depths D 2  and D 3  can be between 1/64 inches and 1.2 inches. 
     In some implementations, the scored or perforated portion  230  can include grooves that are formed only one surface of the compostable packaging wrap  200 . For example, the scored or perforated portion  230  can include only the first score  230   a  that is formed on the top surface of the compostable packaging wrap  200 . Alternatively, the scored or perforated portion  230  can include only the second score  230   b  that is formed on the bottom surface of the compostable packaging wrap  200 . In these implementations, the depth of the grooves can be larger than the depth of the grooves where the scored or perforated portion  230  includes both the first score  230   a  and the second score  230   b.    
     Referring to  FIG. 2C , in some implementations, the scored or perforated portion  230  can have perforations that extend entirely through the sheet of the packaging wrap  200 . A perforation can have a length L 2 ″. For example, the length L 2 ″ can be between 2 inches and 20 inches. 
     Referring to  FIG. 2D , the compostable packaging wrap  200  is in a rolled form. The rolled compostable packaging wrap  200  can have a radius R 2 . In some implementations, where the compostable packaging wrap  200  is primarily made of a starch, the radius R 2  of the compostable packaging wrap  200  can be determined based on the density of the starch material. In some implementations, the radius R 2  of the compostable packaging wrap  200  can be the same as the radius R 1  of the compostable packaging wrap  100  described with reference to  FIG. 1B . In other implementations, to prevent a section from being detached from the compostable packaging wrap  200  due to the tension between two adjacent sections, the radius R 2  can be smaller than the radius R 1 . For example, the radius R 2  can be between 1 inch and 20 inches. The radius of the compostable packaging wrap  200  should not be limited to this particular number, but can be any suitable number. 
       FIGS. 3A to 3C  illustrate a first implementation of a compostable or recyclable packaging wrap  300 .  FIG. 3A  is a perspective view of the compostable or recyclable packaging wrap  300  in an unrolled form,  FIG. 3B  is a cross-sectional view of the compostable or recyclable packaging wrap  300  in an unrolled form, and  FIG. 3C  is a perspective view of the compostable or recyclable packaging wrap  300  in a rolled form. The compostable or recyclable packaging wrap  300  can be the same as or similar to the compostable packaging wrap  200  described above with reference to  FIGS. 2A to 2D  except differences described below. 
     Referring to  FIG. 3A , the compostable or recyclable packaging wrap  300  includes multiple sections, e.g., a first section  310  and a second section  320 , that are respectively divided by a scored or perforated portion, e.g., a scored or perforated portion  330 . In some implementations, the size of the each section of the multiple sections can be the same. For example, a length L 3  of the first section  310  can be the same as a length L 3 ′ of the second section  320 . In some implementations, the size of each section of the multiple sections can be different. For example, the length L 3  of the first section  310  can be different from the length L 3 ′ of the second section  320 . In this example, a user can use different sizes of wraps to wrap different sizes of items. That is, a user can use a smaller section to wrap a small item and a larger section to wrap a large item. 
     In some implementations, each section of the compostable or recyclable packaging wrap  300  includes a pad portion in a central area of the section and a boundary portion that surrounds the pad portion. For example, the first section  310  includes a pad portion  312  and a boundary portion  314  that surrounds the pad portion  312  and the second section  320  includes a pad portion  322  and a boundary portion  324  that surrounds the pad portion  322 . The boundary portion  324  can have a margin M between the pad portion  322  and the edge of the first section  310 . For example, the margin M can be between ½ inches and 5 inches. The margin is not limited to these numbers, but ca be any suitable number. 
     Referring to  FIG. 3B , the compostable or recyclable packaging wrap  300  includes multiple films, e.g., a first film  301  and a second film  302 , and compostable or recyclable pads, e.g., a first pad  342  and a second pad  344 , sandwiched between the films. For example, in the pad portion  312  of the first section  310 , the top halves of the pads  342 ,  344  contacts the first film  301  and the bottom halves of the pads  342 ,  344  contact the second film  302 . In the boundary portion  314  of the first section  310 , two films  301  and  302  are coupled together, e.g., by adhesive. In some implementations, the films  301  and  302  can be secured to the pads  342 , 344  using an adhesive. In some implementations, the pads  342 ,  344  fit in the pockets formed by the films  301  and  302 . In some implementations, the pads  342 ,  344  are substantially constrained in the pockets, e.g., air is evacuated from the pockets. In some implementations, the pads  342 ,  344  sit loose, e.g., are slidable, within the pockets formed by the files  301 ,  302 . 
     In some implementations, a depth of each film can be a half of a depth D 4 . For example, the depth of the film can be 1/16 inches and 1.25 inches. In some implementations, a depth of the pad, e.g., the first pad  342 , can be between 1/16 inches and 2 inches. However the depth D 5  is not limited to these numbers. The depth D 5  can be any suitable number. 
     In some implementations, the scored or perforated portion  330  includes a first score  330   a  that is formed on a surface of the first film  301  and a second score  330   b  that is formed on a surface of the second film  302 . The scores  330   a  and  330   b  can include multiple grooves formed on the surfaces of the films  301  and  302 . The two films  301  and  302  adjacent to the scored or perforated portion  330  are coupled together without any pad between the two films  301  and  302 . Alternatively, in some implementations, the scored or perforated portion  330  can have perforations that extend entirely through the sheet of the packaging wrap  300 . 
     In some implementations, the pads, e.g., the first pad  342  and the second pad  344 , can be primarily formed of compostable material. For example, the compostable material for the pads  342  and  344  is primarily a starch, e.g., a grain starch (e.g., a corn starch, a wheat starch or sorghum, also known as milo), a root starch (e.g., a potato starch), or a vegetable starch. In some implementations, a combinations of different starches can be used for the pads  342  and  344 . In some implementations, at least 85%, e.g., 90-95%, of the pad portion  312  can include a starch by weight of the pad portion  312 . 
     In some implementations, the films, e.g., the first film  301  and the second film  302 , can be compostable, e.g., a bioplastic that meets ASTM D6400 standards. Example materials for a compostable film include polymers based on one or more of polylactic acid (PLA), poly(beta-amino) esters (PBAE), polyhydroxyalkanoate (PHA), polycapralactones (PCL), polybutyrate adipate terephthalate (PBAT) polyvinylalcohol (PVA), or ethylene vinyl alcohol (EVOH). In addition, any combinations of these materials can be used for the films  301  and  302 . For example, a combination of PBAT and PE can be used for the films  301  and  302 . As another example, a combination of PE and PLA can be used for the films  301  and  302 . In some implementations, the polymer can be mixed with an organic product, e.g., a starch. 
     In some implementations, the films, e.g., the first film  301  and the second film  302 , can be recyclable. A suitable material for the recyclable film is polyethylene. For example, the films  301  and  302  can include LDPE, MDPE, HDPE, or polyethylene terephthalate. An advantage of polyethylene is ease of fabrication and good water resistance. 
     In some implementations, the films, e.g., the first film  301  and the second film  302 , can be paper sheets. If the paper is thin enough or is perforated, the paper is compostable. Optionally, the paper can be lined with a water-repellent coating. Either the inner surface of the film, or the outer surface, or both can be lined with the water-repellent coating. The water-repellent coating can be a compostable material, e.g., wax. In this example, the film with paper and coating is compostable. Alternatively, the water-repellent coating can be a recyclable material. In this example, the layer with paper and coating is recyclable. 
     Referring to  FIG. 3C , the compostable or recyclable packaging wrap  300  is in a rolled form. The rolled compostable or recyclable packaging wrap  300  can have a radius R 3 . In some implementations, where the compostable or recyclable packaging wrap  300  includes the pads, e.g., the pads  342  and  344 , between the two films, e.g., the films  301  and  302 , the radius R 3  of the compostable or recyclable packaging wrap  300  can be determined based on the density of the materials for the films or the pads and/or the depth D 5  of the pads and the depth D 4  of the films. For example, the radius R 3  of the compostable or recyclable packaging wrap  300  can be between 1 inch and 20 inches. The radius of the compostable packaging wrap  300  should not be limited to these particular numbers, but can be any suitable number. 
     A variety of combinations of the features discussed above are possible. The drawings show only a limited number of possible combinations, and it should be assumed that the various features described can be used together in any consistent combination. A number of embodiments have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. Accordingly, other embodiments are within the scope of the following claims.