Patent ID: 12246526

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With an increased awareness of the negative effects of plastics and EPS foam on the environment, as discussed above, companies and consumers are increasingly seeking to use environmentally-friendly, recyclable, and biodegradable products as a packing material. The packing materials discussed herein provide environmentally-friendly, recyclable, and biodegradable products while also providing sufficient cushioning effects at an affordable cost. In particular, embodiments discussed herein may be environmentally-friendly, recyclable, and biodegradable replacements for EPS foam.

The packing materials disclosed herein utilize a cushioning element as a base material. The cushioning elements discussed herein are discrete cushioning elements formed from cellulosic materials, like natural cellulosic materials, as such cellulosic materials are recyclable and biodegradable. In embodiments discussed herein, the discrete cushioning element is formed by using a molded pulp process (also known as a molded fiber process), as will be discussed further below. The pulp or fibers used in this process are preferably cellulosic pulp or fibers and, even more preferably, pulp and fibers produced from post-consumer recycled paper, recycled paperboard/fiberboard, recycled cardboard, and the like. The discrete cushioning element is thus a molded cellulosic cushioning element, a molded pulp discrete cushioning element, or a molded paper fiber discrete cushioning element.

The pulp and fibers may be molded into various suitable shapes to form the molded pulp discrete cushioning element. The embodiments discussed herein show various examples of the discrete cushioning element formed into a geometrical shape and the geometrical shape may include a cavity. For example, the discrete cushioning element may be formed by using a molded fiber process to form a cylindrical shape, as shown inFIGS.1A-1D. For clarity with the other molded fiber discrete cushioning elements discussed herein, the cushioning element of this embodiment is referred to as a cylindrical-shaped cellulosic cushioning element100. Such a shape may also be referred to as a cup shape or thimble-like shape.FIG.1Ais a side, perspective view of the cylindrical-shaped cellulosic cushioning element100.FIG.1Bis a top view of the cylindrical-shaped cellulosic cushioning element100.FIG.1Cis a bottom view of the cylindrical-shaped cellulosic cushioning element100.FIG.1Dis a cross-sectional view of the cylindrical-shaped cellulosic cushioning element100, taken along line1D-1D inFIG.1B.

The cylindrical-shaped cellulosic cushioning element100has a substantially cylindrical shape with at least one side wall110, a bottom portion120, and top portion130. In this embodiment, the cylindrical shape is a circular cylindrical shape with the side wall110positioned radially from an axis that extends in an axial direction of the cylindrical-shaped cellulosic cushioning element100. In this embodiment, the axis is a longitudinal axis142. The top portion130is on a side of the cylindrical shape opposite the bottom portion120. The bottom portion120includes a bottom wall122, and the cylindrical-shaped cellulosic cushioning element100has a U-shape, in this embodiment, with the bottom portion120being rounded or having a curved or otherwise chamfered transition from the bottom wall122to the side wall110.

The cylindrical-shaped cellulosic cushioning element100also includes a cavity140(or a pocket) formed therein with an opening144located in the top portion130. The side wall110includes an inward-facing surface112facing the cavity140and an outward-facing surface114. Likewise, the bottom portion120includes an inward-facing surface124facing the cavity140and an outward-facing surface126. The cavity140of this embodiment has a substantially cylindrical shape and, more specifically, a circular cylindrical shape. With the cavity140, the cylindrical-shaped cellulosic cushioning element100is a hollow, discrete cushioning element.

The cylindrical-shaped cellulosic cushioning element100also includes a flange132formed on the top portion130, having a top surface134and a bottom surface136. The opening144is formed in the top surface134of the flange132in this embodiment. The side wall110projects (extends) downwardly from the bottom surface136of the flange132, and the flange132extends outward (radially outward) from the outward facing surface114of the side wall110. The cylindrical-shaped cellulosic cushioning element100may thus have a cylindrical projection154extending from the bottom surface136of the flange132. The flange132includes an outer perimeter138, such as an outer perimeter surface which, in this embodiment, is rectangular in shape.

As noted above, the cylindrical-shaped cellulosic cushioning element100is formed by using a molded pulp process (also known as a molded fiber process). The pulp or fibers used in this process are preferably cellulosic pulp and fibers and, even more preferably, pulp produced from post-consumer recycled paper, recycled paperboard/fiberboard, recycled cardboard, and the like. Waste paper, including paperboard/fiberboard and recycled cardboard, may be dissolved in water to defibrillate paper fibers, forming an aqueous slurry of paper (cellulosic) fibers. Other suitable cellulosic (paper) fibers sources may be used, and, in some embodiments, recycled paper fibers may be blended with other cellulosic (paper) fibers. Other suitable defibrillating methods and pulping methods (such as Kraft methods) may be used depending upon the source of cellulosic fibers.

One such molded pulp process is a vacuum forming process or wet fiber molding process. A forming tool having a surface shaped to correspond to the cylindrical-shaped cellulosic cushioning element100discussed above, such as a surface with a plurality of cylindrical projections, may be placed in the aqueous slurry of paper (cellulosic) fibers. The shaped surface may be referred to as a mold or molding surface. A vacuum is drawn, such as through the molding surface, to remove water and to cause the paper fibers to accumulate on the molding surface and take the shape of the molding surface. Once a desired thickness of paper fibers has been accumulated, the molding surface is removed from the aqueous slurry and the now molded paper fibers are allowed to dry. The molded paper fibers may be removed from the molding surface to complete drying, such as in a drying oven.

A plurality of the cylindrical-shaped cellulosic cushioning elements100may be formed simultaneously using the mold (molding surface), forming a panel150of the cylindrical-shaped cellulosic cushioning elements100.FIG.2Ais a top view of such a panel150, andFIG.2Bis a side view of the panel150. The panel150of this embodiment, includes a generally planar layer152with a plurality of hollow, cylindrical projections154extending therefrom. The cylindrical projections154have the shape discussed above for the cylindrical-shaped cellulosic cushioning element100. The cylindrical projections154are arrayed in a length and width direction of the panel150. The cylindrical projections154may be separated from each other by cutting the planar layer152between the cylindrical projections154and forming the cylindrical-shaped cellulosic cushioning element100. The planar layer152forms the flange132of the cylindrical-shaped cellulosic cushioning element100. Any suitable cutting/separating process may be used, such as die cutting, for example.

Other suitable fiber molding processes may be used including, for example, dry fiber molding processes. In such dry fiber molding processes, the paper pulp/fibers are defibrillated, such as by milling, and then molded in a dry form (e.g., without the aqueous slurry). The dry, defibrillated paper fibers may be molded in a press mold under pressure and temperature to form the desired shape, such as the shapes discussed herein. In some processes, the dry, defibrillated paper fibers may be loosely formed into a sheet (referred to as a fiber sheet) by a vacuum, rolled (or otherwise shaped) to a desired thickness, and then fed to the press mold. Prior to being fed into the press mold, the fiber sheet may optionally include a tissue sheet applied to at least one of the top or bottom of the fiber sheet.

As noted above, the molded fiber discrete cushioning element may have other suitable shapes.FIGS.3A-3Cshow another shape of a molded fiber discrete cushioning element. The molded fiber discrete cushioning element shown inFIGS.3A-3Chas a substantially hemispherical shape and, for clarity with the other molded fiber discrete cushioning elements discussed herein, the cushioning element of this embodiment is referred to as a hemispherical-shaped cellulosic cushioning element102. The hemispherical-shaped cellulosic cushioning element102is similar to the cylindrical-shaped cellulosic cushioning element100but has an alternate shape, and the same reference numerals will be used for features of the hemispherical-shaped cellulosic cushioning element102that are the same or similar to the cylindrical-shaped cellulosic cushioning element100discussed above. The discussion of the cylindrical-shaped cellulosic cushioning element100and these features above also applies to the hemispherical-shaped cellulosic cushioning element102, and a detailed discussion of these features is omitted here.

FIG.3Ais a top, perspective view of the hemispherical-shaped cellulosic cushioning element102.FIG.3Bis a bottom, perspective view of the hemispherical-shaped cellulosic cushioning element102.FIG.3Cis a cross-sectional view of the hemispherical-shaped cellulosic cushioning element102, taken along line3C-C inFIG.3A. The hemispherical-shaped cellulosic cushioning element102includes a hemispherical projection160including a projection wall162projecting downward from the bottom surface136of the flange132. The projection wall162is similar to the bottom wall122discussed above and includes an inward-facing surface164and an outward-facing surface166.

The hemispherical-shaped cellulosic cushioning element102may be formed similarly to the cylindrical-shaped cellulosic cushioning element100discussed above, such as by forming a panel170with a plurality of hemispherical projections160and separating the plurality of hemispherical projections160from each other to form the hemispherical-shaped cellulosic cushioning element102.FIG.4is a side view of the panel170. The panel170is similar to the panel150having a plurality of cylindrical projections154, discussed above, and the discussion of the panel150, applies here. The top view of the panel170is the same as shown inFIG.2A.

FIG.5shows a further shape of a molded fiber discrete cushioning element. The molded fiber discrete cushioning element shown inFIG.5has a substantially spherical shape and, for clarity with the other molded fiber discrete cushioning elements discussed herein, the cushioning element of this embodiment is referred to as a spherical-shaped cellulosic cushioning element104. The spherical-shaped cellulosic cushioning element104is similar to the hemispherical-shaped cellulosic cushioning element102but has an alternate shape. The same reference numerals will be used for features of the spherical-shaped cellulosic cushioning element104that are the same or similar to the hemispherical-shaped cellulosic cushioning element102discussed above. The discussion of the hemispherical-shaped cellulosic cushioning element102and these features above also applies to the spherical-shaped cellulosic cushioning element104, and a detailed discussion of these features is omitted here.

In this embodiment, the spherical-shaped cellulosic cushioning element104is formed from two hemispherical-shaped cellulosic cushioning elements102bonded together with the opening144of a first hemispherical-shaped cellulosic cushioning element102aopposing a corresponding opening144of a second hemispherical-shaped cellulosic cushioning element102b. An adhesive may be applied to the top surface134of one of the first hemispherical-shaped cellulosic cushioning element102aor the second hemispherical-shaped cellulosic cushioning element102b. Preferably, the adhesive is biodegradable. Then, the flanges132and, more specifically, the top surfaces134of the first hemispherical-shaped cellulosic cushioning element102aand the second hemispherical-shaped cellulosic cushioning element102bare positioned to oppose each other and have the flanges132and, more specifically, the top surfaces134adhere to each other.

FIGS.6A and6Billustrate a method of forming the spherical-shaped cellulosic cushioning element104.FIG.6Ais a first step, andFIG.6Bis a second step. Two panels170(a first panel170aand a second panel170b) of the hemispherical-shaped cellulosic cushioning element102are formed. In the step illustrated inFIG.6A, an adhesive is applied to a top surface172of the first panel170a. Then in the step illustrated inFIG.6B, the second panel170bis brought into contact with the first panel170a, and more specifically, the top surface172of the second panel170bis brought into contact with the top surface172of first panel170a(to which adhesive has been applied). Preferably, the openings144of the hemispherical projections160in the second panel170bare aligned with opening144of the hemispherical projections160in the first panel170a. As discussed above, the spherical-shaped cellulosic cushioning element104may then be formed by separating opposed hemispherical projections160, such as by cutting the opposed planar layers152.

The molded fiber discrete cushioning elements may be used to form various packing materials. In the following discussion, the cylindrical-shaped cellulosic cushioning element100will be used to describe the various packing materials, but the following discussion applies to other molded fiber discrete cushioning elements, such as the hemispherical-shaped cellulosic cushioning element102and the spherical-shaped cellulosic cushioning element104. In addition, although the various packing materials discussed below are shown with one shape of molded fiber cushioning elements, a mixture of shapes, such as a plurality of the cylindrical-shaped cellulosic cushioning elements100mixed with a plurality of the hemispherical-shaped cellulosic cushioning elements102, may be used.

A plurality of the cylindrical-shaped cellulosic cushioning elements100may be used on their own as packing material.FIG.7shows, for example, a shipping box10that has an item-to-be-shipped20placed therein. The shipping box10may be any suitable shipping box including a carboard box. The cylindrical-shaped cellulosic cushioning elements100may be placed in the shipping box10to surround the item-to-be-shipped20. The cylindrical-shaped cellulosic cushioning element100is deformable to absorb energy and protect the item-to-be-shipped20. Factors impacting the amount of energy absorbed that may be modified for the desired protection include the thickness of the walls (e.g., the side wall110, the bottom wall122, and the flange132) of the molded pulp/fibers and the volume or size (e.g., diameter) of the cylindrical-shaped cellulosic cushioning element100.

The cylindrical-shaped cellulosic cushioning elements100may also be suitable to make an EPS foam (or other plastic foam) replacement. Such a packing material is referred to herein as a molded packing material200.FIG.8shows a plurality of the molded packing materials200arranged in a configuration to package an item-to-be-shipped20(not shown inFIG.8), such as, for example, a TV. Each of the molded packing materials200inFIG.8has a rectangular shape, but the molded packing material200may be formed in other suitable shapes. For example, instead of a plurality of the molded packing materials200arranged to form an L-shape with a slot (or cavity202) to receive the item-to-be-shipped, the molded packing material200may be formed in the L-shape with the cavity202formed therein. The molded packing material200may thus be formed into a shape in order to pack the item-to-be-shipped20, and the molded shape may include recesses (e.g., cavity202) and/or protrusions.

With the molded packing material200having a rectangular shape, the molded packing material200includes corners. In some embodiments, the molded packing material200may be used with a corner protector204that fits around the corner of the molded packing material200to protect the corner from damage. Such a corner protector204may include three faces that come together at a vertex. The corner protector204may be formed from a suitable material such as corrugated cardboard or be molded pulp/fibers, using the methods discussed above.

FIG.9is a cross-sectional view of the molded packing material200taken along line9-9inFIG.8. The molded packing material200of this embodiment includes a plurality of cylindrical-shaped cellulosic cushioning elements100that are formed into the desired shape and then joined together. The plurality of cylindrical-shaped cellulosic cushioning elements100may be joined together by bonds comprising adhesive and cellulosic (paper) fibers. In some embodiments, the plurality of cylindrical-shaped cellulosic cushioning elements100may be joined together by a matrix212of cellulosic (paper) fibers, and in a preferred embodiment, a matrix212of cellulosic (paper) fibers and an adhesive. Additional features of the bonds and matrix212will be discussed below in connection with the method of manufacturing the molded packing material200. The plurality of cylindrical-shaped cellulosic cushioning elements100and matrix212thus form a mass that has been molded into a shape having exterior surfaces214and an interior216with some of the plurality of cylindrical-shaped cellulosic cushioning elements100being on the exterior surfaces214of the mass and the remainder of the plurality of the cylindrical-shaped cellulosic cushioning elements100being in the interior216of the mass.

A method of manufacturing the molded packing material200shown inFIGS.8and9will be described with reference toFIG.10. First, a mold210having the desired shape is provided. The mold210may preferably be silicon. Optionally, the outer surfaces of the molded packing material200may be covered with a paper fiber shell220. The paper fiber shell220may be formed of multiple portions including a container portion222. The container portion222generally has the shape of the molded packing material200with a cavity224formed therein. The container portion222also includes an opening226that is used to fill the paper fiber shell220with cylindrical-shaped cellulosic cushioning elements100, as discussed below. The paper fiber shell220may also include a cover228to close the opening226after the cavity224has been filled with the cylindrical-shaped cellulosic cushioning elements100. The paper fiber shell220and, more specifically, the container portion222and the cover228, may be formed in the desired shape of the molded packing material200using a molded fiber process, such as the processes discussed above. The paper fiber shell220may also be referred to as a molded fiber shell. In some embodiments, particularly when formed using the wet fiber molding process discussed above, the paper fiber shell220may be referred to as a paper pulp shell or a molded pulp shell. If a paper fiber shell220is used, the container portion222of the paper fiber shell220is placed into the mold210in step S305. In another variation, instead of a paper fiber shell220, outer sheets may be used. The sheet is preferably a cellulosic (paper) sheet and placed into the mold210in a manner similar to the paper fiber shell220. Although the molded packing material200is preferably used with the mold210, using the paper fiber shell220may allow the mold210to be omitted.

In step S310, an emulsion of water, cellulosic (paper) fibers, and preferably adhesive is sprayed onto the surface of the paper fiber shell220. Then, in step S315, the mold210and paper fiber shell220(container portion222), if used, is filled with the cylindrical-shaped cellulosic cushioning elements100.

Next, in step S320, an emulsion of water, cellulosic (paper) fibers, and preferably adhesive is sprayed into the mold210with the cylindrical-shaped cellulosic cushioning elements100. The emulsion flows around and between the cylindrical-shaped cellulosic cushioning elements100. If the paper fiber shell220is used, the cover228may be placed on top of an exposed surface218of the cylindrical-shaped cellulosic cushioning elements100in step S325.

The paper fiber shell220, if used, and cylindrical-shaped cellulosic cushioning elements100with the emulsion is then removed from the mold210in step S330, such as by turning the mold210upside down, and then dried to form the molded packing material200. The drying step, or portions thereof, may also take place before removing the paper fiber shell220and cylindrical-shaped cellulosic cushioning elements100from the mold210.

As the cylindrical-shaped cellulosic cushioning elements100with the emulsion is dried bonds form between the cylindrical-shaped cellulosic cushioning elements100. The emulsion may form, as it is dried, the matrix212around the cylindrical-shaped cellulosic cushioning elements100, and the cylindrical-shaped cellulosic cushioning elements100may be connected to each other by the cellulosic fibers and, when used, the adhesive of the matrix212. The molded packing material200may thus include a plurality of cylindrical-shaped cellulosic cushioning elements100that are interconnected to each other by cellulosic fibers. The cylindrical-shaped cellulosic cushioning elements100may retain some of the air pockets therein. For example, the cylindrical-shaped cellulosic cushioning elements100discussed herein include a cavity140and in some embodiments, the emulsion may not flow completely into the cavity140and the molded packing material200may also be described as having discrete groupings of air (gas) pockets interspersed within a cellulosic (paper) mass.

As discussed above, factors impacting the amount of energy absorbed include the thickness of the walls (e.g., the side wall110, the bottom wall122, and the flange132) of the molded pulp/fibers, the volume or size (e.g., diameter) of the cylindrical-shaped cellulosic cushioning elements100, and the density of the cylindrical-shaped cellulosic cushioning elements. If used, the thickness of the paper fiber shell220may also be modified. In this embodiment, the amount of emulsion and the amount of the cellulosic fibers and the amount of adhesive in the emulsion may also be modified to create a packing material with the desired strength and energy absorbing properties. The emulsions discussed herein may be referred to herein as an aqueous slurry of cellulosic fibers and adhesive. In the emulsions discussed herein the cellulosic fibers are preferably the same fibers as are used in the paper for the cylindrical-shaped cellulosic cushioning elements100. In addition, the adhesive of the emulsion is preferably biodegradable and the emulsion is thus a biodegradable emulsion.

A variation of the method of manufacturing the molded packing material200shown inFIGS.8and9will be described with reference toFIGS.11and12. This method is similar to the method discussed above, and the same reference numerals will be used for features and steps of this method that are the same or similar to the method discussed above with reference toFIG.10. The discussion of such steps and features above also applies to the method discussed with reference toFIG.11, and a detailed discussion of these features and steps is omitted here. In the method discussed above, the emulsion of water, cellulosic (paper) fibers, and preferably adhesive is sprayed into the mold210(in step S310) after the mold210and paper fiber shell220(container portion222), if used, is filled with the cylindrical-shaped cellulosic cushioning elements100(in step S315). In the method illustrated inFIG.11, the emulsion is first mixed with the cylindrical-shaped cellulosic cushioning elements100to form a cushioning element and fiber mixture. Then in step S340, the mold210and paper fiber shell220(container portion222), if used, is filled with the cushioning element and fiber mixture. Accordingly, step S340of the method illustrated inFIG.11may take the place of steps S310, S315, and S320of the method illustrated inFIG.10.

FIG.12shows how the cushioning element and fiber mixture may be formed and how the mold210and paper fiber shell220(container portion222), if used, is filled in step S340. A desired amount of each of the cylindrical-shaped cellulosic cushioning elements100and the emulsion are supplied to a mixing drum342. The mixing drum342can be rotated to agitate and mix the cylindrical-shaped cellulosic cushioning elements100and the emulsion. The mixing drum342is rotated or otherwise moved to pour the cushioning element and fiber mixture from the mixing drum342into a hopper344. The hopper344holds the cushioning element and fiber mixture and then when the mold210and paper fiber shell220(container portion222) is positioned under an outlet of the hopper344, a suitable actuator346, such as a screw type actuator, discharges or otherwise releases a desired amount of the cushioning element and fiber mixture to fill the mold210and paper fiber shell220(container portion222).

Another molded packing material201using the cylindrical-shaped cellulosic cushioning element100is shown and described with reference toFIGS.13and14.FIG.13illustrates a method of manufacturing the molded packing material201.FIG.14shows the features of the molded packing material201in a step of the method shown inFIG.13. In the molded packing material200discussed above, the plurality of cylindrical-shaped cellulosic cushioning elements100are joined together by the matrix212and, in some embodiments, located within a paper fiber shell220. In this embodiment, the molded packing material201does not include the matrix, but instead the cylindrical-shaped cellulosic cushioning elements100are constrained and form the molded shape using the paper fiber shell220. The cylindrical-shaped cellulosic cushioning elements100are free from attachment to one another within the molded packing material201of this embodiment, but the molded packing material201is otherwise similar to the molded packing material200discussed above. The discussion of the molded packing material200above also applies to the molded packing material201of this embodiment. The same reference numerals are used for features of the molded packing material201of this embodiment that are the same or similar to the features of the molded packing material200discussed above, and a detailed discussion of these features is omitted here.

The method of manufacturing the molded packing material201is shown inFIG.13. This method is similar to the methods discussed above, such as the method shown and described with reference toFIG.10, and the same reference numerals will be used for features and steps of this method that are the same or similar to the method discussed above with reference toFIG.10. The discussion of such steps and features above also applies to the method discussed with reference toFIG.13, and a detailed discussion of these features and steps is omitted here. As noted above, the molded packing material201does not include the matrix and thus the emulsion of water, cellulosic (paper) fibers, and preferably adhesive is not used in the method shown inFIG.13, and steps S310, S315, and S320of the method illustrated inFIG.10are omitted in the method shown inFIG.13.

In the method shown inFIG.13, the paper fiber shell220and, more specifically, the container portion222of the paper fiber shell220is provided in step S305. The mold210is optional in this method, but if used, step S305may be substantially the same as the corresponding step shown inFIG.10. Next, in step S350, the paper fiber shell220and, more specifically, the container portion222of the paper fiber shell220is filled with the cylindrical-shaped cellulosic cushioning elements100. Then, in step S355, the cover228is positioned on the container portion222to close the opening226after the cavity224has been filled with the cylindrical-shaped cellulosic cushioning elements100. The cover228may be attached to the container portion222by various suitable means including, for example, adhesive applied to the periphery of the cover228and/or the container portion222. The method then continues to step S330in the manner discussed above.

FIG.14shows the molded packing material201in step S355after the container portion222of the paper fiber shell220is filled with the cylindrical-shaped cellulosic cushioning elements100and before the cover228has been attached to the container portion222. The molded packing material201thus includes the paper fiber shell220with a cavity224formed therein. The cylindrical-shaped cellulosic cushioning elements100are located within the cavity224and may fill the cavity224. More specifically, the paper fiber shell220includes the container portion222having the cavity224formed therein and the opening226for filling the cavity224with the cylindrical-shaped cellulosic cushioning elements100. The paper fiber shell220also includes the cover228positioned over the opening226of the container portion222of the paper fiber shell220to close the opening226.

Although this invention has been described with respect to certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive, and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description.