BIODEGRADABLE PACKAGING COMPONENT

Abstract

An example packaging component according to the present invention includes a first compressible portion and a second compressible portion. The first portion is configured to be compressed onto a first side of a component to conform to a surface geometry of the component, and the second portion configured to be compressed onto a second side of a component opposite the first side to conform to the surface geometry of the component. The first and second portions are configured to be bonded to one another in a bonded region without bonding to the component. An example packaged component and method of packaging a component are also disclosed.

Description

CROSS-REFERENCED TO RELATED APPLICATION

This application claims priority to U.S. Provisional Application No. 62/416,272, which was filed on Nov. 2, 2016.

BACKGROUND

Components such as automotive components are frequently shipped from a first location to a second location. During shipping, the components are protected by packaging materials. The packaging materials can be attached to the components. Such attaching can include the use of adhesives, for example. After being shipped, the packaging materials are removed from the component. Sometimes, this removal step damages the component or requires additional post processing, such as removing the adhesives used to attach the packaging material to the component.

SUMMARY

An example packaging component according to the present invention includes a first compressible portion and a second compressible portion. The first portion is configured to be compressed onto a first side of a component to conform to a surface geometry of the component, and the second portion configured to be compressed onto a second side of a component opposite the first side to conform to the surface geometry of the component. The first and second portions are configured to be bonded to one another in a bonded region without bonding to the component.

An example packaged component according to an embodiment of the present disclosure includes a component and a packing component configured to at least partially surround the component. The packing component comprises a first portion configured to be compressed onto a first side of the component and conform to a surface geometry of the component and a second portion configured to be compressed onto a second side of the component opposite the first side and conform to the surface geometry of the component. The first and second portions are bonded to one another in a bonded region without bonding to the component.

An example method of packaging a component according to the present includes compressing a first portion of a packing component onto a first side of a component, compressing a second portion of a packing component onto a second side of the component, the second side opposite the first side, and bonding the first portion to the second portion in a bonded area such that neither the first portion nor the second portion are bonded to the component.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A schematically illustrates a packaged component.

FIG. 1B schematically illustrates a section of the packaged component of FIG. 1A.

FIG. 1C schematically illustrates an exploded view of the packaged component of FIG. 1B.

FIG. 1D schematically illustrates an alternate packaged component.

FIG. 2 schematically illustrates an alternate packaged component.

DETAILED DESCRIPTION

Referring to FIGS. 1A-D, an example packaged component 8 is shown. The packaged component 8 includes a component 10 and packing components 12. In the example of FIGS. 1A and 1D, the component 10 is generally rectangular and is fitted with multiple generally oversized rectangular or triangular packaging components 12 at its four corners, respectively. Packaging components 12 allow for a variety of sizes of component 10 to be packaged in the same carton. However, it should be understood that any number or configuration of packaging components 12 may be used. It should also be understood that the packaged component 8 can be any shape, as can the packaging components 12. For instance, packaging components 112 can be at one or more edges of the component 10, as shown in FIG. 2. Packaging components 12, 112 protect component 10 during shipment or handling by, for instance, preventing component 10 from moving or jostling. For simplicity, the below description references only packaging components 12. However, it should be understood that the below discussion applies to packaging components 112 as well.

In an example packed component 8, packaging components 12 capture more than 25% of the perimeter and less than 50% of the surface area of the component 10. In another example, packaging components 12 capture more than 50% of the perimeter and the surface area of the component 10.

The component 10 could be any object, such as an object being shipped or handled. In one example, the component 10 is an automotive component, such as a windshield, a sheet metal stamping, or an assembled part like a hood or door. In a further example, the object includes a “Class A” surface that cannot be damaged or scratched during handling or shipping. Alternatively, the components could be any glass, metallic, polymeric, or ceramic object, including but not limited to bed backboards, plate glass, picture frames, etc.

The packaging components 12 comprise a compressible material. In one example, the compressible material includes some degree of porosity, or cavitation. A higher degree of porosity/cavitation generally correlates with increased compressibility. Porosity/cavitation allows for compressibility by the collapsing of voids that occurs when the material is placed under pressure, and also provides softness to the material. In one example, the compressible material can compress more than 30% of its thickness due to lack of stiffness of the material or to voids or pores. Such compressible material can be used for thicker components 10. In another example, packaging material that can compress less than 30% of its thickness due to material stiffness or lack voids or pores can be sufficient for thinner components 10.

Referring to FIG. 1B, a section of the packaged component 8 of FIG. 1A is shown. FIG. 1C shows an exploded view of the packaged component 8. The packaging components 12 each include a first portion 12a and a second portion 12b, which are arranged on opposite sides 11a, 11b of the component 10, respectively. Portions 12a, 12b of packaging components 12 are compressed onto sides 11a, 11b, respectively, such that the portions 12a, 12b conform to the edges and surface geometry of the component 10. In the example of FIG. 1C, neither of portions 12a, 12b have any kind of cutouts or spaces formed to receive the component 10. However, in another example, either one or both of the portions 12a, 12b can have cutouts or spaces formed to receive the component 10 prior to being compressed around component 10.

The portions 12a, 12b are bonded together in a bonded region 16. In one example, portions 12a, 12b are not bonded to one another in any region aside from the bonded region 16. That is, the portions 12a, 12b are bonded to one another, but not to the component 10. Therefore, the component 10 is easily removed from the packaging component 12, without damaging the component 10. Furthermore, no post-shipment processing, such as removing an adhesive from the component 10, is required.

In the example of FIGS. 1A-C, the portions 12a, 12b are bonded together with an adhesive 14. The adhesive 14 can be applied onto one or both portions 12a, 12b. The adhesive 14 adheres to the portions 12a, 12b but not to the component 10 to form the bonded regions 16. That is, the adhesive 14 adheres to the material of the portions 12a, 12b but does not adhere to the material of the component 10. The adhesive 14 can include, for instance, a water based glue, hot-melt, or a non-scratching rubber latex. In one example, the adhesive 14 is a dry pressure-sensitive adhesive commonly known as a press seal adhesive. In another example, the adhesive 14 could have some tack but not enough to adhere to component 10.

Additionally or alternatively to the adhesive 14, in another example, the portions 12a, 12b can be joined together in another manner, such as by mechanical interlocking using a tongue and groove configuration, thermal fusing such as heat staking, or chemical bonding afforded by using a room temperature cured adhesive applied to the portions 12a or 12b, or to the outside the perimeter of component 10.

The compressible material can be a biodegradable material such as a starch-based biodegradable material in the form of a solid homogenous sheet, a convoluted sheet, or a sheet made up from fused pellets bonded together with a variation of voids or interstitial spaces. The starch-based biodegradable material may include, for instance, corn starch or another type of processed or reclaimed starch. In one example, the starch-based material is dissolvable in water. In another example, the biodegradable material is formed of a corn-based cellulosic material (“greencell”) or other cellulose based material. In another example, the biodegradable material is formed by providing starch flour with high amylose content and mixing the starch flour with water and additives. However, any biodegradable material may be used. ASTM International defines testing methods for determining whether a material is considered to be biodegradable.

In one example, the amylose content of the starch-based biodegradable material may be greater than 40% by weight. More particularly, the amylose content may be between 55% and 75% by weight. The amylose acts as a blowing agent which allows the starch-based biodegradable material to expand during processing to create a cavitated foam-like material. In one example, the starch-based biodegradable material is expanded during extrusion to form pellets, and the pellets can be loosely packed together or attached to one another with an adhesive such as one of the adhesives described above, or by fusing the pellets together with heat. In a further example, a material such as a heat-expandable thermoplastic material is added to the biodegradable material in an extruder, or before the biodegradable material is dispensed in the extruder, to enhance properties of the extruded biodegradable material. Spaces between pellets or within each pellet can provide pores or voids which allow the material to be compressed, as described above.

In another example, the compressible virgin or scrap material is shredded paper, corn husks, cotton or wool and an adhesive such as one of the adhesives described above.

Although a preferred embodiment of this disclosure has been disclosed, a worker of ordinary skill in this art would recognize that certain modifications would come within the scope of this disclosure. For that reason, the following claims should be studied to determine the true scope and content of this disclosure.

Claims

1. A packaging component, comprising:

a first compressible portion and a second compressible portion, the first compressible portion configured to be compressed onto a first side of a component to conform to a surface geometry of the component and the second compressible portion configured to be compressed onto a second side of a component opposite the first side to conform to the surface geometry of the component, wherein the first and second portions are configured to be bonded to one another in a bonded region without bonding to the component.

2. The packaging component of claim 1, wherein the first and second portions are bonded to one another by an adhesive.

3. The packaging component of claim 2, wherein the adhesive includes at least one of water based glue, hot-melt, non-scratching rubber latex, and dry pressure-sensitive adhesive.

4. The packaging component of claim 1, wherein the first and second portions are bonded to one another by thermal or chemical bonding.

5. The packaging component of claim 1, wherein the first and second component are bonded to one another by a tongue and groove configuration.

6. The packaging component of claim 1, wherein the first and second portions comprise a starch-based biodegradable material having an amylose content of more than 40% by weight.

7. The packaging component of claim 1, wherein the first and second portions comprise a material having pores or cavities, the pores or cavities providing compressibility to the material.

8. A packaged component comprising:

a component;

a packing component configured to at least partially surround the component, the packing component comprising a first portion configured to be compressed onto a first side of the component and conform to a surface geometry of the component and a second portion configured to be compressed onto a second side of the component opposite the first side and conform to the surface geometry of the component, wherein the first and second portions are bonded to one another in a bonded region without bonding to the component.

9. The packed component of claim 8, wherein the packing component captures more than 25% of the perimeter and less than 50% of the surface area of the component.

10. The packed component of claim 8, wherein at least one of the first portion and the second portion include a cutout for receiving the component.

11. The packed component of claim 8, wherein the first portion and the second portion are bonded together by an adhesive in the bonded region, and the adhesive includes at least one of water based glue, hot-melt, non-scratching rubber latex, and dry pressure-sensitive adhesive.

12. The packed component of claim 8, wherein the component is glass.

13. A method of packaging a component comprising:

compressing a first portion of a packing component onto a first side of a component;

compressing a second portion of a packing component onto a second side of the component, the second side opposite the first side; and

bonding the first portion to the second portion in a bonded area such that neither the first portion nor the second portion are bonded to the component.

14. The method of claim 13, wherein the bonding is accomplished by an adhesive, the adhesive including at least one of water based glue, hot-melt, non-scratching rubber latex, and dry pressure-sensitive adhesive.

15. The method of claim 13, wherein the bonding is accomplished by thermal or chemical bonding.

16. The method of claim 13, further comprising processing a starch-based biodegradable material to provide at least one of the first and second portions, such that the starch-based biodegradable material expands to provide pores or cavities.

17. The method of claim 16, wherein the processing includes expanding the starch-based biodegradable material to form pellets, and loosely attaching the pellets together to provides spaces between the pellets.

18. The method of claim 16, further comprising adding a heat-expandable thermoplastic material to the biodegradable material prior to the processing, to enhance properties of the processed biodegradable material.

19. The method of claim 16, wherein the pores or cavities allow for the compressing.

20. The method of claim 16, wherein the starch-based biodegradable material includes an amylose content of greater than 40% by weight, and wherein the amylose acts as a blowing agent which allows for the expansion.