Patent Description:
Insulated boxes are widely used in many shipping applications. An insulated box is desirable when shipping materials need to be shipped at reduced or elevated temperatures and to help with impact. Similarly, insulated boxes are desirable when shipping materials need to avoid large temperature swings. Such boxes may also lessen impact stresses on the product and thereby lengthen the life of the product being shipped and/or make the product appear to be more durable and of a higher quality. Unfortunately, insulated materials are typically made of disparate materials from those used to form boxes thereby making recycling impossible. <CIT> discloses an insulation material composed of loose-fill short cellulose fibers and longer length synthetic binder fibers. <CIT> discloses an insulative batt composed of thermally bonded cellulose fibers; lofting fiber and thermoplastic binder fibers.

Viewed from a first aspect the present invention provides a repulpable insulation material comprising: a batt formed of a mixture of paper fiber and thermoplastic binder fiber distributed substantially randomly within the paper fiber and bound to the paper fiber, the thermoplastic binder fiber representing between about <NUM>% and about <NUM>% by weight of the fiber mixture, wherein the thermoplastic binder fiber is a bi-component fiber having a length of less than about <NUM>, the batt having a density of less than <NUM>/m<NUM> (<NUM> pounds per cubic foot), wherein the materials of the thermoplastic binder fiber are selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene and mixtures thereof, and wherein the repulpable insulation material is greater than <NUM>% repulpable as measured according to the method described herein.

Viewed from a second aspect the present invention provides a method for producing an insulation material comprising: mixing paper fiber with thermoplastic binder fiber to form a fiber mixture, the thermoplastic binder fiber representing between about <NUM>% and about <NUM>% by weight of the fiber mixture, the thermoplastic binder fiber having a length of less than about <NUM>, wherein the material of the thermoplastic binder fiber is selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene and mixtures thereof; applying heat to the fiber mixture to melt the thermoplastic binder fiber; and allowing the mixture to cool to allow the thermoplastic binder fiber to solidify and thereby couple the paper fiber together to form a batt, the batt having a density of less than <NUM>/m<NUM> (<NUM> pounds per cubic foot), wherein the insulation material is greater than <NUM>% repulpable as measured according to the method described herein.

According to an illustrative embodiment and not forming part of the claimed invention, disclosed is a method of forming a shipping container. The method includes mixing paper fibers with a recycling-compatible fiber to form a mixture of material. The mixture is disposed onto a surface to form a layer of the mixture. At least one of heat and heat and pressure is applied to the layer of the mixture forming a paper fiber batt. The paper fiber batt is then trimmed so it has a fixed width and fixed length. The paper fiber batt is positioned adjacent to a corrugated box, with the shipping container having a repulpability of greater than <NUM>%.

The methods described above or below may include mixing paper fibers with a meltable polyethylene and polypropylene ("PE/PP") bi-component thermoplastic fiber.

The method may include mixing paper reinforcement fibers with between about <NUM>% to about <NUM>% by weight meltable PE/PP bi-component thermoplastic binder fiber having a length less than about <NUM>. The PE/PP bi-component thermoplastic binder fibers are distributed substantially randomly within the paper reinforcement fibers to form a mixture. Heat is applied to the mixture to melt the PE/PP bi-component thermoplastic binder fiber to bind the PE/PP bi-component thermoplastic binder fiber to the paper reinforcement fibers to form a batt. The insulation material has the physical property of being repulpable at a rate greater than <NUM>%.

The methods may include coupling a repulpable paper layer to the batt to form an insulative batt assembly.

The methods may include forming a repulpable paper fiber pad having a compression resistance of between about <NUM> kPa (<NUM> psi) and about <NUM> kPa (<NUM> psi) at compressions of between about <NUM>% and about <NUM>%.

The methods may include forming a repulpable paper fiber pad having a compression set at about <NUM>% of between about <NUM>% and about <NUM>%.

The methods may include forming disposing a water soluble adhesive layer between the paper fiber pad and the first paper layer.

In the method, a mixture of paper fiber with between <NUM>% and <NUM>% thermoplastic binder fiber distributed substantially randomly within the paper fiber may be formed. The mixture is heated to bring the thermoplastic binder fiber above a fiber's glass transition temperature or melting point, thus binding the thermoplastic binder fiber to the paper fiber to form a batt having a density of less than <NUM>/m<NUM> (<NUM> pound per cubic foot). The fibrous web of paper fibers are interlocked with the thermoplastic binder fiber while the batt is subsequently brought to a temperature below the glass transition temperature of the thermoplastic fiber to form an insulative pad that is greater than <NUM>% repulpable. This pad may be disposed within one of an interior surface of a repulpable corrugated cardboard box or a repulpable envelope, to form an assembly that is greater than <NUM>% repulpable.

The fiber mixture may have between about <NUM>% and about <NUM>% PE/PP bi-component thermoplastic fiber having a length of less than about <NUM>.

The fiber mixture may have between about <NUM>% and about <NUM>% PE/PP bi-component thermoplastic binder fiber having varying lengths and having an average length of less than about <NUM>.

The insulation material and any containers, shipping containers, or insulative constructions produced using the insulation material, are greater than <NUM>% repulpable and may have a repulpable paper layer and a repulpable paper fiber pad coupled to the paper layer. The paper fiber pad may have paper reinforcement fibers interlocked with about <NUM>% to about <NUM>% by weight meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly therein.

The meltable thermoplastic fiber may be a chopped fiber having lengths between about <NUM> to about <NUM>.

The meltable thermoplastic fiber may be a chopped fiber PE/PP bi-component having lengths between about <NUM> to about <NUM>.

The containers, shipping containers, insulative materials, and insulative constructions may further have a repulpable corrugated cardboard disposed adjacent to the paper layer.

The containers, shipping containers, insulative materials, and insulative constructions may further have a recycling-compatible or water soluble adhesive layer disposed between the paper layer and the corrugated cardboard.

According to an alternative example which is provided for illustrative purposes only and which does not form part of the present invention the methods include placing loose ground-up fibrous cellulous paper or ground-up cardboard material onto a moving conveyor. The fibers in the fibrous paper or cellulous material can be interlocked by methods such a needling or by use of a melted binder fiber, a bioresorbable adhesive, recycling-compatible, water soluble adhesive, plant based (sugar or pectin) adhesive from, for example, sugar beet, corn, or sugar cane, or starch. The ground up cellulous paper or cardboard material is formed into a slab or batt by passing the continuous layer of material between a pair of tapered edge plates which forms the batt width and thickness of the uncompressed batt. This material can have its thickness and density adjusted using a compression roller which can apply heat.

The batt may be cut into individual pieces using a slicing knife. Optionally, the batt can be cut in half along its thickness using a moving slicing knife or blade. Once the batt is formed into a rectangular shape and thickness, the material is then ready for coupling to or disposing in an inner corrugated box or envelope.

The methods may include taking an inner corrugated box surface off of a roll of appropriate material. The inner corrugated box surface material may be cut into specific lengths and widths. For example, the cardboard box inner surface material can have a width and length larger than the width and length of the fibrous batt.

The containers, shipping containers, insulative materials, and insulative constructions may include a paper layer that can be disposed over the batt, overlapping the expanded portions of the batt underneath all four sides. The ends of the paper layer can be wrapped about and tucked under the ends of the batt. Heat or recycling-compatible or water soluble adhesive can be applied to fix the inner paper layer to the batt.

The methods may include adhering an inner paper layer to the batt on an outside surface of the inner paper layer which can be folded to form a pocket. The folded batt is then placed through an end closure apparatus which closes the side of the inner paper layer, thus forming a pocket. The edges of the folded batt can be sewn shut using an industrial sewing machine.

The methods may include positioning another paper layer about the outside of the folded batt. The outer paper layer can be positioned about the batt on the inner paper layer in a manner which forms a closable flap. This closable flap can include a recycling-compatible or water soluble adhesive in the form of dual sided tape.

The methods may include encapsulating the insulative batt material between the inner and outer paper layer. In this regard, the edge of the outer paper layer can be coupled to the inner paper layer using heat or recycling-compatible or water soluble adhesive, or stitching. Excess material along the edges can be removed.

The method may include forming cellulous fibers by passing recycled cardboard through a hammer mill. These fibers are mixed with paper and with a thermoplastic binder fiber. An insulative paper fiber batt having a first width and first length is formed from the recycled paper fibers. A first paper layer is coupled to the paper fiber batt. The paper fiber batt is coupled to a corrugated box.

The formation of an insulated material and an insulated mailer or a shipping container will be described in the description of <FIG>. As shown in <FIG>, fibrous paper or cellulous material is placed onto a moving conveyor. The fibers can be interlocked by use of a melted binder which represents about <NUM>% to about <NUM>% of the fiber by weight which is mixed within the fibrous paper or cellulous material. The fibrous paper or cellulous material is formed into a slab <NUM> by passing the continuous layer of material between a pair of tapered edge plates that form the batt width. The thickness of the uncompressed slab can be defined by an upper rake or block <NUM>. This material can then have its thickness and density adjusted using a compression roller <NUM>.

After compression, the slab <NUM> is converted to a paper fiber insulative batt <NUM>, which can be manufactured fiber compositions formed by passing recycled cardboard through a mill such as a hammer mill. The batt <NUM> can contain small amounts of meltable fibers such a polypropylene fiber.

Additionally, the binder fibers can be a water soluble (at a water temperature at more than about <NUM> (<NUM> degrees F)) PVOH fiber which can have a denier of about. <NUM> to about <NUM>, and a cut length of about <NUM> to about <NUM>. The binder fiber can be, for example, a KURALON (tm) brand short cut fibers. As a binder fiber, the recyclable PVOH fiber used in the insulation can be about a <NUM> denier to about a <NUM> denier fiber having a length of about <NUM> to about <NUM>.

The insulative material <NUM> is continuously fed on a conveyor between a pair of side guides which define a pair of sides for a continuous strip of insulative material. The side guides define a predetermined width for the pad. Once aligned, the continuous strip of material is positioned under a slicing mechanism which cuts the continuous batt into predefined lengths thus forming the insulative pad <NUM>.

As seen in <FIG>, the pad <NUM> is transported via conveyor to a second location where a first paper layer is draped over the pad. The first paper layer has a length and a width larger than the length and width of the pad. First and second ends of the first paper layer can be tucked under first and second ends of the pad.

As shown in <FIG>, the pad <NUM> can then be cut into individual pieces using a slicing knife <NUM> which can be a rotating band or circular blade. Optionally, the batt can be cut in half along its thickness using a slicing knife <NUM>. Once the batt is formed into a rectangular shape and thickness, the material is then ready for coupling to or placed adjacent an inner corrugated box inner surface.

The inner corrugated box inner surface <NUM> is taken off of a roll of appropriate material that can for instance be pre-perforated or water proofed. As shown in <FIG> and <FIG>, the paper box inner surface material is positioned over the insulated layer and is cut into specific lengths and widths. For example, the paper box inner surface material can have a width and length larger than the width and length of the fibrous pad <NUM>.

As shown in <FIG>, the inner paper layer <NUM> is disposed over the batt <NUM>, overlapping the pad <NUM> on all four sides. The ends <NUM> of the paper layer are wrapped about and tucked under the ends <NUM> of the pad <NUM>. As shown in <FIG>, heat or recycling-compatible or water soluble adhesive can be applied to fix the inner paper layer <NUM> to the pad <NUM>. The inner paper layer <NUM> is then folded in half placing the batt on an outside surface of the inner paper layer which is disposed against itself, thus forming a subassembly.

As shown in <FIG>, the folded batt is then placed through an end closure apparatus which closes the sides of the inner paper layer <NUM>, thus forming a pocket <NUM>. As shown in <FIG>, the edges can be sewn shut using an industrial sewing machine or can be heat staked as appropriate. A row of smaller stitches <NUM> extend from top to bottom of the mailer <NUM> along each side thereof juxtaposed adjacent to the lateral edges <NUM> of pad <NUM>. Spaced slightly inwardly of stitches <NUM> is a second row of larger stitches <NUM> that encompass the pad <NUM> and the paper layer <NUM> on the inside of the pad <NUM> and include the portions <NUM> on the outside of the pad <NUM>. The second rows of stitches only extend longitudinally from the top of the mailer downwardly and terminate with the portions <NUM>. Apart from the stitching and heat sealing of the paper layer <NUM> to paper layer <NUM>, pad <NUM> is not attached to paper layer <NUM>.

<FIG> represents the application of the recycling-compatible or water soluble adhesive to assist binding an exterior paper to the interior paper. Shown in <FIG>, the outer paper sheet <NUM> can then be positioned about the outside of the folded pad <NUM>. The outside box paper layer <NUM> can be positioned about the pad <NUM> on the inner paper layer in a manner which forms a closable flap <NUM>. This closable flap <NUM> can take a recycling-compatible or water soluble adhesive <NUM> in the form of dual sided tape.

The outer paper layer <NUM> is then coupled to the paper box inner surface material, encapsulating the insulative material or pad <NUM> between the inner and outer paper layers. In this regard, the edge of the outer layer can be coupled to the inner layer using heat, recycling-compatible or water soluble adhesive, or stitching. Excess material along the edges can be removed.

The outer surface of the mailer or shipping container <NUM> can comprise a recyclable paper layer or paper <NUM> and can be finished so as to be waterproof or water resistant. Optionally, the paper layer <NUM> extends laterally so its lateral edges or margins <NUM> can be heat sealed together. At the bottom of the mailer the paper layer <NUM> is folded at <NUM>. At the top of the mailer the front top edge <NUM> terminates at the mailer opening <NUM>, and the back continues upwardly to form flap <NUM> to enable the mailer <NUM> to be sealed by folding the flap <NUM> over the front of the mailer closing off the opening <NUM>. The flap <NUM> has a lateral stripe of recyclable or recycling-compatible or water soluble adhesive <NUM> covered with a removable protecting paper <NUM>.

As evident from the above description, the pad <NUM> is covered by the paper layer <NUM> on the inside with paper layer <NUM> extending laterally beyond the pad <NUM> to lie coextensive with the marginal edges of the paper layer <NUM> so all marginal edges can be heat sealed together. Paper layer <NUM> extends around the longitudinal extremities of the pad <NUM> so that the end portions <NUM> of the paper layer <NUM> lie between the pad <NUM> and the outer paper layer <NUM> when the pad <NUM> is located in the mailer <NUM>. These portions <NUM> enable the paper layer <NUM> to be heat sealed together with the paper layer <NUM> around the mailer opening <NUM>, thereby entrapping the pad <NUM>. The portion of the opening <NUM> that lies with the flap <NUM> has pressure-sensitive, biodegradable tape <NUM> (covered with a protective strip <NUM>) in order to seal the top edges of the inner paper layer <NUM> together before the flap <NUM> is sealed to the front of the mailer <NUM>.

The fibers of the pad <NUM> can, for example, be about <NUM>% recyclable cardboard and paper fiber and about <NUM>% binder fiber having a density of about <NUM> grams per square (GSM) i.e., (<NUM>/<NUM>). Additional fiber material construction can be about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM; about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM; about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM; about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM; about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM; and about <NUM>/<NUM> recyclable cardboard/paper fiber and binder fiber at about <NUM> GSM, with the first number being the paper cardboard fiber fraction and second number being the bi-component binder fiber fraction (<NUM>/<NUM> is about <NUM>% paper fiber and about <NUM>% bi-component). The cardboard/paper fiber component is made of about <NUM>/<NUM> fiberized cardboard/paper up to about <NUM>/<NUM> fiberized cardboard/paper mix.

The batt material can have a density can be about <NUM> to about <NUM> grams per cubic meter (g/m3), a thickness of about <NUM> to about <NUM>, and have fibers (cardboard and binder) with a denier range of about <NUM> den to about <NUM> den. The density of the pad is related to the amount of compression of the batt and the percentage of bonding fibers.

Preferably, the material can be formed of about <NUM>% bi-component fiber and about <NUM>% recycled cardboard fiber. The bi-component fiber can be chopped and have a length of less than about <NUM>, less than about <NUM>, or a length between about <NUM> to about <NUM>, and can be mixtures of two or more lengths, preferably between about <NUM> to about <NUM>. The mixtures of two or more lengths can have ratios of from about <NUM>% to about <NUM>% of one fiber length to another fiber length and can have an average length of less than about <NUM>.

It was found that for a batt sample of about 1300GSM, about <NUM>% cardboard with the binder being about <NUM>% (with about <NUM>% <NUM> length bi-component fiber and about <NUM>% <NUM> length bi-component fiber), over <NUM>% of the material is repulpable and therefore recyclable. It should be noted that greater than <NUM>% repulpability is a "passing grade" for recyclability. The bi-component fibers can be between about <NUM> and about <NUM> polyethylene and polypropylene ("PE/PP") bi-component; and can be formed of about a <NUM>/<NUM> percent PE/PP mixture. Optionally, the PE/PP ratio can be between about <NUM>/<NUM> and about <NUM>/<NUM>. These fibers can be, by way of non-limiting example, ES FIBERVISIONSO Polyethylene/polypropylene fiber, including EAC, EPS, ESC, ESE, EDC, Herculon T426 and Herculon T457 versions of fibers.

It was found that a sample of insulation material according to the present teachings, when tested for repulpability is repulpable and therefore recyclable. The insulation material can be repulpable in accordance with the requirements of the <NPL> which is hereby incorporated in its entirety. In the present aspect, the insulation material can be recyclable in accordance with the requirements of the<NPL>. Containers that include the insulation material can be single-stream recyclable wherein all materials comprised by the container can be recycled by a single processing train without requiring separation of any materials or components of the container. The repulpability test results were as follows:.

It was found that for a batt sample of about 1300GSM, about <NUM>% cardboard with the binder being about <NUM>% <NUM> bi-component fiber, over about <NUM>% of the material is repulpable and therefore recyclable. The insulations and shipping containers of the present teachings are more than <NUM>% repulpable with <NUM>% repulpability being a "passing grade" for recyclability. The repulpability test results were as follows:.

Thermoplastic binder fibers are provided having a weight of less than about <NUM>/m<NUM> (<NUM> pounds per square foot) and, more particularly, preferably about <NUM>/m<NUM> (<NUM> pounds per square foot). The remaining reinforcement fiber is greater than about <NUM>/m<NUM> (<NUM> pounds per square foot), and preferably about <NUM>/m<NUM> (<NUM> pounds per square foot). The binder fibers are preferably a mixture of fibers and paper components passed through a hammer mill.

The materials according to the present teaching can have a compression resistance of between about <NUM> kPa (<NUM> psi) and about <NUM> kPa (<NUM> psi) for compression thickness between about <NUM>% and about <NUM>%. For example, a <NUM> (<NUM>/<NUM>") insulation pad has a compression resistance at about <NUM>% thickness of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). A <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). A <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") pad has a compression resistance at about <NUM>% of about <NUM> kPa (<NUM> psi). The same <NUM> (<NUM>/<NUM>") insulation pad can have a tear resistance of between about <NUM> (<NUM> lbs) and about <NUM> (<NUM> lbs).

When an insulated pad of the present disclosure is tested according to ASTM Specification C165-<NUM> about <NUM>% relative humidity, the material has a modulus of elasticity of about <NUM> kPa (<NUM> psi). With a load of about <NUM> kPa (<NUM> psi), it sees about a <NUM>% strain. With a load of about <NUM> kPa (<NUM> psi) it sees about a <NUM>% strain, and with a load of about <NUM> kPa (<NUM> psi) it sees about a <NUM>% strain. The density of the material can be less than about <NUM>/m<NUM> (<NUM> pounds per cubic foot) and preferably about <NUM>/m<NUM> (<NUM> pounds per cubic foot). The thermal conductivity of the material can be about <NUM> watts per meter-kelvin (<NUM> (BTU in/h ft^<NUM> Temp F)), the thermal resistance can be about <NUM>-m<NUM>/W (<NUM> (Temp F Ft^<NUM>/BTU)), and the thermal resistivity can be about <NUM> K/W (<NUM> (Temp F Ft^<NUM>/BTU in)). When tested according to ASTM Specification C165-<NUM>, the tested pad also has an R value of about <NUM> (<NUM>-m<NUM>/W).

The insulative pad <NUM> may be formed by heating the paper fiber batt <NUM> in the oven to a temperature greater than about <NUM> (<NUM>°F) and, more preferably, to a temperature of about <NUM> (<NUM>°F). Such heating causes the binder fibers to melt and couple to the non-binder fibers, thus causing fibers to adhere to each other and solidify during cooling. Upon cooling, the binder fibers solidify and function to couple the non-binder reinforcement fibers together as well as function as reinforcement themselves.

The insulative paper fiber batt <NUM> may be heated to form the insulative pad <NUM> so it has a density of less than about <NUM>/m<NUM> (<NUM> pounds per cubic foot). The insulative pad <NUM> preferably has a density of less than about <NUM>/m<NUM> (<NUM> pounds per cubic foot) and, more preferably, about <NUM>/m<NUM> (<NUM> pounds per cubic foot) with a thickness of about <NUM> (<NUM>/<NUM> inch).

<FIG> represents a system <NUM> to form a folded box <NUM>. Generally, the system utilizes a plurality of linked conveyors <NUM> to move an insulated pad <NUM> as described above through a series of processes to form the folded box <NUM>. The system <NUM> uses a cutting apparatus <NUM> to separate insulated pad <NUM> from a continuous batt <NUM>. A series of rollers <NUM> are then used to position an upper paper layer <NUM> and a lower paper layer <NUM> about the insulated pad <NUM>. A second cutting apparatus <NUM> is used to separate the upper paper layer <NUM> and a lower paper layer <NUM> from the continuous paper layer supply. A sealing and cutting apparatus may be used to cut and seal the edges of the upper and lower paper layers about the insulated pad <NUM>. A heat tunnel can be positioned about a conveyor to couple the paper sheet about the insulated pad <NUM> to form the folded box <NUM>.

<FIG> represents the cutting of and formation of an insulative pad <NUM> from the continuous batt <NUM>. As shown, the batt <NUM> and pad <NUM> are transported along the plurality of linked conveyors <NUM>. The cutting apparatus <NUM> can be a circular blade. Additionally, the cutting apparatus can be a belt blade.

Optionally, the pad can be sliced cross-wise to form two batts having a partial thickness pad that may be of equal thickness (i.e., the textile insulative pad is split in half), or that may be of unequal thickness. The partial thickness of the batt may be about <NUM> (<NUM>/<NUM> of an inch) or greater. The starting insulative pad may be split longitudinally to provide two, three, or more partial thickness batts.

The insulative pad may be controllably and accurately split if the feed rollers are positioned within a predetermined distance from the splitting knife. The distance is important because of the compressible and pliable nature of the insulative pad. Preferably the predetermined distance is from about zero to about two millimeters.

The thermoplastic binder fibers and reinforcement fibers are laid randomly yet consistently in x-y-z axes. The reinforcement fibers are generally bound together by heating the binder fibers above their glass transition temperature. Typically, less than about <NUM>% by weight binder fiber is used, and preferably about <NUM>% binder fiber is used to form the insulative pad.

Thermoplastic binder fibers are provided having a weight of less than about <NUM>/m<NUM> (<NUM> pounds per square foot) and, more particularly, preferably about <NUM>/m<NUM> (<NUM> pounds per square foot). The remaining reinforcement fiber is greater than about <NUM>/m<NUM> (<NUM> pounds per square foot), and preferably about <NUM>/m<NUM> (<NUM> pounds per square foot). The binder fibers are preferably a mixture of thermoplastic polymers which comprise polyethylene/polyester or polypropylene/polyester or combinations thereof.

<FIG> represents the application of an upper paper layer. A series of rollers <NUM> are then used to position an upper paper layer <NUM> and a bottom paper layer <NUM> about the insulated pad <NUM>. As shown, the roller <NUM> can be positioned at an angle which is non-perpendicular to the direction of the moving conveyor. Preferably, this angle can be about <NUM> degrees to the direction of flow of the conveyor.

<FIG> represents the application of a bottom paper layer. Once the upper paper layer is positioned above the pad <NUM>, the rollers <NUM> can position the lower paper layer below the pad <NUM> at the intersection of two conveyors <NUM>. The second cutting apparatus <NUM> is used to separate the upper paper layer <NUM> and a lower paper layer <NUM> from the continuous paper layer supply.

<FIG> and <FIG> represent side sealing of the paper layers about the insulative member. In this regard a series of cutting and sealing rollers <NUM> both cut and seal the sides of the paper layers using recycling-compatible or water soluble adhesive. The cutting and sealing rollers <NUM> are biased onto the paper layer using a load such as a spring.

<FIG> represents the heat tunnel <NUM> optionally used to form the box insulative member or insulative batt should a heat sensitive recycling-compatible or water soluble adhesive be used. Once the construction is sealed on all sides, the subassembly is passed through a heat tunnel which seals the upper and lower paper layers about the insulative pad <NUM>.

As shown in <FIG>, the insulative batt may be coupled to a corrugated box. Optionally, the insulating material can be directly coupled to the box or to an intermediary paper layer prior to the box being cut into its form for a folded box <NUM>. When used to form the pad, the binder material, in the form of recycling-compatible or water soluble adhesive or meltable fibers, can be preferably recyclable or biodegradable and can be preferably selected from the group containing polyethylene, polyester, polypropylene, and mixtures thereof.

The insulation can be used in containers having a polymer bladder for holding liquids or storing gases, or packaging for photosensitive or like materials. In the regard, the insulation can be used to hold the temperature of the materials described above or below ambient.

Optionally, the box can be, for example, a flat box with thermal insulation on the top and bottom surfaces (for example a pizza box). It is envisioned the containers can be used to regulate the change of temperature within the box. For example, the container can contain a device such as a recyclable cold pack which will provide a specific environment for contents, e.g. temperature above or below ambient with thermal insulation. In this regard the cold pack can be a recyclable member which is perforated and holds, for example, dry ice. The containers can be formed by folding or erecting paper blanks. Incorporated into the containers can be removable or non-permanently secured closure members. The containers can include the insulation layer that includes shock-absorbing properties.

The containers, packaging elements, or packages using the insulation according to the present teachings can be adapted to protect organisms, articles, or materials presenting particular transport environment challenges. In this regard, the insulated box can be used to transport live plants or animals. The container can include an integral coupling or dispensing feature to allow the filling or dispensing of carried materials into the insulated container.

The paper, insulation construction is specially adapted to protect contents from mechanical damage. In this regard, the container can have a polygonal cross-section provided with internal protecting layers for contents. Containers or packages can have a special mechanism such as a foldable member or a funnel for dispensing contents, including formed pouring spouts, or dispensing means incorporated in removable or non-permanently secured container closures.

A method of forming an insulated box is presented for illustrative purposes only. The method includes, forming an insulation material according to the present invention having a first width and first length having a density between <NUM> and <NUM> gsm. Optionally, a recyclable first paper layer is coupled to the paper fiber batt on a first side of the batt. The fiber batt can be placed within or coupled to a corrugated box. The paper layer can be coupled to the corrugated paper element, or the batt can be directly coupled to a surface layer of the cardboard. Optionally, a recyclable second paper layer can be coupled to the paper fiber batt on a second side of the batt.

The batt of the insulation material can be formed by melting the binder fibers described above. The first paper layer can be coupled to the paper fiber batt by heating the paper layer or disposing one of a recycling-compatible or water soluble adhesive between the first paper layer and the batt. The first and second layers of recyclable paper can be disposed about the insulation to form a pocket. The first and second layers can be coupled to opposed sides of fiber paper layer by sewing or adhering with one of recycling-compatible or water soluble adhesive the pair of opposed sides. The binder fibers are selected from the group consisting of PVOH, polyethylene, polyester, polypropylene, bi-component and mixtures thereof. The insulative pad is about <NUM> (<NUM>/<NUM> inch) to about <NUM> (<NUM> inch) thick.

An insulative mailer can be formed by cutting a first paper sheet, and coupling a first side of a paper fiber pad having a fibrous web of paper fibers distributed substantially randomly to the first paper sheet. The fibrous web of paper fibers can be interlocked to the first paper sheet. The insulative pad is coupled to a portion of an interior surface of a corrugated cardboard box. After coupling the fibrous web to the interior surface of the box, the process includes stamping an exterior perimeter of the box and folding the corrugated box. The fibers can be interlocked to the paper and cardboard fiber using heat, be it radiant through rollers or steam, to have a density of less than about <NUM>/m<NUM> (<NUM> pounds per cubic foot).

To recycle the insulated containers, clean, used insulated corrugated containers are collected, in many instances as part of a mixed recyclables stream such as single-stream recycling. To optimize recyclability, containers should be free of contaminants such as food, metal foil, wax, etc. The collected insulated corrugated containers are sorted, compacted, and baled with non-insulated corrugated containers for space-efficient storage and handling, either at the point of end-use (store or business) or at the recycling center. Bales are broken open, and the insulated corrugated containers are put into a repulper. The repulper is a huge tub having an agitatable member which agitates the containers with heated water. The water can preferably have a temperature above about <NUM> (<NUM> degrees F). They are agitated to form a slushy pulp (slurry) of fiber and water.

The repulper can have a chain or rope which hangs down into the swirling tub of material used to remove larger contaminates such as twine and long pieces of rope, string or tape, plastic and metal bands that will wrap around the chain and can then be pulled out of the repulper. The remaining pulp slurry goes through different filters where additional metal falls to the bottom for removal, screens, cyclones, and even big tanks where the contaminants float to the top and can be scraped off. The cleaned pulp is then sent to the paper machine.

In the typical paper machine the highly diluted fiber solution is poured out on to a moving screen which allows water to drain away, forming a continuous fiber mat. The continuous fiber matt is pressed between rollers to remove more water. The wet, continuous fiber web is then passed through the dryer where the top and bottom of the web alternately contact the heated surfaces of the drying cylinders, removing the remaining moisture from the paper. At the end of the paper machine, paper is rolled up on a large reel spool.

Corrugated board is formed from this material using three or more pieces of paper containerboard. The outer surfaces are linerboard and the inner, fluted paper is called medium. A sheet of paper which will become the corrugated medium can be softened with steam, and then fed through a machine called a single facer. The medium passes between two huge metal rolls with teeth which give it wavy ridges or "flutes". Starch adhesive is applied to the fluted medium, which is then sandwiched between two flat sheets of paper (linerboard). The insulated material, as described above, can be coupled to the cardboard to form a recycled insulated construction. In this regard, the insulating material can be directly coupled to the box, or recyclable paper disposed about the insulation.

Claim 1:
A repulpable insulation material comprising:
a batt formed of a mixture of paper fiber and thermoplastic binder fiber distributed substantially randomly within the paper fiber and bound to the paper fiber, the thermoplastic binder fiber representing between about <NUM>% and about <NUM>% by weight of the fiber mixture, wherein the thermoplastic binder fiber is a bi-component fiber having a length of less than about <NUM>, the batt having a density of less than <NUM>/m<NUM> (<NUM> pounds per cubic foot), wherein the materials of the thermoplastic binder fiber are selected from a group consisting of polyvinyl alcohol, polyethylene, polyester, polypropylene and mixtures thereof, and wherein the repulpable insulation material is greater than <NUM>% repulpable as measured according to the method described herein.