Abstract:
Disclosed herein is a general purpose, low-cost, highly efficient, biodegradable multi-layer, passive thermal insulator material that can be used for packaging in any application where tight temperature tolerance is required for extended periods. The material comprises inner layers between two outer layers. The outer layers can be themselves multiple layers that may provide strength and moisture protection to the structure. The inner layers can comprise a series of alternating courses of continuous material and discontinuous material containing gaps that can form pockets where the continuous layers are arranged to provide a barrier to seal a gas in the pockets in the discontinuous material.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to Australian Provisional Application Number 2014900207, filed Jan. 24, 2014, the entirety of which is incorporated herein by reference. 
       INTRODUCTION 
       [0002]    Described herein is a general purpose, low-cost, highly efficient, biodegradable multi-layer, passive thermal insulator material that can be used for packaging in any application where tight temperature tolerance is required for extended periods. 
         [0003]    The material comprises inner layers positioned between outer layers. The outer layers can be themselves multiple layers and may provide strength and moisture protection to the structure, For example, the outer layers may comprise from 2-30 or more layers. The inner layers may comprise a series of alternating courses of continuous material and discontinuous material containing gaps that can form pockets where the continuous layers are arranged to provide a barrier to seal a gas in the pockets in the discontinuous material. The use of multiple layers exploits the interface effect to enhance the thermal resistivity of the structure. 
         [0004]    There are many embodiments of the biodegradable multi-layer, passive thermal insulator material including the use therein of various materials for the outer layers and the inner continuous and discontinuous layers. Moreover, the layers can be integrated with a wide range of static and/or active thermal materials. By using low cost, biodegradable materials and simple manufacturing processes the present products are versatile and cost effective. 
       BACKGROUND 
       [0005]    Improper temperature management greatly deteriorates the overall quality of food and is a leading cause of food spoilage. Food packaging in all phases of the supply chain is the main element for the proper control of temperature and thereby the preservation of food quality as food packaging provides barrier protection, communicates information about freshness and controls physical integrity of its contents. 
         [0006]    Thermostatic food packaging solutions are capable of directly assisting in regulating temperature and thereby improving the condition or extending the life of food products. With a market over $2.5 billion (in 2013), thermostatic packaging is a growing tool to protect and extend the quality of food at consumption. 
         [0007]    By way of background, reference can be made to a thermal insulation material made for a seismograph that would operate on the Moon where the day-night cycle undergoes a temperature range &gt;250° C., i.e., from −180° C. to +90° C., conditions not suitable for the operation of the highly sensitive instrument. A thermal insulating blanket was designed using a multi-layer concept similar to the present but of different, much more expensive, and more environmentally resistant materials. While that material was effective and served its purpose in a highly specialized application, the present materials are more economical such that they can be used in everyday application and are biodegradable. 
         [0008]    Of the products available in the market today, few can actively adjust the temperature to achieve desired temperatures “on demand” or passively affect the internal temperature based on external temperatures. 
         [0009]    While thermostatic packaging solutions can come in many forms, they are often divided into active or passive modes of operation. “Active” modes of packaging can compensate for temperature loss/gain to maintain the ideal temperature range or it can lower/raise temperature in order to reach a desired temperature range, e.g. prior to consumption. “Passive” modes of packaging do not offer or generate temperature changes but offer resistance to changes of temperature through effective insulation. 
         [0010]    The ideal thermostatic solution satisfies the fol lowing;
       maintain the temperature of the product within a target range for a target period   is economically beneficial, i, e., it is sufficiently low cost to warrant its use based on the improved quality or improved shelf-life of the product it protects   does not interfere with the product in any way   can be used sustainably.
 
The biodegradable multi-layer, passive thermal insulator material described herein presents a passive packaging solution that addresses these four conditions.
       
 
       SUMMARY 
       [0015]    The materials described herein provide for a low-cost, highly efficient, bio-degradable multi-layer, passive thermal insulator material that can be used for packaging in any application where tight temperature tolerance is required for extended periods such as foodstuffs and other temperature sensitive substances. In addition, the biodegradable multi-layer, passive thermal insulator material can be used in place of plastic back sheet covers conventionally used in diapers, incontinence products and feminine care products. 
         [0016]    The biodegradable multi-layer, passive thermal insulator material comprises a series of inner layers sandwiched between outer layers. The outer layers themselves may be multiple layers and may provide strength and moisture protection to the overall structure. The inner layers may comprise a series of alternating courses of continuous material and discontinuous material containing gaps that can form pockets. The function of the continuous material is to provide a barrier to seal a gas in the pockets in the discontinuous material to form an effective thermal barrier. The use of multiple layers exploits the interface effect to enhance the thermal resistivity of the structure. 
         [0017]    In some embodiments the inner layer comprises continuous layers that comprise newsprint or similar material interleaved with a layer of discontinuous woven or non-woven mesh material such as cheesecloth. Further, to provide structural strength and moisture protection in some embodiments the outer layers comprise a layer of chitosan coated with beeswax or similar biodegradable coating. Depending on the application, the number of total layers in the biodegradable multi-layer, passive thermal insulator material can be small, e.g., 3-5, or large, e.g., 20 or more, allowing the insulating properties to be adjusted to that required in any specific application. It is estimated that a packaging material having 10 discontinuous layers can be created with a thermal resistivity of 27 mK/W or more. This compares favorably with existing synthetic packaging materials. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0018]      FIG. 1  is a schematic illustrating one embodiment where the multi-layer, passive thermal insulator material comprises one discontinuous layer. 
           [0019]      FIG. 2  is a schematic illustrating one embodiment where the multi-layer, passive thermal insulator material comprises three discontinuous layers. 
           [0020]      FIG. 3  is a schematic illustrating one embodiment where the multi-layer, passive thermal insulator material comprises five discontinuous layers. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The present biodegradable multi-layer, passive thermal insulator material is formed as a series of layers resulting in a “sandwich” comprising an inner layer that is lined on each side with an outer layer for strength and moisture protection. Each of the inner layer and the outer layer can comprise multilayers. 
         [0022]      FIG. 1  illustrates an embodiment that comprises inner layer  110  sandwiched between outer layers  100 . Each outer layer  100  comprises layers  102  and  104 . Inner layer  110  comprises a discontinuous layer  114  sandwiched between continuous layers  112 . The assembly of layers is manufactured in a fashion so that the final product contains trapped gas within the discontinuous layer  114 . The trapped gas may be air, carbon dioxide, or any other gas of high thermal resistivity. 
         [0023]    An exemplary material that can be used for continuous layers  112  is newsprint, a highly available and low cost commodity that has great thermal insulation properties and is biodegradable. To function under more extreme requirements a continuous layer  112  may have a reflective coating applied thereto to provide even greater insulation properties. A metalized, e.g., Al, Ag, Au, continuous membrane will also work and provide very good insulation. 
         [0024]    Various woven and nonwoven materials may be used as discontinuous layer  114  as long as the material will trap a gas in the final product. For example, discontinuous layer  114  may comprise a mesh material such as fine cheesecloth. Cheesecloth is a readily available, low cost material with spacing ideally suited for trapping a gas. Cheesecloth made from cotton is also biodegradable. Alternatives include dimple paper which is also low cost, low thermal conductivity and will trap pockets of a gas. 
         [0025]    Outer layer  100  in some embodiments can comprise chitosan as layer  104  coated with beeswax as layer  102  for strength and moisture protection. Chitosan is a natural poly-cationic biopolymer derived from the exoskeletons of crustaceans. It is a polyglucosamine with a cellulose backbone, which by dissolving into solution with weak acids, can be manipulated to form materials and fills with a variety of properties. Chitosan is ideally suited as layer  104  as it can provide strength while its non-toxic, non-allergenic properties make it safe for food. In addition it is readily biodegradable and has known antimicrobial properties that can be enhanced by the incorporation of Zn, Cu, Ag, boric acid, borates, antimicrobial weak acids or other antimicrobial substances. 
         [0026]    Alternatives to chitosan as layer  104  include but are not limited to a mixture of starch with polyvinyl alcohol or a material called biolatexe, both of which are biodegradable and FDA approved. Other alternatives which are less environmentally benign but may still be used include polyethylene or polypropylene having a UV inhibitor. Alternatives to beeswax as layer  102  include materials that provide moisture protection such as paraffin. Layer  102  may also contain antimicrobial substances. 
         [0027]    When used in the inner layer  110 , both the newsprint and the cheesecloth are directly biodegradable. Moreover the chitosan layer will decompose once the protective beeswax layer is compromised. This will occur due to gradual water penetration over time. 
         [0028]    While it is preferred that biodegradable materials are used in the multi-layer, passive thermal insulator material, non-biodegradable materials may be used as desired. For example, polymeric, ceramic or metallic woven or nonwoven mesh materials may be used as discontinuous layer  114  and non-biodegradable materials such as plastics can be used in the various layers. 
         [0029]      FIG. 2  illustrates an embodiment that comprises inner layer  210  that contains three discontinuous layers sandwiched between outer layers  200 . Each outer layer  200  comprises layers  202  and  204 . Inner layer  210  comprises discontinuous layers  214  sandwiched between continuous layers  212 . The assembly of layers is manufactured in a fashion so that the final product contains trapped gas within the discontinuous layers  214 . 
         [0030]    The same or similar materials described above in relation to the embodiment illustrated in Fig. I may be used in the various layers of the biodegradable multi-layer, passive thermal insulator material illustrated in  FIG. 2 . 
         [0031]      FIG. 3  illustrates an embodiment that comprises inner layer  310  that contains five discontinuous layers sandwiched between outer layers  300 . Each outer layer  310  comprises layers  302  and  304 . Inner layer  310  comprises discontinuous layers  314  sandwiched between continuous layers  312 . The assembly of layers is manufactured in a fashion so that the final product contains trapped gas within the discontinuous layers  314 . 
         [0032]    The same or similar materials described above in relation to the embodiment illustrated in Fig. I may be used in the various layers of the biodegradable multi-layer, passive thermal insulator material illustrated in  FIG. 3 . 
         [0033]    In joining the various layers to form the biodegradable multi-layer, passive thermal insulator material the objective is to minimize potential conductive thermal paths, One method is to join the various layers together through use of conventional adhesives or thermal bonding techniques in either a continuous or discontinuous manner. Other techniques include binding the layers using cotton thread and buttons or just thread sewn in small points spaced far apart. Double layer seams can be used to join the sandwich sections to form a container. 
         [0034]    Containers formed from the present product can have various shapes and sizes depending on the application. Cylindrical or box shapes are simplest and therefore lower costs. Preferably the cutting, layering and sewing to construct a container are fully automated although manual operations are possible. 
         [0035]    The biodegradable multi-layer, passive thermal insulator material can be further combined with other active heating/cooling technology including but not limited to: thermoelectric heating/cooling using dissimilar metals (thermocouples), chemical phase changes substances, oxidative exothermic chemical reactions or other active sources such as resistive heating. 
         [0036]    Phase change materials (“PCMs”) can also be used in the various layers of the biodegradable multi-layer, passive thermal insulator material to enhance its thermal resistivity. Encapsulated PCMs that comprise PCMs fully contained within spherical shells are preferred. The encapsulated PCMs come in various sizes, e.g., macro-encapsulated forms that are 3-4 mm and micro-encapsulated forms that can vary in size from 15-25 microns. 
         [0037]    The thermal resistivity of the encapsulated PCMs can be set by selecting the melting point of the PCM. Typically, a low density wax or similar substance can be used in forming the PCMs that will melt in a wide range of temperatures, e.g., −30° C. to +40′ C. Micro-encapsulated PCMs are readily available, have a wide range of target temperatures and can be readily used to coat various materials. Microencapsulated PCMs can be used to coat the inner continuous layer(s), coat the inner discontinuous layer as well as forming the inner discontinuous layer. Micro-encapsulated PCMs provide for increased thermal resistance around a fixed target temperature. 
         [0038]    While the thermal characteristics of the biodegradable multi-layer, passive thermal insulator material will vary depending on the materials used, they can be estimated for one embodiment as specified below. This theoretical estimate is based on the thermal resistivity of the components and the layer dimensions specified. 
         [0039]    Table 1 provides the thermal resistivity of representative materials that may be used as the components that make up the present products. Where we could not find identical materials we have extrapolated from similar materials. 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
                 TABLE 1 
               
               
                   
                   
               
               
                   
                   
                 Thermal 
                 Thermal 
                   
               
               
                   
                   
                 Conductivity 
                 Resistivity 
               
               
                   
                 Material 
                 W/(m · K) 
                 m · K/W 
                 Source 
               
               
                   
                   
               
             
             
               
                   
                 Air 
                 0.024* 
                 42* 
                 Ref[1] 
               
               
                   
                 Beeswax 
                 0.25  
                 4 
                 Ref[3] 
               
               
                   
                 Chitosan 
                  0.05-0.08 
                 16  
                 Ref[4] 
               
               
                   
                 Cotton 
                 0.042-0.05 
                 22  
                 Ref[5] 
               
               
                   
                 Paper 
                 0.05*  
                 20* 
                 Ref[1] 
               
               
                   
                   
               
               
                   
                 *These FIGURES at 25° C. 
               
             
          
         
       
     
         [0040]    As the sources of the data vary, there is possibly significant variation in the conditions under which the measurements were taken. However they should be sufficiently accurate for an order of magnitude calculation of the thermal resistivity of the biodegradable multi-layer, passive thermal insulator material. 
         [0041]    To calculate the thermal resistivity of the multiple layers of the biodegradable multi-layer, passive thermal insulator material, a weighted average of the thermal resistivity of each layer was used with the weighting factor being the thickness of the layer. 
         [0042]    The following information was used in the calculations: 
         [0043]    Inner layer
       Continuous layer—Newsprint with a thickness of approximately 75 microns,   Discontinuous layer Cheesecloth (composition approximately cotton 20% and air 80%) and approximately 150 microns in thickness       
 
         [0046]    Outer Layer
       Inner Layer Chitosan, approximately 100 microns   Outer LayerBeeswax approximately 100 microns       
 
         [0049]    The order of magnitude calculation of the thermal resistivity of various embodiments of the biodegradable multi-layer, passive thermal insulator material is summarized in Table 2. 
         [0000]    
       
         
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
             
           
               
                   
                 TABLE 2 
               
             
             
               
                   
                   
               
               
                   
                 Outer layers 
                 Inner layers 
                   
               
             
          
           
               
                   
                 Beeswax 
                 Chitosan 
                 Paper 
                 Total 
                 Layers 
                 Continuous 
                 Discontinuous 
                 Total 
                 Aggregate 
               
               
                   
                   
               
             
          
           
               
                 Example 1 
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 One 
               
               
                 discontinuous 
               
               
                 layer 
               
               
                 Thickness 
                 200 
                 200 
                 75 
                 475 
                 1 
                 75 
                 150 
                 225 
                 700 
               
               
                 Thermal Resistivity 
                 4 
                 16 
                 20 
                   
                   
                 20 
                 36 
               
               
                 Product 
                 800 
                 3200 
                 1500 
                 5500 
                 1 
                 1500 
                 5400 
                 6900 
                 12400 
               
             
          
           
               
                 Av. Thermal Res. 
                 11.58 
                 30.67 
                 17.71 
               
             
          
           
               
                 Example 2 
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Five 
               
               
                 discontinuous 
               
               
                 layers 
               
               
                 Thickness 
                 200 
                 200 
                 75 
                 475 
                 5 
                 75 
                 150 
                 1125 
                 1600 
               
               
                 Thermal Resistivity 
                 4 
                 16 
                 20 
                   
                   
                 20 
                 36 
               
               
                 Product 
                 800 
                 3200 
                 1500 
                 5500 
                 5 
                 1500 
                 5400 
                 34500 
                 40000 
               
             
          
           
               
                 Av. Thermal Res. 
                 11.58 
                 30.67 
                 25 
               
             
          
           
               
                 Example 3 
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Ten 
               
               
                 discontinuous 
               
               
                 layers 
               
               
                 Thickness 
                 200 
                 200 
                 75 
                 475 
                 10 
                 75 
                 150 
                 2250 
                 2725 
               
               
                 Thermal Resistivity 
                 4 
                 16 
                 20 
                   
                   
                 20 
                 36 
               
               
                 Product 
                 800 
                 3200 
                 1500 
                 5500 
                 10 
                 1500 
                 5400 
                 69000 
                 74500 
               
             
          
           
               
                 Av. Thermal Res. 
                 11.58 
                 30.67 
                 27.34 
               
             
          
           
               
                 Example 4 
                   
                   
                   
                   
                   
                   
                   
                   
                   
               
               
                 Twenty 
               
               
                 discontinuous 
               
               
                 layers 
               
               
                 Thickness 
                 200 
                 200 
                 75 
                 475 
                 20 
                 75 
                 150 
                 4500 
                 4975 
               
               
                 Thermal Resistivity 
                 4 
                 16 
                 20 
                   
                   
                 20 
                 36 
               
               
                 Product 
                 800 
                 3200 
                 1500 
                 5500 
                 20 
                 1500 
                 5400 
                 138000 
                 143500 
               
             
          
           
               
                 Av. Thermal Res. 
                 11.58 
                 30.67 
                 28.84 
               
               
                   
               
               
                 * Thermal Resistivity in mK/W 
               
             
          
         
       
     
         [0050]    The estimates indicate that, as the number of layers increases, the thermal resistivity of the biodegradable multi-layer, passive thermal insulator material can be increased towards a maximum which depends on the relative air content in the discontinuous layer. In the above examples, the calculated maximum thermal resistivity value is 31 mK/W while the product of Example 3 has a calculated value of 27.34 mK/W and the product of Example 4 has a calculated value of 28.84 mK/W. 
         [0051]    As a comparison, Table 3 sets forth the thermal resistivity of common packaging materials. 
         [0000]    
       
         
               
               
               
               
             
           
               
                   
                 TABLE 3 
               
               
                   
                   
               
               
                   
                   
                 Thermal Resistivity 
                   
               
               
                   
                 Material 
                 (mK/W) 
                 Source 
               
               
                   
                   
               
             
             
               
                   
                 Insulation materials 
                 From 6-29 
                 Ref[1] 
               
               
                   
                 Polystyrene 
                 33 
                 Ref[1] 
               
               
                   
                 Polyurethane Foam 
                 33 
                 Ref[1] 
               
               
                   
                 Cardboard 
                 20-25 
                 Ref[6] 
               
               
                   
                 Polyethylene Foam 
                 20 
                 Ref[6] 
               
               
                   
                   
               
             
          
         
       
     
         [0052]    While some of the synthetic insulating materials may provide a better thermal resistivity than the exemplified examples of the biodegradable multi-layer, passive thermal insulator material, they are of the same order of magnitude as the biodegradable multi-layer, passive thermal insulator material. However, the biodegradable multi-layer. passive thermal insulator material provides distinct advantages over these listed materials as follows:
       thermal performance of the same order of magnitude as the best synthetic insulating materials   number of layers can be used to tailor the insulating properties to the needs of the materials to be packaged low cost to manufacture and to use   inert materials are used that will not contaminate food   can be fully biodegradable.       
 
         [0057]    The biodegradable multi-layer, passive thermal insulator materials described herein are in no way limited to the described specific embodiments or the listing of specific components. 
       REFERENCES 
       [0000]    
       
         
           
             1. The Engineering Toolbox, http://www.engineeringtoolbox.com/thermal-conductivity-d_429.html 
             2. Singh S. P., et al.,  Packaging Technology and Science, Vol  21, 1. 1:25-35, January/February 2008, “Performance Comparison of Thermal Insulated Packaging Boxes, Bags and Refrigerants for Single-parcel Shipments” 
             3. DeracDelta.co.UK,  Science and Engineering Encyclopedia,  http://www.diracdelta.co.uk/science/source/t/h/thermal%20conduetion/source.html#. UbPRy9LF1Bk 
             4. Jean-Denis M, et al.,  Int J Mol Sci.  2011; 12(2): 1175-1186, “Development of a Chitosan-Based Biofoam: Application to the Processing of a Porous Ceramic Material” http://www.ncbi.nlm.nih.gov/pmc/artieles/PMC3083698/table/tl-ijms-12-01175/ 
             5. Chidambararn Pr, et al.,  African Journal of Basic  &amp;  Applied Sciences  4 (2):60-66, 2012, “Study of Therma Comfort Properties of Cotton/Regenerated Bamboo Knitted Fabrics” http://idosi.org/ajbas/ajbas4(2)12/6.pdf 
             6. Wikipedia R-Value(insulation), from table of per thickness R-values converted to common SI units, http://en.wikipedia.org/wiki/R-value_(insulation) 
             7. http://en.wikipedia.org/wiki/Phase-change_material 
             8. http://www.microteklabs.com/which-pcm-is-the-right-one-for-you.html)