U.S. patent application number 15/393489 was filed with the patent office on 2018-07-05 for packaging with three-dimensional loop material.
The applicant listed for this patent is Dow Global Technologies LLC. Invention is credited to Marc S. Black, Justin D. Burke, Joshua M. Jones, Jill M. Martin, Michael Edwin Meyers, Daniel S. Woodman.
Application Number | 20180186546 15/393489 |
Document ID | / |
Family ID | 61018013 |
Filed Date | 2018-07-05 |
United States Patent
Application |
20180186546 |
Kind Code |
A1 |
Martin; Jill M. ; et
al. |
July 5, 2018 |
Packaging with Three-Dimensional Loop Material
Abstract
The present disclosure provides a packaging article. In an
embodiment, the packaging article includes (A) a container having
(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 includes (B) an upper sheet in
the compartment, the upper sheet composed of 3-dimensional random
loop material (3DRLM). The upper sheet extends between and contacts
two opposing sidewalls of the container. The packaging article
includes (C) a lower sheet in the compartment, the lower sheet
composed of 3DRLM. The lower sheet extends between and contacts two
opposing sidewalls of the container. The two sheets are in opposing
relation to each other. The packaging article includes (D) a
product disposed between the upper sheet and the lower sheet.
Inventors: |
Martin; Jill M.; (Pearland,
TX) ; Black; Marc S.; (Midland, MI) ; Jones;
Joshua M.; (Midland, MI) ; Burke; Justin D.;
(Midland, MI) ; Meyers; Michael Edwin; (Westfield,
IN) ; Woodman; Daniel S.; (Edenville, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Dow Global Technologies LLC |
Midland |
MI |
US |
|
|
Family ID: |
61018013 |
Appl. No.: |
15/393489 |
Filed: |
December 29, 2016 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 81/022 20130101;
B65D 81/113 20130101; B65D 85/32 20130101; B65D 85/34 20130101;
B65D 81/1075 20130101; B65D 5/5088 20130101; B65D 81/107
20130101 |
International
Class: |
B65D 81/107 20060101
B65D081/107; B65D 81/02 20060101 B65D081/02; B65D 5/50 20060101
B65D005/50; B65D 85/32 20060101 B65D085/32; B65D 85/34 20060101
B65D085/34 |
Claims
1. A packaging article comprising: A. 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; B. an upper sheet in the compartment, the upper sheet
composed of 3-dimensional random loop material (3DRLM), the upper
sheet extending between and contacting two opposing sidewalls of
the container; C. a lower sheet in the compartment, the lower sheet
composed of 3DRLM, the lower sheet extending between and contacting
two opposing sidewalls of the container, the two sheets in opposing
relation to each other; and D. a product disposed between the upper
sheet and the lower sheet.
2. The article of claim 1 wherein the container comprises four
sidewalls; and at least one sheet extends between and contacts each
of the four sidewalls.
3. The article of claim 1 wherein at least one of the first sheet
and the second sheet move from a neutral state to a compressed
state around the product, when the container is in a closed
configuration.
4. The article of claim 3 wherein a portion of the first sleeve
contacts a portion of the second sleeve when the container is in a
closed configuration.
5. The article of claim 4 wherein 3DRLM from the first sheet and
3DRLM from the second sheet completely surrounds a perimeter of the
product when the container is viewed from (i) a plan view and (ii)
from a sectional view.
6. The article of claim 5 wherein the two sheets compressively hold
the product in a stationary position in the container.
7. The article of claim 1 wherein at least one sheet comprises a
cut-out portion, the cut-out portion configured to receive at least
a portion the product.
8. The article of claim 1 wherein the product is a consumer
electronics product.
9. The article of claim 1 wherein the product is a comestible.
10. A packaging article comprising: A. a container having (i) a top
wall and a bottom wall; (ii) an optional sidewall extending between
the top wall and the bottom wall, the walls defining a compartment
with four corners; B. a first set of mated strips and a second set
of mated strips in the compartment, each set comprising an upper
strip and a lower strip, the upper strip and the lower strip in
opposing relation to each other, each strip composed of
3-dimensional random loop material (3DRLM); C. each set extending
between two opposing sides of the compartment, the sets spaced
apart and in parallel relation to each other; and D. a product
extending across the two sets, the product disposed between the
upper strips and the lower strips.
11. The article of claim 10 wherein at least one strip moves from a
neutral state to a compressed state around the product, when the
container is in a closed configuration; and the sets compressively
hold the product in a stationary position in the container.
12. The article of claim 11 wherein for each set a portion of the
upper strip contacts a portion of the lower strip when the
container is in the closed configuration.
13. The article of claim 10 wherein each strip comprises a cut-out
portion for receiving the product.
14. The article of claim 10 wherein the product is a consumer
electronics product.
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 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) a container having
(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 includes (B) an upper sheet in
the compartment, the upper sheet composed of 3-dimensional random
loop material (3DRLM). The upper sheet extends between and contacts
two opposing sidewalls of the container. The packaging article
includes (C) a lower sheet in the compartment, the lower sheet
composed of 3DRLM. The lower sheet extends between and contacts two
opposing sidewalls of the container. The two sheets are in opposing
relation to each other. The packaging article includes (D) a
product disposed between the upper sheet and the lower sheet.
[0007] The present disclosure provides another packaging article.
In an embodiment, the packaging article includes (A) a container
having (i) a top wall and a bottom wall, and (ii) an optional
sidewall extending between the top wall and the bottom wall. The
walls define a compartment with four corners. (B) The packaging
article includes a first set of mated strips and a second set of
mated strips in the compartment. Each set comprises an upper strip
and a lower strip. The upper strip and the lower strip are in
opposing relation to each other. Each strip is composed of
3-dimensional random loop material (3DRLM). Each set extends
between two opposing corners of the compartment. The sets are
spaced apart and in parallel relation to each other. The packaging
article includes (D) a product extending across the two sets. The
product is disposed between the upper strips and the lower
strips.
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 DUL 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 Hexacontane ##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). Differential
Scanning calorimetry (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 or
hydraulically-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-C.sub.8
.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, lneos, 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.TM. 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 an exploded perspective view of a packaging
article for a product in accordance with an embodiment of the
present disclosure.
[0048] FIG. 2 is a sectional view taken along line 2-2 of FIG. 1
showing the packaging article of FIG. 1 in an open
configuration.
[0049] FIG. 3 is a sectional view taken along line 2-2 of FIG. 1
showing the packaging article of FIG. 1 in a closed
configuration.
[0050] FIG. 4 is an exploded perspective view of a packaging
article for a product in accordance with an embodiment of the
present disclosure.
[0051] FIG. 5 is an exploded perspective view of a packaging
article, including a product, and a band element in accordance with
an embodiment of the present disclosure.
[0052] FIG. 6 is a perspective view of the packaging article with
the band element of FIG. 5.
[0053] FIG. 7 is an elevational view of the packaging article of
FIG. 5 in an open configuration.
[0054] FIG. 8 is a sectional view taken along line 8-8 of FIG. 6
showing the packaging article of FIG. 6 in the closed
configuration.
[0055] FIG. 9 is an exploded perspective view of a packaging
article for a product in accordance with an embodiment of the
present disclosure.
DETAILED DESCRIPTION
[0056] The present disclosure provides a packaging article. In an
embodiment, the packaging article includes (A) a container having
(i) a top wall and a bottom wall, and (ii) a plurality of sidewalls
extending between the top wall and bottom wall, the walls defining
a compartment. The packaging article includes (B) an upper sheet
and (C) a lower sheet located in the compartment. Each sheet is
composed of 3-dimensional random loop material (3DRLM). The upper
sheet extends between and contacts two opposing sidewalls of the
container. The lower sheet extends between and contacts two
opposing sidewalls of the container. The upper sheet is in opposing
relation to the lower sheet. The packaging article includes (D) a
product disposed between the upper sheet and the lower sheet in the
compartment.
1. Container
[0057] Referring to the drawings and initially to FIG. 1, a
packaging article is indicated generally by the reference numeral
10. The packaging article 10 includes a container 12, an upper
sheet 14, a lower sheet 16, and a product 18.
[0058] The container 12 includes a top wall 20, a bottom wall 22,
and sidewalls 24 extending between the top wall and the bottom
wall. The walls 20-24 form a compartment 26. The container 12 can
have from, three, or four, to five, or six, or seven, or eight, or
more sidewalls.
[0059] In an embodiment, the container 12 has four sidewalls 24 as
shown in FIG. 1.
[0060] The top wall 20 and/or the bottom wall 22 may or may not be
attached to one or more sidewalls. For example, the top wall 20 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 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 FIGS. 1-4.
[0061] The top wall and/or the bottom wall 20, 22 may comprise one,
two, or more flaps attached to respective one, two, or more
sidewalls.
[0062] The container 12 and the format compartment 26 have a
geometric shape. 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. It is understood that when the geometric shape of the
container 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.
[0063] The top wall and/or the bottom 20, 22 wall may comprise one,
two, or more flaps attached to respective one, two, or more
sidewalls.
[0064] The container 12 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.
[0065] The walls 20-24 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 12 has top/bottom walls and
four sidewalls the walls 20-24 are made of a corrugated
cardboard.
[0066] In an embodiment, the container 12 is a roll end lock front
container or a "RELF" container. The RELF container may or may not
include dust flaps.
[0067] The container 12 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 12 is in the closed configuration, the walls
form a completely enclosed compartment. For example, FIG. 1 shows
the container 12 in an open configuration with top wall retracted,
permitting access to the compartment 26. FIG. 3 shows a
cross-sectional view of container 12 in the closed
configuration.
2. 3-Dimensional Random Loop Material
[0068] The packaging article 10 includes upper sheet 14 and lower
sheet 16. Each sheet is composed of a 3-dimensional random loop
material 30. A "3-dimensional random loop material" (or "3DRLM") is
a mass or a structure of a multitude of loops 32 formed by allowing
continuous fibers 34, to wind, permitting respective loops to come
in contact with one another in a molten state and to be heat-bonded
at most of the contact points 36. Even when a great stress to cause
significant deformation is given, the 3DRLM 30 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.
[0069] A nonlimiting method for producing 3DRLM 30 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 (due to gravity). 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.
[0070] 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.
[0071] In an embodiment, the 3DRLM 30 has, one, some, or all of the
properties (i)-(iii) below: [0072] (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 [0073] (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 [0074] (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 30 will vary based on the type of product to
be packaged.
[0075] The 3DRLM 30 is formed into a three dimensional geometric
shape to form each sheet (i.e., a prism). The 3DRLM 30 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 30 has a "neutral state" when no compressive force
and no stretch force is imparted upon the 3DRLM 30. The three
dimensional random loop material 30 has "a compressed state" when a
compressive force is imparted upon the 3DRLM 30. The three
dimensional random loop material 30 has "a stretched state" when a
stretching force is imparted upon the 3DRLM 30. The sheets 14, 16
can be compressed (compressed state), be neutral (neutral state),
and be stretched (stretched state) in a similar manner.
[0076] The three dimensional random loop material 30 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.
[0077] 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.
[0078] In an embodiment, the ethylene-based polymer is a
homogeneously branched random ethylene/.alpha.-olefin
copolymer.
[0079] "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.
[0080] 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.
[0081] 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.
[0082] 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.
[0083] The homogeneously branched random ethylene/.alpha.-olefin
copolymer may have one, some, or all of the following properties
(i)-(iii) below: [0084] (i) a melt index (1.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 [0085] (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 [0086] (iii) a molecular weight
distribution (Mw/Mn) from 2.0, or 2.5, or 3.0 to 3.5, or 4.0.
[0087] In an embodiment, the ethylene-based polymer is a
heterogeneously branched random ethylene/.alpha.-olefin
copolymer.
[0088] 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).
[0089] 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.
[0090] The heterogeneously branched random ethylene/.alpha.-olefin
copolymer may have one, some, or all of the following properties
(i)-(iii) below: [0091] (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; [0092] (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 [0093] (iii) an Mw/Mn from 3.0, or 3.5 to 4.0, or 4.5.
[0094] In an embodiment, the 3DRLM 30 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:
[0095] (i) a Mw/Mn from 2.5, or 3.0 to 3.5, or 4.0, or 4.5; [0096]
(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; [0097] (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
[0098] (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 [0099] (v) a percent
crystallinity from 25%, or 30%, or 35%, or 40% to 45%, or 50%, or
55%.
[0100] 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.
[0101] 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.
[0102] 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.
[0103] 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.
[0104] 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.
[0105] 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.
[0106] 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: [0107] (i) a
highest DSC temperature melting peak from 90.0.degree. C. to
115.0.degree. C.; and/or [0108] (ii) a zero shear viscosity ratio
(ZSVR) from 1.40 to 2.10; and/or [0109] (iii) a density in the
range of from 0.860 to 0.925 g/cc; and/or [0110] (iv) a melt index
(I.sub.2) from 1 g/10 min to 25 g/10 min; and/or [0111] (v) a
molecular weight distribution (Mw/Mn) in the range of from 2.0 to
4.5.
[0112] 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.
[0113] 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.
[0114] 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: [0115] (i) a density of from 0.840 g/cc,
or 0.850 g/cc to 0.900 g/cc; and/or [0116] (ii) a highest DSC
melting peak temperature from 50.0.degree. C. to 120.0.degree. C.;
and/or [0117] (iii) a melt flow rate (MFR) from 1 g/10 min, or 2
g/10 min to 50 g/10 min, or 100 g/10 min; and/or [0118] (iv) a
Mw/Mn of less than 4; and/or [0119] (v) a percent crystallinity in
the range of from 0.5% to 45%; and/or [0120] (vi) a DSC
crystallization onset temperature, Tc-Onset, of less than
85.degree. C.
[0121] 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.
3. Sheets
[0122] The packaging article 10 includes upper sheet 14 and lower
sheet 16. Each sheet 14, 16, is made of 3DRLM 30. The composition,
and/or the size, and/or the shape of each sheet 14, 16 may be the
same or different. In an embodiment, the composition, the size, and
the shape of upper sheet 14 is the same as, or substantially the
same as, the composition, size, and shape of the lower sheet 16. In
a further embodiment, each sheet 14, 16 has the same shape that is
a prism.
[0123] The upper sheet 14 extends between and contacts at least two
opposing sidewalls of the container 12. The lower sheet 16 extends
between and contacts at least two opposing sidewalls of the
container 12. Upper sheet 14 is in opposing relation to lower sheet
16.
[0124] In an embodiment, each sheet 14, 16 is sized and shaped to
friction fit against opposing sidewalls when placed in the
compartment 26. In a further embodiment, each sheet 14,16 is
removable from the container. Each sheet 14,16 is thereby reusable
and/or recyclable.
4. Product
[0125] The packaging article 10 includes the product 18. 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.
[0126] 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; and 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.
[0127] 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.
[0128] 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.
[0129] 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.
[0130] The product 18 is disposed between the upper sheet 14 and
the lower sheet 16. A bottom surface of the upper sheet 14 contacts
the product 18 and a top surface of the lower sheet 16 contacts the
product 18.
[0131] In an embodiment, the container 12 has four sidewalls as
shown in FIG. 1. At least one of the sheets 14, 16 extends between
and contacts each of the four sidewalls. In a further embodiment,
each sheet 14, 16 extends between and contacts each of the four
sidewalls. The sheets 14, 16 are sized and shaped to fit, or
friction fit, within the compartment 26, the 3DRLM of each sheet in
contact with the inner surface of each sidewall. The product 18 is
located between, or otherwise sandwiched by, upper sheet 14 and
lower sheet 16.
[0132] Collectively, the sheets 14, 16 have a perimeter that is
greater than the perimeter of the product 18 when viewed both (i)
from plan view and (ii) when viewed from sectional view. FIG. 1
shows that sheets 14, 16 each have a perimeter greater than the
perimeter of the product 18 from top plan view. In this way, the
sheets provide a border of 3DRLM protective cushion around the
product providing cushioning and protection from vertical shock of
the product 18 in the container 12.
[0133] In an embodiment, FIG. 2 shows the container 12 in an open
configuration and the sheets 14, 16, each in the neutral state,
each sheet having a height, N. The product 18 is disposed between
the sheets 14, 16 (hereafter referred to as the
"sheet-product-sheet sandwich" or "SPS sandwich"), the SPS sandwich
having a height H1 that is greater than the depth D of the
compartment 26. When the container 12 is moved from the open
configuration in FIG. 2 to the closed configuration in FIG. 3, the
walls of the container impart a compressive force upon the sheets
14, 16. The SPS sandwich is compressed to a height, H2 equal to, or
substantially equal to, the depth D of the compartment 26. Height
H1 (open configuration) is greater than height H2 (closed
configuration). One (or both) sheets 14, 16 move from the neutral
state (N) to a compressed state, C when the container is moved from
the open configuration (FIG. 2) to the closed configuration (FIG.
3). In the closed configuration of FIG. 3, the elastic nature of
the 3DRLM 30 enables one (or both) sheets 14, 16 contort under the
compression force of the walls, the 3DRLM 30 of the sheet(s),
intimately conforming around the product 18. In other words, the
sheets 14, 16 form a reciprocal shape of the product, when the
container 12 is in the closed configuration.
[0134] In the closed configuration, the opposing relation of the
sheets 14, 16 compressively holds the product 18 in a stationary
position within the container 12. The fibers 34 of sheet 14
contact, or otherwise touch, the fibers 34 of the sheet 16. The
3DRLM 30 of sheets 14, 16 surround, and contact substantially every
surface, or contact every surface, of the product 18. The product
18 is completely surrounded, or fully engulfed, in protective 3DRLM
30 such that the product 18 is immobilized within the 3DRLM 30 and
within the container 12. In the closed configuration, the
compressed sheet(s) 14, 16 provide both vertical and lateral
support to the product 18, (i) preventing the product 18 from
moving up and down, and (ii) preventing the product 18 from moving
side to side within the container, when a lateral shock load, or
other shock is imparted to the packaging article, for example. The
3DRLM 30 of sheets 14, 16 prevents the product 18 from hitting the
sidewalls (and the top/bottom walls) when the container is subject
to a lateral shock load, or other force.
[0135] FIG. 3 further shows sheets 14, 16 collectively also have a
perimeter greater than the perimeter of the product 18 along a
cross-sectional view. In this way, the sheets 14, 16 hold the
product 18 stationary, or otherwise hold the product 18 firmly in
place, in the compartment 26. The sheets prevent lateral,
longitudinal, and/or vertical movement of the product within the
container 12. The polymeric material of the 3DRLM also contributes
to impart frictional force, or a "holding force" upon the product
18 within the container 12.
[0136] In an embodiment, the packaging article 10 includes product
18 that is a laptop computer and an accessory 40 as shown in FIGS.
1-3. The accessory is located in the compartment 26 along with the
product 18. The 3DRLM 30 of sheet 14 and/or sheet 16 compresses
upon the accessory 40 to immobilize the accessory 40 within the
container 12. In a further embodiment, the size, and/or shape,
and/or dimension of one or both sheets 14, 16 is/are adjusted to
accommodate the size, and/or shape of the accessory 40 within the
compartment 26.
5. Cut-Out
[0137] FIG. 4 shows another embodiment of the packaging article. In
this embodiment, one or both of upper sheet/lower sheet 14a, 16a
includes a respective cut-out portion. A "cut-out" is a shape
formed into the 3DRLM of a sheet, the shape creating a void in the
3DRLM, the shaped-void pre-determined and adapted to receive at
least a portion of, or all of, the product. The size and shape of
the shaped-void is adapted to the size and shape of the product to
be packaged. The cut-out may be formed in a molding process, a
cutting procedure, and combinations thereof. The cut-out is present
when the 3DRLM is in the neutral state, the cut-out portion being
distinct from the compressed state and/or the stretched state of
the 3DRLM 30. In this sense, the cut-out is a void shape that is
reciprocal in shape to the positive space and shape (or a portion
of the positive space and shape) occupied by the product 18.
[0138] One or both sheets 14a, 16a can have a cut-out. Although
FIG. 4 shows lower sheet 16a having a cut-out 50, it is understood
that upper sheet 14a may also have a cut-out, alone, or in
combination with the cut-out 50.
[0139] In an embodiment, the product 18 is a laptop computer,
having a rectangular prism shape. In FIG. 4, the lower sheet 16a
has a cut-out 50 that is the void of a rectangular prism, the
cut-out 50 a void-shape sized and shaped to receive the product
18--a rectangular prism. The cut-out 50 is sized and configured to
receive, or otherwise accommodate, the entire product 18. The upper
sheet 14a is placed over lower sheet 16a, and over the cut-out 50
so that the 3DRLM 30 of the two sheets 14a, 16a fully encompasses,
or otherwise fully surrounds, the product 18. The 3DRLM fibers 34
of upper sheet 14a contact, or otherwise touch, the fibers 34 of
the lower sheet 16a. In this way, the two sheets 14a, 16a provide a
protective border around the entire outer surface of the product.
In other words, the sheets 14a, 16a collectively completely
surround the product with 3DRLM because the perimeter of collective
sheets 14a, 16a is (i) greater than the perimeter of the product
from plan view and (ii) greater than the perimeter of the product
from sectional view.
[0140] In an embodiment, the cut-out is sized and shaped to receive
the product 18 (such as a laptop computer, for example) and the
cut-out is also sized and shaped to receive an accessory (such as a
cord and/or a power pack, for example).
[0141] In an embodiment, one or both sheets 14a, 16a include a
cut-out and the product is a comestible, such as a fruit or a
vegetable, for example. The void-shape of the cut-out is adapted to
receive a portion of, or all of, the comestible. In other words,
the void-shape of the cut-out is reciprocal to (or substantially
reciprocal to) the positive space and shape occupied by the
comestible.
6. Sets of Strips
[0142] FIGS. 5-9 show other embodiments of the present packaging
article. In an embodiment, another packaging article 110 is
provided. The packaging article 110 includes (A) a container 112,
(B) a first set 114 of strips and a second set 116 of strips, and
(C) a product 118. The container 112 includes (i) a top wall 120
and a bottom wall 122, and an optional sidewall 124 extending
between the top wall and the bottom wall. The walls define a
compartment 126.
[0143] In an embodiment, the top wall 120 and the bottom wall 122
each is attached by way of a hinge to the sidewall 124 (i.e., folds
between the sidewall and each of the top wall and the bottom wall).
Alternatively, the top wall 120 is detached from the bottom wall
122.
[0144] Each set 114, 116 includes a respective pair of mated
strips. FIG. 5 shows set 114 having strip 115a and strip 115b. Set
116 includes strip 117a and strip 117b. For each set 114, 116, an
upper strip (115a, 117a) contacts, or is otherwise attached to, to
the top wall 120. For each set 114, 116, lower strip (115b, 117b)
contacts, or is otherwise attached to, the bottom wall 122. In each
set 114, 116, the strips are mated whereby the strips are in
opposing relation to each other. FIGS. 7-8 show strip 115a (117a)
in contact with the top wall, strip 115a (117a) opposing strip 115b
(117b) and strip 115b (117b) being in contact with the bottom wall
122. In each set, the strips are sized, shaped and positioned to be
mirror images of each other in the compartment 126. In an
embodiment, strip 115a (117a) has the same, or substantially the
same, size and shape of strip 115b (117b). Each strip 115a, 115b,
117a, 117b is made of the 3DRLM 130 as disclosed above.
[0145] The walls 120, 122, 124 define compartment 126 corners I, J,
K, L. Each set of strips 114, 116 extends between two opposing
corners of the compartment 126. Set 114 extends between corner I
and opposing corner J. Set 116 extends between corner K and
opposing corner L. Set 114 is spaced apart from set 116. Set 114 is
parallel to, or substantially parallel to, set 116. In other words,
the sets 114, 116 are in parallel relation to each other in a
spaced-apart manner.
[0146] The product 118 is supported by the sets, the product 118
extending from set 114 to set 116. The product is sandwiched
between upper strips 115a, 117a and lower strips 115b, 117b. In
FIG. 8, the container 112 is placed into a closed configuration and
one, some, or all of the strips 115a, 115b, 117a, 117b move from
the neutral state to a compressed state and conform around, and to
the shape of, the product 118. In this way, the strips 115a, 115b,
compressively hold the product 118 in a stationary position
(vertically, horizontally, and laterally) within the compartment
126.
[0147] In an embodiment, the packaging article 110 includes a third
set 128 of strips. The set 128 includes mated strips 129a, 129b,
each made of the 3DRLM 130. The set 128 is located between set 114
and set 116 in a spaced-apart manner, with space between set 114
and set 128, and space between set 128 and set 116. Set 128 is
parallel to set 114 and set 128 is parallel to set 116. The strips
129a, 129b are mated as discussed above with respect to strips
115a, 115b and 117a, 117b.
[0148] FIG. 6 illustrates an embodiment wherein a band element 140
maintains the container 112 in the closed configuration.
Nonlimiting examples of a suitable band element include a sleeve,
rope, twine, string, cable, belt, adhesive tape, stretch film,
shrink film, and any combination thereof. In a further embodiment,
the container 112 is a sub-container that is placed within a larger
container 160. In a further embodiment, the band element 140 is a
sleeve composed of a polymeric material the sleeve surrounding the
container 112 as shown in FIG. 6.
[0149] FIG. 9 shows another embodiment of the packaging article
110. In this embodiment, one, some, or all of the strips include a
respective cut-out portion 150a-f.
[0150] In an embodiment, the product 118 is a laptop computer, with
a rectangular prism shape. In FIG. 9, strips 115a, 115b, 117a,
117b, and 129a, 129b each have a respective cut-out portion 150a,
150b, 150c, 150d, 150e, 150f shaped to receive a portion of the
rectangular prism shape of the product 118, the laptop
computer.
[0151] For sets 114, 116, the cut-out includes ends 152a, 152b,
152c, 152d. The ends 152a-d prevent lateral movement of the product
118 within the container 112 as previously disclosed herein. The
strips 115a, 115b, 117a, 117b, 129a, and 129b prevent vertical
movement, prevent horizontal movement, and prevent lateral movement
of the product 118 within the container 112 as previously disclosed
herein.
[0152] In an embodiment, the packaging article 110 includes an
accessory. The accessory may be located in the void space in the
compartment 126 that is present between the spaced-apart strips.
Alternatively, some or all of the accessory is sandwiched between
opposing strips of one or more sets, along with the sandwiching of
the product. In a further embodiment, one or more cut-outs
150a-150f are sized and/or shaped to receive the accessory.
[0153] 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.
* * * * *