U.S. patent application number 15/393600 was filed with the patent office on 2018-07-05 for packaging article with three-dimensional loop material.
The applicant listed for this patent is Dow Global Technologies LLC. Invention is credited to Sanjib Biswas, Marc S. Black, Marcus Vinicius Pereira De Carvalho, Kurt A. Koppi, Bruno Rufato Pereira, Viraj K. Shah, Piyush R. Thakre.
Application Number | 20180186543 15/393600 |
Document ID | / |
Family ID | 60997576 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180186543 |
Kind Code |
A1 |
Shah; Viraj K. ; et
al. |
July 5, 2018 |
Packaging Article with Three-Dimensional Loop Material
Abstract
The present disclosure provides a packaging article. In an
embodiment, the packaging article includes a body having a
geometric shape, the body composed of a three-dimensional random
loop material (3DRLM). The 3DRLM is composed of an olefin-based
polymer. The packaging article includes a sleeve having opposing
ends on respective opposing surfaces of the body. The sleeve
extends through an interior portion of the body. The sleeve has an
opening at each respective end. Each opening has a closed width.
The packaging article includes a product having an insert shape.
The insert shape has an insert width that is greater than or equal
to the closed width of the sleeve opening. A portion of the 3DRLM
moves from a neutral state to a stretched state when the product is
inserted into the sleeve.
Inventors: |
Shah; Viraj K.; (Pearland,
TX) ; Pereira; Bruno Rufato; (Sao Paulo, BR) ;
De Carvalho; Marcus Vinicius Pereira; (Salvador, BR)
; Koppi; Kurt A.; (Midland, MI) ; Biswas;
Sanjib; (Pearland, TX) ; Thakre; Piyush R.;
(Lake Jackson, TX) ; Black; Marc S.; (Midland,
MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dow Global Technologies LLC |
Midland |
MI |
US |
|
|
Family ID: |
60997576 |
Appl. No.: |
15/393600 |
Filed: |
December 29, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/509 20130101;
B65D 5/66 20130101; B65D 85/32 20130101; B65D 81/03 20130101; B65D
81/1075 20130101; B65D 5/5088 20130101; B65D 85/34 20130101; B65D
81/058 20130101; B65D 81/022 20130101 |
International
Class: |
B65D 81/02 20060101
B65D081/02; B65D 81/107 20060101 B65D081/107; B65D 5/50 20060101
B65D005/50; B65D 85/32 20060101 B65D085/32; B65D 85/34 20060101
B65D085/34; B65D 5/66 20060101 B65D005/66 |
Claims
1. A packaging article comprising: a body having a geometric shape
and composed of a three-dimensional random loop material (3DRLM)
composed of an olefin-based polymer; a sleeve having opposing ends
on respective opposing surfaces of the body, the sleeve extending
through an interior portion of the body and having an opening at
each respective end; each opening having a closed width; a product
having an insert shape, the insert shape having an insert width
that is greater than the closed width of the sleeve opening; and a
portion of the 3DRLM moves from a neutral state to a stretched
state when the product is inserted into the sleeve.
2. The packaging article of claim 1 wherein the body has an
original geometric shape and the body maintains its original
geometrical shape when the product is located in the sleeve.
3. The packaging article of claim 1 wherein the sleeve stretches
from the closed width to the insert width when the product is
located in the sleeve.
4. The packaging article of claim 1 wherein the 3DRLM compressively
engages at least two opposing surfaces of the product.
5. The packaging article of claim 1 wherein the body forms a border
area around a circumference of the product.
6. The packaging article of claim 1 wherein the body provides from
1.0 cm to 10.0 cm of 3DRLM around each side of the product.
7. (canceled)
8. (canceled)
9. (canceled)
10. The packaging article of claim 1 wherein the 3DRLM is composed
of a material selected from the group consisting of an
ethylene-based polymer, a propylene-based polymer, and combinations
thereof.
11. The packaging article of claim 1 comprising a container having
(i) a top wall and a bottom wall; (ii) a plurality sidewalls
extending between the top wall and bottom wall, the walls defining
a compartment; and the body and the product are located in the
compartment.
12. The packaging article of claim 11 wherein the packaging article
passes the drop test or the vibration test as measured in
accordance with ISTA 3A.
13. (canceled)
14. (canceled)
15. (canceled)
16. The packaging article of claim 1 wherein the sleeve opposing
ends are located on respective opposing outermost surfaces of the
body, and the sleeve has an opening at each respective end.
17. The packing article of claim 1 wherein the 3DRLM stretches from
the closed width to the insert width when the product is inserted
into the sleeve.
18. The packing article of claim 1 wherein the 3DRLM stretches such
that a sleeve width expands from the closed width to the insert
width when the product is inserted into the sleeve.
Description
FIELD
[0001] The present disclosure relates to protective packaging, and
more particularly, to an economical reusable protective packaging
article for packing and shipping delicate product susceptible to
damage by impact and/or vibration.
BACKGROUND
[0002] Packaging is a fundamental item in supply chain management.
Packaging serves to protect valuable product during shipping and
storage. Packaging requires sturdy construction and a cushioning
feature in order to fulfill its primary function of product
protection from physical shock during shipping and storage. As a
result, packaging must withstand many stresses such as falls,
drops, tips, puncture, vibration and environmental stresses such as
extreme temperatures and water. Known are common packaging
materials such as corrugated cardboard, packing peanuts, bubble-out
bags, air pillow, bubble wrap, and foam sheets.
[0003] Overly expensive packaging can reduce an entity's return on
investment. Excess packaging material has an undue environmental
impact and creates a disposal problem for the customer. Excess
packaging material also impacts logistics by increasing the amount
of pallet space that each package consumes and the dimensional
weight of each package. On the other hand, poor or improper
packaging can expose product to undue risk of damage.
[0004] Packaging success is the safe arrival of the packaged
product to a customer. Safe arrival depends upon adequate exterior
strength to allow stacking of packages during shipping and adequate
interior strength to keep the packaged product from harm in the
event of excessive accelerations, such as dropping of the package.
Damaged product as a result of defective packaging, impedes the
supply chain, is costly, and is deleterious to customer
relations.
[0005] Consequently, the art recognizes the need for versatile
packaging materials that are sturdy, lightweight, and shock
absorbing to meet the demand needs of supply chain management. Also
needed is packaging material that is economical, convenient to use
and handle, and packaging that is re-usable and/or recyclable.
SUMMARY
[0006] The present disclosure provides a packaging article. In an
embodiment, the packaging article includes a body having a
geometric shape, the body composed of a three-dimensional random
loop material (3DRLM). The 3DRLM is composed of an olefin-based
polymer. The packaging article includes a sleeve having opposing
ends on respective opposing surfaces of the body. The sleeve
extends through an interior portion of the body. The sleeve has an
opening at each respective end. Each opening has a closed width.
The packaging article includes a product having an insert shape.
The insert shape has an insert width that is greater than or equal
to the closed width of the sleeve opening. A portion of the 3DRLM
moves from a neutral state to a stretched state when the product is
inserted into the sleeve.
[0007] The present disclosure provides another packaging article.
In an embodiment, the packaging article includes a container. The
container has (i) a top wall and a bottom wall, and (ii) a
plurality sidewalls extending between the top wall and bottom wall.
The walls define a compartment. The packaging article has at least
two bodies. Each body has a geometric shape of an endcap. Each
endcap is composed of a three-dimensional random loop material
(3DRLM). The 3DRLM is composed of an olefin-based polymer. Each
endcap has a pocket in an interior portion of the body. Each pocket
has an opening, each opening having a closed width. The packaging
article includes a product having opposing ends. Each product end
has an insert shape. The insert shape has an insert width that is
greater than or equal to the closed width of the opening. A portion
of the 3DRLM moves from a neutral state to a stretched state when a
product end is inserted into a respective pocket.
Definitions and Test Methods
[0008] All references to the Periodic Table of the Elements herein
shall refer to the Periodic Table of the Elements, published and
copyrighted by CRC Press, Inc., 2003. Also, any references to a
Group or Groups shall be to the Groups or Groups reflected in this
Periodic Table of the Elements using the IUPAC system for numbering
groups. Unless stated to the contrary, implicit from the context,
or customary in the art, all components and percents are based on
weight. For purposes of United States patent practice, the contents
of any patent, patent application, or publication referenced herein
are hereby incorporated by reference in their entirety (or the
equivalent US version thereof is so incorporated by reference).
[0009] The numerical ranges disclosed herein include all values
from, and including, the lower value and the upper value. For
ranges containing explicit values (e.g., 1, or 2, or 3 to 5, or 6,
or 7) any subrange between any two explicit values is included
(e.g., 1 to 2; 2 to 6; 5 to 7; 3 to 7; 5 to 6; etc.).
[0010] Unless stated to the contrary, implicit from the context, or
customary in the art, all components and percents are based on
weight, and all test methods are current as of the filing date of
this disclosure.
[0011] Apparent density. A sample material is cut into a square
piece of 38 cm.times.38 cm (15 in.times.15 in) in size. The volume
of this piece is calculated from the thickness measured at four
points. The division of the weight by the volume gives the apparent
density (an average of four measurements is taken) with values
reported in grams per cubic centimeter, g/cc.
[0012] Bending Stiffness. The bending stiffness is measured in
accordance with DIN 53121 standard, with compression molded plaques
of 550 .mu.m thickness, using a Frank-PTI Bending Tester. The
samples are prepared by compression molding of resin granules per
ISO 293 standard. Conditions for compression molding are chosen per
ISO 1872-2007 standard. The average cooling rate of the melt is
15.degree. C./min. Bending stiffness is measured in 2-point bending
configuration at room temperature with a span of 20 mm, a sample
width of 15 mm, and a bending angle of 40.degree.. Bending is
applied at 6.degree./second (s) and the force readings are obtained
from 6 to 600 s, after the bending is complete. Each material is
evaluated four times with results reported in Newton millimeters
("Nmm").
[0013] "Blend," "polymer blend" and like terms is a composition of
two or more polymers. Such a blend may or may not be miscible. Such
a blend may or may not be phase separated. Such a blend may or may
not contain one or more domain configurations, as determined from
transmission electron spectroscopy, light scattering, x-ray
scattering, and any other method known in the art. Blends are not
laminates, but one or more layers of a laminate can comprise a
blend.
[0014] .sup.13C Nuclear Magnetic Resonance (NMR)
[0015] Sample Preparation
[0016] The samples are prepared by adding approximately 2.7 g of a
50/50 mixture of tetrachloroethane-d2/orthodichlorobenzene that is
0.025M in chromium acetylacetonate (relaxation agent) to 0.21 g
sample in a 10 mm NMR tube. The samples are dissolved and
homogenized by heating the tube and its contents to 150.degree.
C.
[0017] Data Acquisition Parameters
[0018] The data is collected using a Bruker 400 MHz spectrometer
equipped with a Bruker Dual DUB high-temperature CryoProbe. The
data is acquired using 320 transients per data file, a 7.3 sec
pulse repetition delay (6 sec delay+1.3 sec acq. time), 90 degree
flip angles, and inverse gated decoupling with a sample temperature
of 125.degree. C. All measurements are made on non-spinning samples
in locked mode. Samples are homogenized immediately prior to
insertion into the heated (130.degree. C.) NMR Sample changer, and
are allowed to thermally equilibrate in the probe for 15 minutes
prior to data acquisition.
[0019] "Composition" and like terms is a mixture of two or more
materials. Included in compositions are pre-reaction, reaction and
post-reaction mixtures the latter of which will include reaction
products and by-products as well as unreacted components of the
reaction mixture and decomposition products, if any, formed from
the one or more components of the pre-reaction or reaction
mixture.
[0020] The terms "comprising," "including," "having," and their
derivatives, are not intended to exclude the presence of any
additional component, step or procedure, whether or not the same is
specifically disclosed. In order to avoid any doubt, all
compositions claimed through use of the term "comprising" may
include any additional additive, adjuvant, or compound, whether
polymeric or otherwise, unless stated to the contrary. In contrast,
the term, "consisting essentially of" excludes from the scope of
any succeeding recitation any other component, step or procedure,
excepting those that are not essential to operability. The term
"consisting of" excludes any component, step or procedure not
specifically delineated or listed.
[0021] Crystallization Elution Fractionation (CEF) Method
[0022] Comonomer distribution analysis is performed with
Crystallization Elution Fractionation (CEF) (PolymerChar in Spain)
(B Monrabal et al, Macromol. Symp. 257, 71-79 (2007)).
Ortho-dichlorobenzene (ODCB) with 600 ppm antioxidant butylated
hydroxytoluene (BHT) is used as solvent. Sample preparation is done
with autosampler at 160.degree. C. for 2 hours under shaking at 4
mg/ml (unless otherwise specified). The injection volume is 300
.mu.m. The temperature profile of CEF is: crystallization at
3.degree. C./min from 110.degree. C. to 30.degree. C., the thermal
equilibrium at 30.degree. C. for 5 minutes, elution at 3.degree.
C./min from 30.degree. C. to 140.degree. C. The flow rate during
crystallization is at 0.052 ml/min. The flow rate during elution is
at 0.50 ml/min. The data is collected at one data point/second. CEF
column is packed by the Dow Chemical Company with glass beads at
125 .mu.m+6% (MO-SCI Specialty Products) with 1/8 inch stainless
tubing. Glass beads are acid washed by MO-SCI Specialty with the
request from The Dow Chemical Company. Column volume is 2.06 ml.
Column temperature calibration is performed by using a mixture of
NIST Standard Reference Material Linear polyethylene 1475a (1.0
mg/ml) and Eicosane (2 mg/ml) in ODCB. Temperature is calibrated by
adjusting elution heating rate so that NIST linear polyethylene
1475a has a peak temperature at 101.0.degree. C., and Eicosane has
a peak temperature of 30.0.degree. C. The CEF column resolution is
calculated with a mixture of NIST linear polyethylene 1475a (1.0
mg/ml) and hexacontane (Fluka, purum, >97.0, 1 mg/ml). A
baseline separation of hexacontane and NIST polyethylene 1475a is
achieved. The area of hexacontane (from 35.0 to 67.0.degree. C.) to
the area of NIST 1475a from 67.0 to 110.0.degree. C. is 50 to 50,
the amount of soluble fraction below 35.0.degree. C. is <1.8 wt
%. The CEF column resolution is defined in the following
equation:
Resolution = Peak temperature of NIST 1475 a - Peak Temperature of
Hexacontane Half - height Width of NIST 1475 a + Half - height
Width of Hexacontance ##EQU00001##
[0023] where the column resolution is 6.0.
[0024] Density is measured in accordance with ASTM D 792 with
values reported in grams per cubic centimeter, g/cc.
[0025] Differential Scanning calorimetry (DSC). DSC is used to
measure the melting and crystallization behavior of a polymer over
a wide range of temperatures. For example, the TA Instruments Q1000
DSC, equipped with an RCS (refrigerated cooling system) and an
autosampler is used to perform this analysis. During testing, a
nitrogen purge gas flow of 50 ml/min is used. Each sample is melt
pressed into a thin film at about 175.degree. C.; the melted sample
is then air-cooled to room temperature (approx. 25.degree. C.). The
film sample is formed by pressing a "0.1 to 0.2 gram" sample at
175.degree. C. at 1,500 psi, and 30 seconds, to form a "0.1 to 0.2
mil thick" film. A 3-10 mg, 6 mm diameter specimen is extracted
from the cooled polymer, weighed, placed in a light aluminum pan
(ca 50 mg), and crimped shut. Analysis is then performed to
determine its thermal properties. The thermal behavior of the
sample is determined by ramping the sample temperature up and down
to create a heat flow versus temperature profile. First, the sample
is rapidly heated to 180.degree. C., and held isothermal for five
minutes, in order to remove its thermal history. Next, the sample
is cooled to -40.degree. C., at a 10.degree. C./minute cooling
rate, and held isothermal at -40.degree. C. for five minutes. The
sample is then heated to 150.degree. C. (this is the "second heat"
ramp) at a 10.degree. C./minute heating rate. The cooling and
second heating curves are recorded. The cool curve is analyzed by
setting baseline endpoints from the beginning of crystallization to
-20.degree. C. The heat curve is analyzed by setting baseline
endpoints from -20.degree. C. to the end of melt. The values
determined are peak melting temperature (Tm), peak crystallization
temperature (Tc), onset crystallization temperature (Tc onset),
heat of fusion (Hf) (in Joules per gram), the calculated %
crystallinity for polyethylene samples using: % Crystallinity for
PE=((Hf)/(292 J/g)).times.100, and the calculated % crystallinity
for polypropylene samples using: % Crystallinity for PP=((Hf)/165
J/g)).times.100. The heat of fusion (Hf) and the peak melting
temperature are reported from the second heat curve. Peak
crystallization temperature and onset crystallization temperature
are determined from the cooling curve
[0026] Elastic Recovery. Resin pellets are compression molded
following ASTM D4703, Annex A1, Method C to a thickness of
approximately 5-10 mil. Microtensile test specimens of geometry as
detailed in ASTM D1708 are punched out from the molded sheet. The
test specimens are conditioned for 40 hours prior to testing in
accordance with Procedure A of Practice D618.
[0027] The samples are tested in a screw-driven tensile tester
using flat, rubber faced grips. The grip separation is set at 22
mm, equal to the gauge length of the microtensile specimens. The
sample is extended to a strain of 100% at a rate of 100%/min and
held for 30 s. The crosshead is then returned to the original grip
separation at the same rate and held for 60 s. The sample is then
strained to 100% at the same 100%/min strain rate.
[0028] Elastic recovery may be calculated as follows:
Elastic Recovery = ( Initial Applied Strain - Permanent Set )
Initial Applied Strain .times. 100 % ##EQU00002##
[0029] An "ethylene-based polymer" is a polymer that contains more
than 50 weight percent polymerized ethylene monomer (based on the
total weight of polymerizable monomers) and, optionally, may
contain at least one comonomer. Ethylene-based polymer includes
ethylene homopolymer, and ethylene copolymer (meaning units derived
from ethylene and one or more comonomers). The terms
"ethylene-based polymer" and "polyethylene" may be used
interchangeably. Nonlimiting examples of ethylene-based polymer
(polyethylene) include low density polyethylene (LDPE) and linear
polyethylene. Nonlimiting examples of linear polyethylene include
linear low density polyethylene (LLDPE), ultra low density
polyethylene (ULDPE), very low density polyethylene (VLDPE),
multi-component ethylene-based copolymer (EPE),
ethylene/.alpha.-olefin multi-block copolymers (also known as
olefin block copolymer (OBC)), single-site catalyzed linear low
density polyethylene (m-LLDPE), substantially linear, or linear,
plastomers/elastomers, and high density polyethylene (HDPE).
Generally, polyethylene may be produced in gas-phase, fluidized bed
reactors, liquid phase slurry process reactors, or liquid phase
solution process reactors, using a heterogeneous catalyst system,
such as Ziegler-Natta catalyst, a homogeneous catalyst system,
comprising Group 4 transition metals and ligand structures such as
metallocene, non-metallocene metal-centered, heteroaryl,
heterovalent aryloxyether, phosphinimine, and others. Combinations
of heterogeneous and/or homogeneous catalysts also may be used in
either single reactor or dual reactor configurations.
[0030] "High density polyethylene" (or "HDPE") is an ethylene
homopolymer or an ethylene/.alpha.-olefin copolymer with at least
one C.sub.4-C.sub.10 .alpha.-olefin comonomer, or C.sub.4
.alpha.-olefin comonomer and a density from greater than 0.94 g/cc,
or 0.945 g/cc, or 0.95 g/cc, or 0.955 g/cc to 0.96 g/cc, or 0.97
g/cc, or 0.98 g/cc. The HDPE can be a monomodal copolymer or a
multimodal copolymer. A "monomodal ethylene copolymer" is an
ethylene/C.sub.4-C.sub.10 .alpha.-olefin copolymer that has one
distinct peak in a gel permeation chromatography (GPC) showing the
molecular weight distribution. A "multimodal ethylene copolymer" is
an ethylene/C.sub.4-C.sub.10 .alpha.-olefin copolymer that has at
least two distinct peaks in a GPC showing the molecular weight
distribution. Multimodal includes copolymer having two peaks
(bimodal) as well as copolymer having more than two peaks.
Nonlimiting examples of HDPE include DOW.TM. High Density
Polyethylene (HDPE) Resins (available from The Dow Chemical
Company), ELITE.TM. Enhanced Polyethylene Resins (available from
The Dow Chemical Company), CONTINUUM.TM. Bimodal Polyethylene
Resins (available from The Dow Chemical Company), LUPOLEN.TM.
(available from LyondellBasell), as well as HDPE products from
Borealis, Ineos, and ExxonMobil.
[0031] An "interpolymer" is a polymer prepared by the
polymerization of at least two different monomers. This generic
term includes copolymers, usually employed to refer to polymers
prepared from two different monomers, and polymers prepared from
more than two different monomers, e.g., terpolymers, tetrapolymers,
etc.
[0032] "Low density polyethylene" (or "LDPE") consists of ethylene
homopolymer, or ethylene/.alpha.-olefin copolymer comprising at
least one C.sub.3-C.sub.10 .alpha.-olefin, preferably
C.sub.3-C.sub.4 that has a density from 0.915 g/cc to 0.940 g/cc
and contains long chain branching with broad MWD. LDPE is typically
produced by way of high pressure free radical polymerization
(tubular reactor or autoclave with free radical initiator).
Nonlimiting examples of LDPE include MarFlex.TM. (Chevron
Phillips), LUPOLEN.TM. (LyondellBasell), as well as LDPE products
from Borealis, Ineos, ExxonMobil, and others.
[0033] "Linear low density polyethylene" (or "LLDPE") is a linear
ethylene/.alpha.-olefin copolymer containing heterogeneous
short-chain branching distribution comprising units derived from
ethylene and units derived from at least one C.sub.3-C.sub.10
.alpha.-olefin comonomer or at least one C.sub.4-C.sub.8
.alpha.-olefin comonomer, or at least one C.sub.6-C.sub.8
.alpha.-olefin comonomer. LLDPE is characterized by little, if any,
long chain branching, in contrast to conventional LDPE. LLDPE has a
density from 0.910 g/cc, or 0.915 g/cc, or 0.920 g/cc, or 0.925
g/cc to 0.930 g/cc, or 0.935 g/cc, or 0.940 g/cc. Nonlimiting
examples of LLDPE include TUFLIN.TM. linear low density
polyethylene resins (available from The Dow Chemical Company),
DOWLEX.TM. polyethylene resins (available from the Dow Chemical
Company), and MARLEX.TM. polyethylene (available from Chevron
Phillips).
[0034] "Ultra low density polyethylene" (or "ULDPE") and "very low
density polyethylene" (or "VLDPE") each is a linear
ethylene/.alpha.-olefin copolymer containing heterogeneous
short-chain branching distribution comprising units derived from
ethylene and units derived from at least one C.sub.3-C.sub.10
.alpha.-olefin comonomer, or at least one C.sub.4-C.sub.8
.alpha.-olefin comonomer, or at least one C.sub.6-C.sub.8
.alpha.-olefin comonomer. ULDPE and VLDPE each has a density from
0.885 g/cc, or 0.90 g/cc to 0.915 g/cc. Nonlimiting examples of
ULDPE and VLDPE include ATTANE.TM. ultra low density polyethylene
resins (available form The Dow Chemical Company) and FLEXOMER.TM.
very low density polyethylene resins (available from The Dow
Chemical Company).
[0035] "Multi-component ethylene-based copolymer" (or "EPE")
comprises units derived from ethylene and units derived from at
least one C.sub.3-C.sub.10 .alpha.-olefin comonomer, or at least
one C.sub.4-C.sub.8 .alpha.-olefin comonomer, or at least one
C.sub.6-C.sub.8 .alpha.-olefin comonomer, such as described in
patent references U.S. Pat. No. 6,111,023; U.S. Pat. No. 5,677,383;
and U.S. Pat. No. 6,984,695. EPE resins have a density from 0.905
g/cc, or 0.908 g/cc, or 0.912 g/cc, or 0.920 g/cc to 0.926 g/cc, or
0.929 g/cc, or 0.940 g/cc, or 0.962 g/cc. Nonlimiting examples of
EPE resins include ELITE' enhanced polyethylene (available from The
Dow Chemical Company), ELITE AT.TM. advanced technology resins
(available from The Dow Chemical Company), SURPASS.TM. Polyethylene
(PE) Resins (available from Nova Chemicals), and SMART.TM.
(available from SK Chemicals Co.).
[0036] "Single-site catalyzed linear low density polyethylenes" (or
"m-LLDPE") are linear ethylene/.alpha.-olefin copolymers containing
homogeneous short-chain branching distribution comprising units
derived from ethylene and units derived from at least one
C.sub.3-C.sub.10 .alpha.-olefin comonomer, or at least one
C.sub.4-C.sub.8 .alpha.-olefin comonomer, or at least one
C.sub.6-C.sub.8 .alpha.-olefin comonomer. m-LLDPE has density from
0.913 g/cc, or 0.918 g/cc, or 0.920 g/cc to 0.925 g/cc, or 0.940
g/cc. Nonlimiting examples of m-LLDPE include EXCEED.TM.
metallocene PE (available from ExxonMobil Chemical), LUFLEXEN.TM.
m-LLDPE (available from LyondellBasell), and ELTEX.TM. PF m-LLDPE
(available from Ineos Olefins & Polymers).
[0037] "Ethylene plastomers/elastomers" are substantially linear,
or linear, ethylene/.alpha.-olefin copolymers containing
homogeneous short-chain branching distribution comprising units
derived from ethylene and units derived from at least one
C.sub.3-C.sub.10 .alpha.-olefin comonomer, or at least one
C.sub.4-C.sub.8 .alpha.-olefin comonomer, or at least one
C.sub.6-C.sub.8 .alpha.-olefin comonomer. Ethylene
plastomers/elastomers have a density from 0.870 g/cc, or 0.880
g/cc, or 0.890 g/cc to 0.900 g/cc, or 0.902 g/cc, or 0.904 g/cc, or
0.909 g/cc, or 0.910 g/cc, or 0.917 g/cc. Nonlimiting examples of
ethylene plastomers/elastomers include AFFINITY.TM. plastomers and
elastomers (available from The Dow Chemical Company), EXACT.TM.
Plastomers (available from ExxonMobil Chemical), Tafmer.TM.
(available from Mitsui), Nexlene.TM. (available from SK Chemicals
Co.), and Lucene.TM. (available LG Chem Ltd.).
[0038] Melt flow rate (MFR) is measured in accordance with ASTM D
1238, Condition 280.degree. C./2.16 kg (g/10 minutes).
[0039] Melt index (MI) is measured in accordance with ASTM D 1238,
Condition 190.degree. C./2.16 kg (g/10 minutes).
[0040] "Melting Point" or "Tm" as used herein (also referred to as
a melting peak in reference to the shape of the plotted DSC curve)
is typically measured by the DSC (Differential Scanning
calorimetry) technique for measuring the melting points or peaks of
polyolefins as described in U.S. Pat. No. 5,783,638. It should be
noted that many blends comprising two or more polyolefins will have
more than one melting point or peak, many individual polyolefins
will comprise only one melting point or peak.
[0041] Molecular weight distribution (Mw/Mn) is measured using Gel
Permeation Chromatography (GPC). In particular, conventional GPC
measurements are used to determine the weight-average (Mw) and
number-average (Mn) molecular weight of the polymer and to
determine the Mw/Mn. The gel permeation chromatographic system
consists of either a Polymer Laboratories Model PL-210 or a Polymer
Laboratories Model PL-220 instrument. The column and carousel
compartments are operated at 140.degree. C. Three Polymer
Laboratories 10-micron Mixed-B columns are used. The solvent is
1,2,4 trichlorobenzene. The samples are prepared at a concentration
of 0.1 grams of polymer in 50 milliliters of solvent containing 200
ppm of butylated hydroxytoluene (BHT). Samples are prepared by
agitating lightly for 2 hours at 160.degree. C. The injection
volume used is 100 microliters and the flow rate is 1.0
ml/minute.
[0042] Calibration of the GPC column set is performed with 21
narrow molecular weight distribution polystyrene standards with
molecular weights ranging from 580 to 8,400,000, arranged in 6
"cocktail" mixtures with at least a decade of separation between
individual molecular weights. The standards are purchased from
Polymer Laboratories (Shropshire, UK). The polystyrene standards
are prepared at 0.025 grams in 50 milliliters of solvent for
molecular weights equal to or greater than 1,000,000, and 0.05
grams in 50 milliliters of solvent for molecular weights less than
1,000,000. The polystyrene standards are dissolved at 80.degree. C.
with gentle agitation for 30 minutes. The narrow standards mixtures
are run first and in order of decreasing highest molecular weight
component to minimize degradation. The polystyrene standard peak
molecular weights are converted to polyethylene molecular weights
using the following equation (as described in Williams and Ward, J.
Polym. Sci., Polym. Let., 6, 621 (1968)):
M.sub.polypropylene=0.645(M.sub.polystyrene).
[0043] Polypropylene equivalent molecular weight calculations are
performed using Viscotek TriSEC software Version 3.0.
[0044] An "olefin-based polymer," as used herein, is a polymer that
contains more than 50 weight percent polymerized olefin monomer
(based on total amount of polymerizable monomers), and optionally,
may contain at least one comonomer. Nonlimiting examples of
olefin-based polymer include ethylene-based polymer and
propylene-based polymer.
[0045] A "polymer" is a compound prepared by polymerizing monomers,
whether of the same or a different type, that in polymerized form
provide the multiple and/or repeating "units" or "mer units" that
make up a polymer. The generic term polymer thus embraces the term
homopolymer, usually employed to refer to polymers prepared from
only one type of monomer, and the term copolymer, usually employed
to refer to polymers prepared from at least two types of monomers.
It also embraces all forms of copolymer, e.g., random, block, etc.
The terms "ethylene/.alpha.-olefin polymer" and
"propylene/.alpha.-olefin polymer" are indicative of copolymer as
described above prepared from polymerizing ethylene or propylene
respectively and one or more additional, polymerizable
.alpha.-olefin monomer. It is noted that although a polymer is
often referred to as being "made of" one or more specified
monomers, "based on" a specified monomer or monomer type,
"containing" a specified monomer content, or the like, in this
context the term "monomer" is understood to be referring to the
polymerized remnant of the specified monomer and not to the
unpolymerized species. In general, polymers herein are referred to
has being based on "units" that are the polymerized form of a
corresponding monomer.
[0046] A "propylene-based polymer" is a polymer that contains more
than 50 weight percent polymerized propylene monomer (based on the
total amount of polymerizable monomers) and, optionally, may
contain at least one comonomer.
BRIEF DESCRIPTION OF THE DRAWINGS
[0047] FIG. 1 is a perspective view of a packaging article having a
sleeve and a product (a laptop computer), to be inserted into the
sleeve, in accordance with an embodiment of the present
disclosure.
[0048] FIG. 2 is a perspective view of the product of FIG. 1 being
inserted into the sleeve of the packaging article, in accordance
with an embodiment of the present disclosure.
[0049] FIG. 3 is a top plan view of the product located in the
sleeve of the packaging article, in accordance with an embodiment
of the present disclosure.
[0050] FIG. 4 is an enlarged fragmentary perspective view of area 4
of FIG. 2, showing the stretching of the three dimensional loop
material during insertion of the product into the sleeve.
[0051] FIG. 5 is an enlarged fragmentary perspective view of area 5
of FIG. 3 with the product inserted into the sleeve.
[0052] FIG. 6 is a perspective view of a packaging article and a
product (a bottle), in accordance with an embodiment of the present
disclosure.
[0053] FIG. 7 is a perspective view of the bottle of FIG. 6 after
insertion into a pocket of the packaging article of FIG. 6, in
accordance with an embodiment of the present disclosure.
[0054] FIG. 8 is a top plan view of the bottle located in the
pocket of the packaging article of FIG. 6.
[0055] FIG. 9 is a top perspective view of a packaging article and
a product (eggs), in accordance with an embodiment of the present
disclosure.
[0056] FIG. 10 is a top plan view of the eggs located in the
pockets of the packaging article of FIG. 9.
[0057] FIG. 11 is an exploded perspective view of another packaging
article in accordance with an embodiment of the present
disclosure.
[0058] FIG. 12 is a sectional view taken along line 12-12 of FIG.
11.
DETAILED DESCRIPTION
[0059] The present disclosure provides a packaging article. In an
embodiment, the packaging article includes a body having a
geometric shape. The body is composed of a three-dimensional random
loop material (3DRLM). The 3DRLM is composed of an olefin-based
polymer. A sleeve extends through an interior portion of the body.
The sleeve has opposing ends on respective opposing surfaces of the
body. The sleeve includes an opening at each respective end on the
respective opposing surfaces of the body. Each opening has a closed
width. The packaging article includes a product. The product has an
insert shape, the insert shape has an insert width that is greater
than or equal to the closed width of the sleeve opening. A portion
of the 3DRLM moves from a neutral state to a stretched state when
the product is inserted into the sleeve.
1. Body and 3D Loop Structure
[0060] Referring to the drawings, and initially to FIG. 1, a
packaging article is shown and indicated generally by the reference
numeral 10. The packaging article 10 includes a body 12 having a
geometric shape, the body being composed of a three-dimensional
random loop material 14. A "geometric shape," as used herein, is a
three dimensional shape or a three dimensional configuration having
a length, a width, and a height. The geometric shape can be a
regular three dimensional shape, an irregular three dimensional
shape, and combinations thereof. Nonlimiting examples of regular
three-dimensional shapes include cube, prism, sphere, cone, and
cylinder. The body may be solid or hollow. It is understood that
when the geometric shape of the body is a prism, the prism can have
a cross-sectional shape that is a regular polygon, or an irregular
polygon having three, four, five, six, seven, eight, nine, 10 or
more sides.
[0061] The body is composed of a three dimensional random loop
material 14. A "three dimensional random loop material" (or
"3DRLM") is a mass or a structure of a multitude of loops 16 formed
by allowing continuous fibers 18, to wind to permit respective
loops to come in contact with one another in a molten state and to
be heat-bonded at most of the contact points 19. Even when a great
stress to cause significant deformation is given, the 3DRLM 18
absorbs the stress with the entire net structure composed of
three-dimensional random loops melt-integrated, by deforming
itself; and once the stress is lifted, elastic resilience of the
polymer manifests itself to allow recovery to the original shape of
the structure. When a net structure composed of continuous fibers
made from a known non-elastic polymer is used as a cushioning
material, plastic deformation is developed and the recovery cannot
be achieved, thus resulting in poor heat-resisting durability. When
the fibers are not melt-bonded at contact points, the shape cannot
be retained and the structure does not integrally change its shape,
with the result that a fatigue phenomenon occurs due to the
concentration of stress, thus unbeneficially degrading durability
and deformation resistance. In certain embodiments, melt-bonding is
the state where all contact points are melt-bonded.
[0062] A nonlimiting method for producing 3DRLM 14 includes the
steps of (a) heating a molten olefin-based polymer, at a
temperature 10.degree. C.-140.degree. C. higher than the melting
point of the polymer in a typical melt-extruder; (b) discharging
the molten interpolymer to the downward direction from a nozzle
with plural orifices to form loops by allowing the fibers to fall
naturally. The polymer may be used in combination with a
thermoplastic elastomer, thermoplastic non-elastic polymer or a
combination thereof. The distance between the nozzle surface and
take-off conveyors installed on a cooling unit for solidifying the
fibers, melt viscosity of the polymer, diameter of orifice and the
amount to be discharged are the elements which decide loop diameter
and fineness of the fibers. Loops are formed by holding and
allowing the delivered molten fibers to reside between a pair of
take-off conveyors (belts, or rollers) set on a cooling unit (the
distance therebetween being adjustable), bringing the loops thus
formed into contact with one another by adjusting the distance
between the orifices to this end such that the loops in contact are
heat-bonded as they form a three-dimensional random loop structure.
Then, the continuous fibers, wherein contact points have been
heat-bonded as the loops form a three-dimensional random loop
structure, are continuously taken into a cooling unit for
solidification to give a net structure. Thereafter, the structure
is cut into a desired length and shape. The method is characterized
in that the olefin-based polymer is melted and heated at a
temperature 10.degree. C.-140.degree. C. higher than the melting
point of the interpolymer and delivered to the downward direction
in a molten state from a nozzle having plural orifices. When the
polymer is discharged at a temperature less than 10.degree. C.
higher than the melting point, the fiber delivered becomes cool and
less fluidic to result in insufficient heat-bonding of the contact
points of fibers.
[0063] Properties, such as, the loop diameter and fineness of the
fibers constituting the cushioning net structure provided herein
depend on the distance between the nozzle surface and the take-off
conveyor installed on a cooling unit for solidifying the
interpolymer, melt viscosity of the interpolymer, diameter of
orifice and the amount of the interpolymer to be delivered
therefrom. For example, a decreased amount of the interpolymer to
be delivered and a lower melt viscosity upon delivery result in
smaller fineness of the fibers and smaller average loop diameter of
the random loop. On the contrary, a shortened distance between the
nozzle surface and the take-off conveyor installed on the cooling
unit for solidifying the interpolymer results in a slightly greater
fineness of the fiber and a greater average loop diameter of the
random loop. These conditions in combination afford the desirable
fineness of the continuous fibers of from 100 denier to 100000
denier and an average diameter of the random loop of not more than
100 mm, or from 1 millimeter (mm), or 2 mm, or 10 mm to 25 mm, or
50 mm. By adjusting the distance to the aforementioned conveyor,
the thickness of the structure can be controlled while the
heat-bonded net structure is in a molten state and a structure
having a desirable thickness and flat surface formed by the
conveyors can be obtained. Too great a conveyor speed results in
failure to heat-bond the contact points, since cooling proceeds
before the heat-bonding. On the other hand, too slow a speed can
cause higher density resulting from excessively long dwelling of
the molten material. In some embodiments the distance to the
conveyor and the conveyor speed should be selected such that the
desired apparent density of 0.005-0.1 g/cc or 0.01-0.05 g/cc can be
achieved.
[0064] In an embodiment, the 3DRLM 30 has, one, some, or all of the
properties (i)-(iii) below:
[0065] (i) an apparent density from 0.016 g/cc, or 0.024 g/cc, or
0.032 g/cc to 0.040 g/cc, or 0.048 g/cc; and/or
[0066] (ii) a fiber diameter from 0.1 mm, or 0.5 mm, or 0.7 mm, or
1.0 mm, or 1.5 mm to 2.0 mm to 2.5 mm, or 3.0 mm; and/or
[0067] (iii) a thickness (machine direction) from 1.0 cm, 2.0 cm,
or 3.0, cm, or 4.0 cm, or 5.0 cm, or 10 cm, or 20 cm to 50 cm, or
75 cm, or 100 cm, or more. It is understood that the thickness of
the 3DRLM 14 will vary based on the type of product to be
packaged.
[0068] The 3DRLM 14 is formed into a three dimensional geometric
shape to form the body 12. The 3DRLM 14 is an elastic material
which can be compressed and stretched and return to its original
geometric shape. An "elastic material," as used herein, is a
rubber-like material that can be compressed and/or stretched and
which expands/retracts very rapidly to approximately its original
shape/length when the force exerting the compression and/or the
stretching is released. The three dimensional random loop material
14 has a "neutral state" when no compressive force and no stretch
force is imparted upon the 3DRLM 14. The three dimensional random
loop material 14 has "a compressed state" when a compressive force
is imparted upon the 3DRLM 14. The three dimensional random loop
material 14 has "a stretched state" when a stretching force is
imparted upon the 3DRLM 14. The body 12 can be compressed
(compressed state), be neutral (neutral state), and be stretched
(stretched state) in a similar manner.
[0069] The three dimensional random loop material 14 is composed of
one or more olefin-based polymers. The olefin-based polymer can be
one or more ethylene-based polymers, one or more propylene-based
polymers, and blends thereof.
[0070] In an embodiment, the ethylene-based polymer is an
ethylene/.alpha.-olefin polymer. Ethylene/.alpha.-olefin polymer
may be a random ethylene/.alpha.-olefin polymer or an
ethylene/.alpha.-olefin multi-block polymer. The .alpha.-olefin is
a C.sub.3-C.sub.20 .alpha.-olefin, or a C.sub.4-C.sub.12
.alpha.-olefin, or a C.sub.4-C.sub.8 .alpha.-olefin. Nonlimiting
examples of suitable .alpha.-olefin comonomer include propylene,
butene, methyl-1-pentene, hexene, octene, decene, dodecene,
tetradecene, hexadecene, octadecene, cyclohexyl-1-propene (allyl
cyclohexane), vinyl cyclohexane, and combinations thereof.
[0071] In an embodiment, the ethylene-based polymer is a
homogeneously branched random ethylene/.alpha.-olefin
copolymer.
[0072] "Random copolymer" is a copolymer wherein the at least two
different monomers are arranged in a non-uniform order. The term
"random copolymer" specifically excludes block copolymers. The term
"homogeneous ethylene polymer" as used to describe ethylene
polymers is used in the conventional sense in accordance with the
original disclosure by Elston in U.S. Pat. No. 3,645,992, the
disclosure of which is incorporated herein by reference, to refer
to an ethylene polymer in which the comonomer is randomly
distributed within a given polymer molecule and wherein
substantially all of the polymer molecules have substantially the
same ethylene to comonomer molar ratio. As defined herein, both
substantially linear ethylene polymers and homogeneously branched
linear ethylene are homogeneous ethylene polymers.
[0073] The homogeneously branched random ethylene/.alpha.-olefin
copolymer may be a random homogeneously branched linear
ethylene/.alpha.-olefin copolymer or a random homogeneously
branched substantially linear ethylene/.alpha.-olefin copolymer.
The term "substantially linear ethylene/.alpha.-olefin copolymer"
means that the polymer backbone is substituted with from 0.01 long
chain branches/1000 carbons to 3 long chain branches/1000 carbons,
or from 0.01 long chain branches/1000 carbons to 1 long chain
branches/1000 carbons, or from 0.05 long chain branches/1000
carbons to 1 long chain branches/1000 carbons. In contrast, the
term "linear ethylene/.alpha.-olefin copolymer" means that the
polymer backbone has no long chain branching.
[0074] The homogeneously branched random ethylene/.alpha.-olefin
copolymers may have the same ethylene/.alpha.-olefin comonomer
ratio within all copolymer molecules. The homogeneity of the
copolymers may be described by the SCBDI (Short Chain Branch
Distribution Index) or CDBI (Composition Distribution Branch Index)
and is defined as the weight percent of the polymer molecules
having a comonomer content within 50 percent of the median total
molar comonomer content. The CDBI of a polymer is readily
calculated from data obtained from techniques known in the art,
such as, for example, temperature rising elution fractionation
(abbreviated herein as "TREF") as described in U.S. Pat. No.
4,798,081 (Hazlitt et al.), or in U.S. Pat. No. 5,089,321 (Chum et
al.) the disclosures of all of which are incorporated herein by
reference. The SCBDI or CDBI for the homogeneously branched random
ethylene/.alpha.-olefin copolymers is preferably greater than about
30 percent, or greater than about 50 percent.
[0075] The homogeneously branched random ethylene/.alpha.-olefin
copolymer may include at least one ethylene comonomer and at least
one C.sub.3-C.sub.20 .alpha.-olefin, or at least one
C.sub.4-C.sub.12 .alpha.-olefin comonomer. For example and not by
way of limitation, the C.sub.3-C.sub.20 .alpha.-olefins may include
but are not limited to propylene, isobutylene, 1-butene, 1-hexene,
4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, and 1-decene,
or, in some embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and
1-octene.
[0076] The homogeneously branched random ethylene/.alpha.-olefin
copolymer may have one, some, or all of the following properties
(i)-(iii) below:
[0077] (i) a melt index (I.sub.2) from 1 g/10 min, or 5 g/10 min,
or 10 g/10 min, or 20 g/10 min to 30 g/10 min, or 40 g/10 min, or
50 g/10 min, and/or
[0078] (ii) a density from 0.075 g/cc, or 0.880 g/cc, or 0.890 g/cc
to 0.90 g/cc, or 0.91 g/cc, or 0.920 g/cc, or 0.925 g/cc;
and/or
[0079] (iii) a molecular weight distribution (Mw/Mn) from 2.0, or
2.5, or 3.0 to 3.5, or 4.0.
[0080] In an embodiment, the ethylene-based polymer is a
heterogeneously branched random ethylene/.alpha.-olefin
copolymer.
[0081] The heterogeneously branched random ethylene/.alpha.-olefin
copolymers differ from the homogeneously branched random
ethylene/.alpha.-olefin copolymers primarily in their branching
distribution. For example, heterogeneously branched random
ethylene/.alpha.-olefin copolymers have a distribution of
branching, including a highly branched portion (similar to a very
low density polyethylene), a medium branched portion (similar to a
medium branched polyethylene) and an essentially linear portion
(similar to linear homopolymer polyethylene).
[0082] Like the homogeneously branched random
ethylene/.alpha.-olefin copolymer, the heterogeneously branched
random ethylene/.alpha.-olefin copolymer may include at least one
ethylene comonomer and at least one C.sub.3-C.sub.20 .alpha.-olefin
comonomer, or at least one C.sub.4-C.sub.12 .alpha.-olefin
comonomer. For example and not by way of limitation, the
C.sub.3-C.sub.20 .alpha.-olefins may include but are not limited
to, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene,
1-heptene, 1-octene, 1-nonene, and 1-decene, or, in some
embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene.
In one embodiment, the heterogeneously branched
ethylene/.alpha.-olefin copolymer may comprise greater than about
50% by wt ethylene comonomer, or greater than about 60% by wt., or
greater than about 70% by wt. Similarly, the heterogeneously
branched ethylene/.alpha.-olefin copolymer may comprise less than
about 50% by wt .alpha.-olefin monomer, or less than about 40% by
wt., or less than about 30% by wt.
[0083] The heterogeneously branched random ethylene/.alpha.-olefin
copolymer may have one, some, or all of the following properties
(i)-(iii) below:
[0084] (i) a density from 0.900 g/cc, or 0.0910 g/cc, or 0.920 g/cc
to 0.930 g/cc, or 0.094 g/cc;
[0085] (ii) a melt index (I.sub.2) from 1 g/10 min, or 5 g/10 min,
or 10 g/10 min, or 20 g/10 min to 30 g/10 min, or 40 g/10 min, or
50 g/10 min; and/or
[0086] (iii) an Mw/Mn from 3.0, or 3.5 to 4.0, or 4.5.
[0087] In an embodiment, the 3DRLM 14 is composed of a blend of a
homogeneously branched random ethylene/.alpha.-olefin copolymer and
a heterogeneously branched ethylene/.alpha.-olefin copolymer, the
blend having one, some, or all of the properties (i)-(v) below:
[0088] (i) a Mw/Mn from 2.5, or 3.0 to 3.5, or 4.0, or 4.5;
[0089] (ii) a melt index (I.sub.2) from 3.0 g/10 min, or 4.0 g/10
min, or 5.0 g/10 min, or 10 g/10 min to 15 g/10 min, or 20 g/10
min, or 25 g/10 min;
[0090] (iii) a density from 0.895 g/cc, or 0.900 g/cc, or 0.910
g/cc, or 0.915 g/cc to 0.920 g/cc, or 0.925 g/cc; and or
[0091] (iv) an I.sub.10/I.sub.2 ratio from 5 g/10 min, or 7 g/10
min to 10 g/10 min, or 15 g/10 min; and/or
[0092] (v) a percent crystallinity from 25%, or 30%, or 35%, or 40%
to 45%, or 50%, or 55%.
[0093] According to Crystallization Elution Fractionation (CEF),
the ethylene/.alpha.-olefin copolymer blend may have a weight
fraction in a temperature zone from 90.degree. C. to 115.degree. C.
or about 5% to about 15% by wt., or about 6% to about 12%, or about
8% to about 12%, or greater than about 8%, or greater than about
9%. Additionally, as detailed below, the copolymer blend may have a
Comonomer Distribution Constant (CDC) of at least about 100, or at
least about 110.
[0094] The present ethylene/.alpha.-olefin copolymer blend may have
at least two, or three melting peaks when measured using
Differential Scanning calorimetry (DSC) below a temperature of
130.degree. C. In one or more embodiments, the
ethylene/.alpha.-olefin copolymer blend may include a highest
temperature melting peak of at least 115.degree. C., or at least
120.degree. C., or from about 120.degree. C. to about 125.degree.
C., or from about from 122 to about 124.degree. C. Without being
bound by theory, the heterogeneously branched
ethylene/.alpha.-olefin copolymer is characterized by two melting
peaks, and the homogeneously branched ethylene/.alpha.-olefin
copolymer is characterized by one melting peak, thus making up the
three melting peaks. Further without being bound by theory, it is
believed that 3DRLM having an ethylene/.alpha.-olefin copolymer
blend with a highest DSC melting peak of at least 115.degree. C.
can demonstrate effective heat resistance when subjected to high
temperature sterilization processes. Specifically, heat and/or
steam sterilization of a 3DRLM may degrade the structural integrity
of a structure having a DSC highest melting peak below 115.degree.
C. (for example, via compression of the structure), whereas 3DRLM
having an ethylene/.alpha.-olefin copolymer blend with a highest
DSC melting peak of at least 115.degree. C. can be heat resistant
and retain their structure. Further, the ethylene/.alpha.-olefin
copolymer blend may have an enthalpy of fusion value .DELTA.H of at
least 120 J/g, or at least 125 J/g when measured via DSC.
[0095] Additionally, the ethylene/.alpha.-olefin copolymer blend
may comprise from about 10 to about 90% by weight, or about 30 to
about 70% by weight, or about 40 to about 60% by weight of the
homogeneously branched ethylene/.alpha.-olefin copolymer.
Similarly, the ethylene/.alpha.-olefin copolymer blend may comprise
from about 10 to about 90% by weight, about 30 to about 70% by
weight, or about 40 to about 60% by weight of the heterogeneously
branched ethylene/.alpha.-olefin copolymer. In a specific
embodiment, the ethylene/.alpha.-olefin copolymer blend may
comprise from about 50% to about 60% by weight of the homogeneously
branched ethylene/.alpha.-olefin copolymer, and 40% to about 50% of
the heterogeneously branched ethylene/.alpha.-olefin copolymer.
[0096] Moreover, the strength of the ethylene/.alpha.-olefin
copolymer blend may be characterized by one or more of the
following metrics. One such metric is elastic recovery. Here, the
ethylene/.alpha.-olefin copolymer blend has an elastic recovery,
Re, in percent at 100 percent strain at 1 cycle of between 50-80%.
Additional details regarding elastic recovery are provided in U.S.
Pat. No. 7,803,728, which is incorporated by reference herein in
its entirety.
[0097] The ethylene/.alpha.-olefin copolymer blend may also be
characterized by its storage modulus. In some embodiments, the
ethylene/.alpha.-olefin copolymer blend may have a ratio of storage
modulus at 25.degree. C., G' (25.degree. C.) to storage modulus at
100.degree. C., G' (100.degree. C.) of about 20 to about 60, or
from about 20 to about 50, or about 30 to about 50, or about 30 to
about 40.
[0098] Moreover, the ethylene/.alpha.-olefin copolymer blend may
also be characterized by a bending stiffness of at least about 1.15
Nmm at 6 s, or at least about 1.20 Nmm at 6 s, or at least about
1.25 Nmm at 6 s, or at least about 1.35 Nmm at 6 s. Without being
bound by theory, it is believed that these stiffness values
demonstrate how the ethylene/.alpha.-olefin copolymer blend will
provide cushioning support when incorporated into 3DRLM fibers
bonded to form a cushioning net structure.
[0099] In an embodiment, the ethylene-based polymer is an
ethylene/.alpha.-olefin interpolymer composition having one, some,
or all of the following properties (i)-(v) below:
[0100] (i) a highest DSC temperature melting peak from 90.0.degree.
C. to 115.0.degree. C.; and/or
[0101] (ii) a zero shear viscosity ratio (ZSVR) from 1.40 to 2.10;
and/or
[0102] (iii) a density in the range of from 0.860 to 0.925 g/cc;
and/or
[0103] (iv) a melt index (I.sub.2) from 1 g/10 min to 25 g/10 min;
and/or
[0104] (v) a molecular weight distribution (Mw/Mn) in the range of
from 2.0 to 4.5.
[0105] In an embodiment, the ethylene-based polymer contains a
functionalized commoner such as an ester. The functionalized
comonomer can be an acetate commoner or an acrylate comonomer.
Nonlimiting examples of suitable ethylene-based polymer with
functionalized comonomer include ethylene vinyl acetate (EVA),
ethylene methyl acrylate EMA, ethylene ethyl acrylate (EEA), and
any combination thereof.
[0106] In an embodiment, the olefin-based polymer is a
propylene-based polymer. The propylene-based polymer can be a
propylene homopolymer or a propylene/.alpha.-olefin polymer. The
.alpha.-olefin is a C.sub.2 .alpha.-olefin (ethylene) or a
C.sub.4-C.sub.12 .alpha.-olefin, or a C.sub.4-C.sub.8
.alpha.-olefin. Nonlimiting examples of suitable .alpha.-olefin
comonomer include ethylene, butene, methyl-1-pentene, hexene,
octene, decene, dodecene, tetradecene, hexadecene, octadecene,
cyclohexyl-1-propene (allyl cyclohexane), vinyl cyclohexane, and
combinations thereof.
[0107] In an embodiment, the propylene interpolymer includes from
82 wt % to 99 wt % units derived from propylene and from 18 wt % to
1 wt % units derived from ethylene, having one, some, or all of the
properties (i)-(vi) below:
[0108] (i) a density of from 0.840 g/cc, or 0.850 g/cc to 0.900
g/cc; and/or
[0109] (ii) a highest DSC melting peak temperature from
50.0.degree. C. to 120.0.degree. C.; and/or
[0110] (iii) a melt flow rate from 1 g/10 min, or 2 g/10 min to 50
g/10 min, or 100 g/10 min; and/or
[0111] (iv) a Mw/Mn of less than 4; and/or
[0112] (v) a percent crystallinity in the range of from 0.5% to
45%; and/or
[0113] (vi) a DSC crystallization onset temperature, Tc-Onset, of
less than 85.degree. C.
[0114] In an embodiment, the olefin-based polymer used in the
manufacture of the 3DRLM 14 contains one or more optional
additives. Nonlimiting examples of suitable additives include
stabilizer, antimicrobial agent, antifungal agent, antioxidant,
processing aid, ultraviolet (UV) stabilizer, slip additive,
antiblocking agent, color pigment or dyes, antistatic agent,
filler, flame retardant, and any combination thereof.
2. Sleeve
[0115] The body 12 has a sleeve 20. A "sleeve," as used herein, is
an orifice that extends through the interior of the body, the
sleeve having a first end on a first surface of the body and an
opposing second end on an opposing second surface of the body. The
sleeve is a channel formed through the surrounding 3DRLM 14 for
receiving, holding, and supporting an object within the body
interior. FIGS. 1-3 show the sleeve 20 has a first end 21a with an
opening 22. The sleeve 20 has a second end 21b with an opening 23.
The openings 22,23 provide ingress and egress into/from the sleeve.
Each opening 22, 23 is located on an outer surface, or on an
outermost surface, of the body 12.
[0116] The opening (and/or the sleeve) can be formed in the body
during the fabrication of the 3DRLM. Alternatively, the opening
(and/or the sleeve) can be formed post-fabrication by cutting a
slit into the body with a blade member or other cutting device. In
this way, the opening (sleeve) can be a slit, formed by cutting the
3DRLM 14 with a blade, such as an electric knife, for example.
[0117] Each opening 22, 23 has a closed width. A "closed width," as
used herein, is the width of the opening (sleeve) when the three
dimensional random loop material is in the neutral state. FIGS. 1-3
show openings 22, 23 each having a closed width, the closed width
having a distance of W1.
[0118] The packaging article 10 includes a product. A "product," as
used herein, is a tangible object with a mass of at least one gram
and having three dimensions--namely, a length, a width, and a
height. Nonlimiting examples of suitable products include consumer
electronics products, household goods, medical products,
comestibles, and any combination thereof.
[0119] Nonlimiting examples of suitable consumer electronics
products include computer disk drives, computer input and output
(I/O) devices, such as a keyboard, a mouse; speakers; video
display/monitor; computer; laptop computer; tablet computer;
cellphone; smartphone; camera; handheld computing device;
television; audio device; computer printer; 3-D printer; wearable
technology; drone; virtual reality equipment; video game equipment;
media device; accessories such as power cord and power pack; and
any combination thereof.
[0120] Nonlimiting examples of suitable household goods include
cutlery, glassware, glass picture frames, dishware, small
appliances (hair dryer, microwave oven, toaster, food processing
device, blender), light bulbs, hardware such as screwdrivers and
hammers, and decorative items such as candle holders or vases, and
any combination thereof.
[0121] Nonlimiting examples of suitable medical products include
vials, ampules, syringes, intravenous (IV) bags, medical devices
used in surgical suites including trocars, forceps, clamps,
retractors, endoscopes, staplers, specula, drills, and any
combination thereof.
[0122] Nonlimiting examples of suitable comestibles include produce
such as fruit and vegetables. Nonlimiting examples of suitable
fruit and vegetables include apple; apricot; artichoke; asparagus;
avocado; banana; beans; beets; bell peppers; blackberries;
blueberries; bok Choy; boniato; boysenberries; broccoli; Brussel
sprouts; cabbage; cantaloupe; carambola; carrots; cauliflower;
celery; chayote; cherimoya; cherries; citrus; clementines; collard
greens; coconuts; corn; cranberries; cucumber; dates; dragon
fruits; durian; eggplant; endive; escarole; feijoa; fennel; figs;
garlic; gooseberries; grapefruit; grapes; green beans; green
onions; greens (turnip, beet, collard, mustard); guava; horminy;
honeydew melon; horned melon; lettuce (iceberg, leaf and romaine);
jackfruit; jicama; kale, kiwifruit; kohirabi; kumquat; leeks;
lemons; lettuce; lima beans; limes; longan; loquat; lychee;
mandarins; malanga; mandarin oranges; mangos; mangosteen;
mulberries; mushrooms; mustard greens; napa; nectarines; okra;
onion; oranges; papayas; parsnip; passion fruit; peaches; pears;
peas; peppers (bell--red, yellow, green, chili); persimmons;
pineapple; plantains; plums; pomegranate; potatoes; prickly pear;
prunes; pummel; pumpkin; quince; radicchio; radishes; raisins;
rambutan; raspberries; red cabbage; rhubarb; romaine lettuce;
rutabaga; shallots; snap peas; snow peas; spinach; sprouts; squash
(acorn, banana, buttercup, butternut, hubbard, summer);
strawberries; starfruit; string beans; stone fruits; sweet potato;
tamarind; tomatoes, tangelo; tangerines; tomatilio; tomato; turnip;
ugli fruit; water chestnuts; waxed beans; yams; yellow squash;
yucca/cassava; zucchini; and any combination thereof.
3. Insert Width
[0123] Each opening is located on a surface of the body as
disclosed above and hereafter is referred to as "an opening
surface." The product has an insert shape. The "insert shape," as
used herein, is the cross sectional shape of the product, when the
product is being inserted into the sleeve 20. The insert shape has
a width, hereafter the "insert width," that is (i) greater than or
equal to the closed width of the sleeve 20 and (ii) is less than
the width of the opening surface 30, as shown in FIG. 1 and in FIG.
3. A portion of the 3DRLM 14 moves from a neutral state to a
stretched state when the product 24 is inserted into the pocket 20
as shown in FIG. 2.
[0124] In an embodiment, FIGS. 1-3 show the product as a consumer
electronics product, such as a laptop computer 24, for example. The
laptop computer 24 has an insert shape 26 that is a rectangle,
(cross section of the laptop computer when computer is inserted
into opening 22). The insert shape 26 has an insert width W.sub.c
shown in FIGS. 1-3. The insert width W.sub.c of the laptop computer
24 is greater than the closed width W1 of the sleeve 20. As the
laptop computer 24 is inserted into the sleeve 20, the laptop
computer 24 stretches the 3DRLM 14 and extends the length of the
opening 22 from the closed width, W1 to the insert width
W.sub.c.
[0125] The "closed height" is the height of the opening 22 (and/or
opening 23) when the 3DRLM 14 is in the neutral state. In an
embodiment, the insert shape 26 has a height, hereafter the "insert
height," that is (i) greater than or equal to the closed height,
h1, of the sleeve 20 and (ii) is less than height 32 of the opening
surface 28 shown in FIG. 1 and FIG. 3. In a further embodiment, the
product 24 has an insert height, h.sub.c, that is greater than the
closed height, h1, of the opening 22 and/or the opening 23.
[0126] A portion of the 3DRLM 14 moves from a neutral state to a
stretched state when the product 24 is inserted into the sleeve 20
as shown in FIG. 2. FIG. 3 shows the laptop computer 24 fully
residing in the sleeve 20. The 3DRLM 14 stretches so the width of
the sleeve 20 expands from the closed width W1 to the insert width
W.sub.c, in order to accommodate the product therein. The insert
width W.sub.c is greater than the closed width, W1. The 3DRLM 14 in
contact with the product 24 stretches around the inserted product,
such that the 3DRLM 14 imparts an elastic and compressive contact
on and around the laptop computer 24. In this way, the 3DRLM 14
intimately contacts, or otherwise imparts a squeezing force, around
opposing sides, or around two sides, or around three sides, or
around four sides, or around five sides, or around six sides of the
product 24, (i.e., the laptop computer). The squeezing force of the
stretched state 3DRLM 14 around the product 24 in the sleeve 20
enables the body to apply a restraining force, or a holding force,
upon the product in the sleeve.
[0127] The opening may or may not return to the closed width once
the product is inserted into the sleeve. In an embodiment, the
opening 22 and the opening 23 each return to the closed width W1
once the product 24 is fully inserted into the sleeve 20, as shown
in FIG. 3.
[0128] In an embodiment, the insert width W.sub.c is from 1.0, or
1.01, 1.05, or 1.07, or 1.10, or 1.15, or 1.2, to 1.3, or 1.4, or
1.5 times greater than the closed width, W1 (width measured in
centimeters, cm). For example, the product can be a smartphone with
a width (i.e., insert width) of 6.4 cm (2.5 inches), a length of
14.0 cm (5.5 inches), and a perimeter of 40.0 cm. The body has an
opening with a closed width of 6.0 cm. The body also has a length
greater than 14.0 cm in order to accommodate and fully receive the
smartphone. When the smartphone is inserted into the closed width,
the 3DRLM 14 of the body moves to a stretched state, and the width
of the opening increases to the insert width of the smartphone, 6.4
cm. The insert width (6.4 cm) of the smartphone is 1.07 times
greater than the closed width (6.0 cm) of the opening.
[0129] FIG. 3 shows the opening surface 28 has a width 30. In an
embodiment, the insert width W.sub.c is from 0.4, or 0.5, or 0.6 to
0.7, or 0.8, or 0.9 times the length of the width 30 of the opening
surface 28.
[0130] In an embodiment, the body is a prism with a regular
polygonal shape. The body has a single, or one and only one,
opening on a single (or one and only one) surface.
[0131] In an embodiment, the 3DRLM 14 forms a border area around a
circumference of the product 24.
[0132] In an embodiment, the body 12 provides from 1.0 cm, or 2.0
cm, or 3.0 cm, or 4.0 cm, or 5.0 cm, or 6.0 cm, or 7.0 cm to 8.0
cm, or 9.0 cm, or 10.0 cm, or 11.0 cm, or 12.0 cm, or 13.0 cm, or
14.0 cm of 3DRLM 14 around each surface of the product 24, when the
product is fully inserted into the pocket 20. In this way, the body
is cushion around the product and protects product 24 from damage
due to falls, drops, tips, and/or stacking of the packaging article
10.
[0133] FIGS. 6-8 show an embodiment of the present disclosure
wherein a packaging article 110 is provided. The packaging article
110 includes a body 112 having a cylindrical shape, or a
substantially cylindrical shape. The body 112 is composed of, or is
otherwise formed from, a three-dimensional random loop material
114. The 3DRLM 114 can be any 3DRLM as previously disclosed herein.
The 3DRLM 214 has loops 116 and fibers 118. The 3DRLM 114 is formed
into a three dimensional shape of the body 112, in this embodiment,
a cylinder.
[0134] The body 112 has a pocket 120. A "pocket," as used herein,
is an enclosure in the interior of the body, the pocket formed by
the surrounding 3DRLM 14 for receiving, holding, and supporting an
object within the body interior. The pocket has a single opening
(or one and only one opening) for ingress and egress into/from the
enclosure. The opening is located on an outer surface, or on an
outermost surface, of the body 112.
[0135] In an embodiment, the pocket is a sleeve, whereby one of the
sleeve ends has an opening and the opposing sleeve end is closed,
or otherwise has no opening. The closed sleeve end is composed of
3DRLM and is part of the body.
[0136] The pocket 120 has a single opening 122 for ingress and
egress into/from the pocket 120. In an embodiment, the opening 122
is located on a top outer surface of the body 112 as shown in FIGS.
6-8. The top outer surface is the opening surface 128.
[0137] The opening 122 has a closed width, W.sub.2. The product is
a comestible, such as a bottle 124 containing a liquid, such as a
liquid beverage, for example. The insert shape 126 of the bottle
124, from cross sectional view, is a circle. The insert width, Wd,
of the insert shape 126 is the diameter of the circle, or the width
(diameter) of the insert shape (circle). The insert width, Wd, is
greater than the closed width, W2, and the insert width, Wd, is
less than the width 130 of the opening surface 128.
[0138] A portion of the 3DRLM 114 surrounding the bottle 124 moves
from a neutral state to a stretched state when the bottle 124 is
inserted into the pocket 120. The body maintains its geometric
shape of a cylinder when the bottle 124 is completely inserted into
the pocket 120.
[0139] FIGS. 9-10 show an embodiment of the present disclosure
wherein a packaging article 210 is provided. The packaging article
210 includes a body 212 having a regular geometric shape that is a
rectangular prism. The body 212 is composed of, or is otherwise
formed from, a three-dimensional random loop material 214. The
3DRLM 214 can be any 3DRLM as previously disclosed herein. The
3DRLM 214 is formed into a three dimensional shape to form the body
212. The body 212 has a plurality of pockets 220a, 220b, 220c,
220d, 220e, 220f.
[0140] Each pocket 220a-220f has a respective opening 222a-222f,
that is a slit, for ingress and egress into/from the pockets
220a-220f. The openings 222a-222f are located on the same top outer
surface of the body 212. The top surface is the opening surface
228.
[0141] Each opening 222a-222f has a respective closed width, W3.
The product is a food product, such as an egg 224. The insert shape
226 for each egg, from cross sectional view, is a circle. The
insert width, We, for each egg is the diameter of the circle, or
the width (diameter) of the insert shape (circle). The insert
width, We, is greater than the closed width, W3.
[0142] A portion of the 3DRLM 214 surrounding each egg 224 moves
from a neutral state to a stretched state when the eggs 224 are
inserted into respective pockets 120a-120f. The body 214 maintains
its geometric shape of a rectangular prism when the eggs 224 are
completely inserted into respective pockets 220a-22f.
[0143] When an egg is located in its respective pocket, the elastic
nature of the 3DRLM 214 enables the 3DRLM 214 to compressively
contact all, or substantially all, the outer surface of each egg,
cushioning the entire surface of each egg and providing a holding
force, or grip, on each egg. The elasticity of the 3DRLM 214
advantageously holds the eggs in place and reduces the risk of the
eggs inadvertently falling from the packaging article 210. The
elasticity of the 3DRLM 214 can be tailored to the product (eggs in
this embodiment) by adjusting the polymeric composition used to
form the 3DRLM. The polymeric composition of the 3DRLM can be
selected such that the elasticity of the 3DRLM is sufficient to
hold the egg in the pocket with a gentle compressive force that
avoids damaging or cracking the egg.
[0144] In an embodiment, the body is a rectangular prism with the
openings 220a-220f on a single surface (i.e., opening surface 228)
of the rectangular prism.
[0145] In an embodiment, FIGS. 9-10 show the packaging article
includes a container 230. The container 230 includes a top wall
231, a bottom wall 232 and four sidewalls 234. The walls 231-234
form a compartment 236. The top wall 231 and/or the bottom wall 232
may or may not be attached to one or more sidewalls. For example,
the top wall 231 may be a discrete stand-alone component, that is
placed on the sidewalls, forming a closed compartment (along with
the bottom wall). In an embodiment, the top wall 231 is attached by
way of a hinge to one of the sidewalls (i.e., a fold between the
top wall and the sidewall).
[0146] FIGS. 9-10 show body 214 (with the product 224 (eggs))
placed in the compartment 236. The container 230 is an outer
container and provides additional protection to the product.
Nonlimiting examples of suitable material for the container 230
include paper product (paper, cardboard), polymeric material, wood,
metal, and any combination thereof.
[0147] In an embodiment, the packaging article 210 passes the drop
test and/or the vibration test as measured in accordance with
International Safe Transit Association ("ISTA") 3A. In a further
embodiment, the product of the packaging article is a laptop
computer and the packaging article passes the drop test and/or the
vibration test as measured in accordance ISTA 3A.
[0148] ISTA Test procedure 3A is for packaged-products weighing 150
lb. (70 kg) or less, and is a general simulation test for
individual packaged-products shipped through a parcel delivery
system. The 3A test is appropriate for four different types of
packages commonly distributed as individual packages, either by air
or ground. The types include standard, small, flat and elongated
packages. The 3A test includes an optional test combining Random
Vibration under Low Pressure (simulated high altitude). This tests
the container's (whether primary package of transport package)
ability to hold a seal of closure and the retention of contents
(liquid, powder or gas) without leaking.
[0149] STANDARD packaged-products are defined as any
packaged-product that does not meet any of the definitions below
for a small, flat, or elongated packaged-product. A standard
packaged-product may be packages such as traditional fiberboard
cartons, as well as plastic wooden or cylindrical containers.
[0150] SMALL packaged-products are defined as any packaged-product
where the volume is less than 13,000 cm3 (800 in.sup.3), longest
dimension is 350 mm (14 in) or less, and weight is 4.5 kg (10 lb)
or less.
[0151] FLAT packaged-products are defined as any packaged-product
where the shortest dimension is 200 mm (8 in) or less, next longest
dimension is four (4) or more times larger than the shortest
dimension, and volume is 13,000 cm.sup.3 (800 in.sup.3) or
greater.
[0152] ELONGATED packaged-products are defined as any
packaged-product where the longest dimension is 900 mm (36 in) or
greater, and both of the packages other dimensions are each 2
percent or less of that of the longest dimension.
Test Sequence STANDARD
TABLE-US-00001 [0153] For ISTA Sequence # Test Category Test Type
Certification 1 Atmospheric Temperature Required Preconditioning
TEST and Humidity BLOCK 1 2 Atmospheric Controlled Optional
Conditioning TEST Temperature BLOCK 1 and Humidity 3 Shock TEST
BLOCK 3 Drop Required 4 Vibration TEST BLOCKS Random Required 4
& 7 for Standard TEST Vibration BLOCKS 5 & 7 for Pails
Under Low And Short Cylinders Pressure 5 Vibration TEST BLOCKS
Random Optional 2 & 8 Vibration Under Low Pressure 6 Shock TEST
BLOCK 9 Drop Required
Test Sequence SMALL
TABLE-US-00002 [0154] For ISTA Sequence # Test Category Test Type
Certification 1 Atmospheric Temperature Required Preconditioning
TEST and Humidity BLOCK 1 2 Atmospheric Controlled Optional
Preconditioning TEST Temperature BLOCK 1 and Humidity 3 Shock TEST
BLOCK 3 Drop Required 4 Vibration TEST BLOCKS Random with Required
6 & 7 and without Top Load 5 Vibration TEST BLOCKS Random
Optional 2 & 8 Vibration Under Low Pressure 6 Shock TEST BLOCK
9 Drop Required
Test Sequence FLAT
TABLE-US-00003 [0155] For ISTA Sequence # Test Category Test Type
Certification 1 Atmospheric Temperature Required Preconditioning
TEST and Humidity BLOCK 1 2 Atmospheric Controlled Optional
Conditioning TEST Temperature BLOCK 1 and Humidity 3 Shock TEST
BLOCK 3 Drop Required 4 Vibration TEST BLOCKS Random with Required
4 & 7 and without Top Load 5 Vibration TEST BLOCKS Random
Optional 2 & 6 Vibration Under Low Pressure 6 Shock TEST BLOCK
9 Drop Required 7 Shock TEST BLOCK 10 Rotational Required Edge Drop
8 Shock TEST BLOCK 11 Full Rotational Required Flat Drop 9 Shock
TEST BLOCK 12 Concentration Required Impact
Test Sequence ELONGATED
TABLE-US-00004 [0156] For ISTA Sequence # Test Category Test Type
Certification 1 Atmospheric Temperature Required Preconditioning
TEST and Humidity BLOCK 1 2 Atmospheric Controlled Optional
Conditioning TEST Temperature BLOCK 1 and Humidity 3 Shock TEST
BLOCK 3 Drop Required 4 Vibration TEST BLOCKS Random with Required
4 & 7 and without Top Load 5 Vibration TEST BLOCKS Random
Optional 2 & 8 Vibration Under Low Pressure 6 Shock TEST BLOCK
9 Drop Required 7 Shock TEST BLOCK 10 Rotational Required Edge Drop
8 Shock TEST BLOCK 11 Full Rotational Required Flat Drop 9 Shock
TEST BLOCK 13 Bridge Impact Required
[0157] The present disclosure provides another packaging article.
FIGS. 11-12 show an embodiment wherein packaging article 310
includes a container 312. The container 312 includes a top wall
320, a bottom wall 322, and sidewalls 324 extending between the top
wall and the bottom wall. The walls 320-324 form a compartment 326.
The container 312 has four sidewalls 324 shown in FIGS. 11-12.
[0158] The top wall 320 and/or the bottom wall 322 may or may not
be attached to one or more sidewalls. For example, the top wall 320
may be a discrete stand-alone component, that is placed on the
sidewalls, forming a closed compartment (along with the bottom
wall). In an embodiment, the top wall 320 is attached by way of a
hinge to one of the sidewalls (i.e., a fold between the top wall
and the sidewall) as shown in FIG. 11.
[0159] The top wall and/or the bottom wall 320, 322 may comprise
one, two, or more flaps attached to respective one, two, or more
sidewalls.
[0160] The container 312 can be openable from the top wall, the
bottom wall, or a sidewall. In an embodiment, the container 12 is
openable by way of the top wall.
[0161] The walls 320-324 are made of a rigid material. Nonlimiting
examples of suitable material for the walls include cardboard,
polymeric material, metal, wood, fiberglass, and any combination
thereof. In an embodiment, container 312 has top/bottom walls and
four sidewalls, the walls 320-324 are made of a corrugated
cardboard.
[0162] In an embodiment, the container 312 is selected from a
corrugated cardboard shipping box (such as Federal Express (FedEx)
or United Parcel Service (UPS) corrugated cardboard shipping box),
or a roll end lock front container or a "RELF" container. The RELF
container may or may not include dust flaps.
[0163] The container 312 is openable and closable between an open
configuration and a closed configuration. An "open configuration"
is an arrangement of the walls which allows access to the
compartment. A "closed configuration" is an arrangement of the
walls preventing, or otherwise denying, access to the compartment.
When the container 312 is in the closed configuration, the walls
form a completely enclosed compartment. For example, FIG. 11 shows
the container 312 in an open configuration with top wall retracted,
permitting access to the compartment 326. FIG. 12 shows a
cross-sectional view of container 312 in the closed
configuration.
[0164] The packaging article 310 includes at least two bodies, each
body being a geometric shape that is an endcap 313, 315. An
"endcap," as used herein, is a prism of 3DRLM 314 having a pocket
and a surface with an opening for the pocket. The endcap is
dimensioned to have opposing sides that extend and contact opposing
sidewalls of the container when the endcap is placed in the
compartment, while maintaining accessibility to the pocket for
insertion of the product.
[0165] Each endcap 313,315 is composed of a three-dimensional
random loop material (3DRLM) 314 composed of an olefin-based
polymer as disclosed above. Each endcap 313, 315 has a respective
pocket 321a, 321b in an interior portion of the body. Each pocket
321a, 321b has a respective opening 323a, 323b. Each opening 323a,
323b is located on a respective opening surface 328a, 328b. Each
opening 323a, 323b has a closed width 330a, 330b. A product 325
(such as a laptop computer in FIGS. 11-12, for example) has
opposing ends 332a, 332b. In an embodiment, endcap 313 has the
same, or substantially the same, size and shape of endcap 315. Each
endcap 313, 315 is made of the 3DRLM as disclosed above.
[0166] Each product end 332a, 332b has an insert shape. In FIGS.
11-12, the insert shape of for each product end 332a, 332b of the
laptop computer is a rectangle. The insert width 334a, 334b for
respective product ends 332a, 332b (rectangle) of the laptop
computer is greater than the respective pocket closed widths 330a,
330b.
[0167] Endcaps 313, 315 are placed around the product 325 by
inserting the product ends 332a, 332b of the laptop computer
(product 325) into respective pocket openings 323a, 323b. For each
endcap 313, 315, a portion of (or all of) the 3DRLM 314 moves from
a neutral state to a stretched state when the product ends 332a,
332b are inserted into respective pocket openings 323a, 323b.
[0168] The endcap-product-endcap assembly is subsequently placed
into the compartment 326. In the compartment 326, endcap 313
contacts the front sidewall and extends to, and contacts, the
opposing sidewall, namely the rear sidewall. Similarly, endcap 315
contacts the front sidewall and extends to, and contacts, the
opposing rear sidewall. In the compartment 326, the endcaps 313,
315 are spaced apart from each other and are in parallel relation
to each other (or in substantially parallel relation to each
other). In other words, the endcaps 313, 315 are parallel to, and
spaced apart from, each other in the compartment 326.
[0169] FIGS. 11-12 show the endcaps 313, 315 oppose each other when
in the compartment 326 so that opening 323a of the endcap 313
opposes, or otherwise faces, the opening 323b of endcap 315.
[0170] In an embodiment, the endcap-product-endcap assembly has a
height that is greater than the depth of the compartment 326. When
the container 312 is in the closed configuration, the walls
(top/bottom walls 320,322 in particular) compress the 3DRLM 314 of
each endcap. The endcaps 313, 315 support the product 325, such
that the product 325 (laptop computer) does not contact any wall of
the container 312. FIG. 12 shows the product 325 (laptop computer)
extending from endcap 313 to endcap 315, the product 325 (laptop
computer) suspended below the top wall 320, and product 325 also
suspended above the bottom wall 322. The 3DRLM 314 at the closed
end of each endcap 313, 315 prevents the product ends 332a, 332b
from contacting any of the walls. When the container 312 is in the
closed configuration, the 3DRLM 314 of each endcap 313, 315
simultaneously experiences both (i) a stretched state (vis-a-vis
product end insertion into the pocket) and a compressed state
(compressive force imparted onto the 3DRLM by the walls).
[0171] In an embodiment, the packaging article 310 passes the drop
test and/or the vibration test as measured in accordance with ISTA
3A. In a further embodiment, the product of the packaging article
is a laptop computer and the packaging article passes the drop test
and/or the vibration test as measured in accordance with ISTA
3A.
[0172] The present packaging article 10, 110, 210, 310 each
advantageously provides one, some, or all of the following features
(1)-(5) provided below:
[0173] (1) Energy management--the body (bodies) composed of 3DRLM
provides resistance and protects the product from impact, shock,
vibration, or compression resistance typically experienced by a
packaging article during handling and shipping via truck, rail,
air, etc. The present packaging article provides ease-of-use to
package while simultaneously providing higher drop/impact and/or
vibration resistance, yielding a conformed energy management
packaging system.
[0174] (2) Conformability--as the product is introduced into the
opening, the body of 3DRLM stretches and conforms around the
product.
[0175] (3) Breathable and Hygenic--the body composed of 3DRLM
provides the packaging article with enhanced breathability, which
is advantageous for products such as fresh produce which may
contain excess moisture. Because of 3DRLM's open loop structure,
the body does not retain water and therefore the packaging article
reduces, or eliminates the risk of bacterial/fungal/mold growth
within the packaging article. Low or no risk of contamination
vis-a-vis the packaging is particularly beneficial when the product
is a comestible such as fresh produce, for example.
[0176] (4) Washable--the body is readily washable and quickly
drains and dries after washing or wetting. In addition, moisture or
wetness does not detract from the 3DRM's ability to cushion and
protect the product. The body composed of 3DRLM operates in wet or
dry conditions without loss of performance.
[0177] (5) Reusable--The body composed of 3DRLM is reusable and/or
recyclable which is advantageous over packaging material composed
of polyurethane foam, crosslinked foams, and/or polystyrene foams,
for example.
[0178] By way of example, and not limitation, examples of the
present disclosure are provided.
EXAMPLES
Example 1
[0179] Ends (product ends) of a laptop computer (laptop) are
inserted into pockets of two respective endcaps composed of 3DRLM,
as shown in FIGS. 11-12. 3DRLM has an apparent density of 0.3 g/cc
and is formed from a linear low density polyethylene (LLDPE). The
laptop ends stretch each pocket closed width to the insert width of
each respective laptop end. The endcap-laptop-endcap assembly is
placed in a FedEx Large Box having inside dimensions
17.88''.times.12.38''.times.3'' (45.40 cm.times.31.43 cm.times.7.62
cm). The endcap-laptop-endcap assembly has a height that is greater
than the height of the FedEx Large Box, i.e., a height greater than
7.62 cm. The FedEx Large Box is sealed closed, compressing the
3DRLM of each endcap and forming the packaging article. The sealed
FedEx Large Box is subsequently subjected to the drop test protocol
and the vibration test protocol in accordance with ISTA 3A. After
the ISTA 3A testing the FedEx Large Box is opened the laptop
computer is removed and the endcaps removed from the laptop. Manual
inspection finds no visual damage to the laptop. The laptop is
powered on and tested for operational damage and defects. The
laptop performs all normal and expected and functions as does the
same type of laptop that is not subjected to the ISTA 3A testing
protocol. With these results and delivery of a fully operational
laptop, the packaging article is certified as passing (i) the ISTA
3A drop test and (ii) the ISTA 3A vibration test.
[0180] It is specifically intended that the present disclosure not
be limited to the embodiments and illustrations contained herein,
but include modified forms of those embodiments including portions
of the embodiments and combinations of elements of different
embodiments as come with the scope of the following claims
* * * * *