U.S. patent application number 16/763016 was filed with the patent office on 2020-09-03 for protective packaging.
The applicant listed for this patent is Hewlett-Packard Development Company, L.P.. Invention is credited to Stephen Henning, Stefan Wenner.
Application Number | 20200277099 16/763016 |
Document ID | / |
Family ID | 1000004841425 |
Filed Date | 2020-09-03 |
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United States Patent
Application |
20200277099 |
Kind Code |
A1 |
Wenner; Stefan ; et
al. |
September 3, 2020 |
PROTECTIVE PACKAGING
Abstract
There is provided a method of manufacturing a protective
packaging structure comprising the steps of providing a moulded
structure comprising an attachment surface, the moulded structure
including a recessed portion defining a shock absorbing region,
applying the moulded structure to a packaging substrate using the
attachment surface, and configuring the substrate to form the
protective packaging structure. A protective packaging comprising a
moulded structure based on paper plate technology is also
disclosed.
Inventors: |
Wenner; Stefan; (Boeblingen,
DE) ; Henning; Stephen; (Fort Collins, CO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hewlett-Packard Development Company, L.P. |
Spring |
TX |
US |
|
|
Family ID: |
1000004841425 |
Appl. No.: |
16/763016 |
Filed: |
November 17, 2017 |
PCT Filed: |
November 17, 2017 |
PCT NO: |
PCT/US2017/062386 |
371 Date: |
May 11, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/5052 20130101;
B65D 5/5069 20130101; B65D 81/058 20130101; B65D 2585/689 20130101;
B65D 85/305 20130101 |
International
Class: |
B65D 5/50 20060101
B65D005/50; B65D 81/05 20060101 B65D081/05; B65D 85/30 20060101
B65D085/30 |
Claims
1. A method of manufacturing a protective packaging structure
comprising the steps of: providing a moulded structure comprising
an attachment surface, the moulded structure including a recessed
portion defining a shock absorbing region; applying the moulded
structure to a packaging substrate using the attachment surface;
and configuring the substrate to form the protective packaging
structure.
2. A method as claimed in claim 1, further comprising configuring
the substrate whereby to conform to an outer dimension of an
article to be packaged.
3. A method as claimed in claim 1, further comprising the step of
inserting a plurality of moulded structures into respective
pre-positioned depressions in an assembly tray of a conveyer system
or rotary table system.
4. A method as claimed in claim 3, wherein the moulded structures
are inserted manually by operators or automatically by robotic arms
or dispensers,
5. A method as claimed in claim 3 further comprising the step of
applying adhesive to the attachment surfaces.
6. A method as claimed in claim 5, wherein the flat sheet is
pressed onto the attachment surfaces of the moulded structures.
7. A method as claimed in claim 5, further comprising the step of
folding the flat sheet to form a half-box having the moulded
structures attached thereto.
8. A method as claimed in claim 1, wherein the step of applying
comprises one or more of: gluing; stapling; sandwiching; and
interconnecting.
9. A method as claimed in claim 8, wherein the moulded structures
are glued onto the substrate in a flat-laying arrangement and are
subsequently moved into a final position and orientation by folding
the substrate.
10. A protective packaging, the packaging comprising: a paper-based
moulded structure, the moulded structure comprising an attachment
surface and a recessed portion defining a shock absorbing region;
and a substrate, wherein the attachment surface is arranged to
secure the moulded structure to the packaging substrate.
11. A protective packaging as claimed in claim 10, wherein the
moulded structure comprises an intermediate section comprising at
least one hinge that is alignable with a hinge on the substrate to
enable joint pivoting.
12. A protective packaging as claimed in claim 10, wherein the
moulded structure comprises a first section and a second section
and the attachment surface is formed at a periphery of the first
section and second section.
13. A protective packaging as claimed in claim 11, wherein the
moulded structure can be pivoted about the hinge to form a
substantially L-shaped structure.
14. A protective packaging as claimed in claim 10, wherein the
moulded structure is secured between two substrates.
15. A protective packaging as claimed in claim 10, wherein the
packaging is an end-cap suitable for protecting a printing product.
Description
BACKGROUND
[0001] Protective packaging can be used to pack a range of products
including hardware products, such as printers, in order to prevent
damage to the products in the event of an external impact or
vibration force, For example, protective packaging prevents damage
to a product if it is accidentally dropped during transportation,
or a vibration from transportation is transferred to the outside of
the packaging, Packaging cushions can be provided around a product
to absorb any impact forces exerted onto the product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0002] Various features of certain examples will be apparent from
the detailed description which follows, taken in conjunction with
the accompanying drawings, which together illustrate, by way of
example only, a number of features, and wherein:
[0003] FIGS. 1A-E are schematics of a moulded structure for
protective packaging according to an example;
[0004] FIG. 1F is a schematic of nesting or stacking a moulded
structure according to an example;
[0005] FIGS. 2A and 2B are schematics of protective packaging
according to an example;
[0006] FIGS. 3A-C show an example of a production line for
assembling protective packaging according to an example;
[0007] FIGS. 4A-C are flow charts each showing a method for
manufacturing protective packaging according to an example;
[0008] FIGS. 5A and 5B are schematics of attachment of a moulded
structure according to an example;
[0009] FIG. 6 is a schematic of a moulded structure for protective
packaging according to an example;
[0010] FIGS. 7A and 7B are schematics of a moulded structure for
protective packaging according to an example;
[0011] FIGS. 7C and 7D are schematics of a moulded structure for
protective packaging according to an example;
[0012] FIG. 8A is a schematic of protective packaging according to
an example;
[0013] FIG. 8B is a schematic of protective packaging according to
an example;
[0014] FIG. 8C is a schematic of an arrangement of moulded
structures for protecting a hardware product according to an
example;
[0015] FIG. 9 is a schematic of a moulded structure for protective
packaging according to an example;
[0016] FIG. 10A is a schematic of a moulded structure for
protective packaging according to an example;
[0017] FIGS. 10BD are schematics of a moulded structure for
protective packaging according to an example; and
[0018] FIGS. 11A and 11B are schematics of nesting or stacking a
moulded structure according to an example.
DETAILED DESCRIPTION
[0019] In the following description, for purposes of explanation,
numerous specific details of certain examples are set forth.
Reference in the specification to "an example" or similar language
means that a particular feature, structure, or characteristic
described in connection with the example is included in at least
that one example, but not necessarily in other examples.
[0020] Packaging cushions can be provided as protective packaging
inside of a corrugated box for example, and may include soft
materials and ribs. Cushions can be made from moulded pulp,
corrugated paper, polystyrene (known as Styrofoam, EPS) or expanded
polyethylene (EPE) or other material.
[0021] Reinforced protection can be provided at the corners of
packaging, for example by gluing, to improve protection. Shock
absorbers may be adjustable, via slits in EPS, to better shape the
protective packaging to a product. For example, cushioning boards
made of paperboard can be connected to a packaging box with hinges
to protect items such as glass bottles, where the cushioning boards
are wrapped around the bottles. Other paper-based shock absorbers
may be cut to shape to fit onto packaging, such as a cardboard box,
by gluing to form the protective packaging.
[0022] The disclosure relates to paper-based protective packaging.
Protective packaging may include paper-based moulded structures or
cushions for protecting hardware products that are packed inside
the packaging. The moulded structures may resemble cushioning ribs
that are manufactured using paper-plate technology. The moulded
structures may protect a product along a flat region of the product
or an edge or corner of the product.
[0023] In an example, the moulded structure is moulded in an
I-shaped form, such as that shown in FIGS. 1A and 1B. The structure
comprises a first section 110 having a recessed region 115 and a
second section 120 having a recessed region 125. An intermediate
section 130 is disposed between the first section and the second
section. The moulded structure comprises an attachment surface 140
which may be formed at or around a periphery of the first section
and second section. The intermediate section may comprise a hinge
145 about which the first and/or second section can pivot. The
intermediate section may comprise a sloped surface 150 on the first
section or first shell and a corresponding sloped surface 160 on
the second section or second shell. The attachment surface may
comprise the sloped surfaces. In the example shown, when the first
section is pivoted about the hinge the sloped surfaces 150, 160
connect, hence closing the open V-shape of the intermediate
section. In the open configuration shown in FIGS. 1A and 1B, both
the first and second sections extend along the same direction
190.
[0024] FIGS. 1C and 1D show the moulded structure in a closed
configuration in which the first section has been rotated about the
hinge 145. In the closed configuration, the second section extends
along a first direction 190 and the first section extends along a
second direction 195. The first direction may be substantially
perpendicular to the second direction, or positioned at another
angle. The moulded structure may be substantially L-shaped. The
first section and second section may be linearly shaped with the
intermediate section forming a corner between the first section and
second section.
[0025] FIG. 1E shows the moulded structure provided with a notched
region 197. The notched region may be provided to allow a better
flow of the paper material in the hinge-area during the moulding
process (unlike vacuum moulding of plastics paper which cannot be
stretched/expanded). Although not shown in FIGS. 1A-D, a notch may
be provided in the moulded structure.
[0026] Each recessed region may define a hollow shell such that the
moulded structure can be nested within a further moulded structure.
FIG. 1F is a schematic showing the nesting or stacking of moulded
structures according to an example.
[0027] FIGS. 2A and 2B show a protective packaging in which moulded
structures are attached to a package or sleeve or shell. The
moulded structures may be arranged on the inside of the protective
packaging around a product contained within the packaging. An outer
layer of packaging may also be provided for further protection or
reinforcement during storage or shipping. In an example, the
outside shell or tray holding the moulded structures may comprise
cardboard or corrugated board, where the arrangement of the sheet
facing the outer shipping carton can add to the compressive
stacking strength of that outer shipping carton. Thus, a shipping
carton with lower strength and costs may be selected in conjunction
with these extra shells to achieve the same overall compressive
stacking strength as compared to standard cushions.
[0028] FIGS. 2A and 2B show assembly steps of how ribs are glued or
stapled to a cardboard or corrugated sheet and then folded into a
tray acting as a left and right end-cap for an inkjet printer
according to an example, The protective packaging comprises a
plurality of moulded structures attached to the outer surface of a
package, such as a cardboard box. The moulded structures may be
arranged on all sides of the package. In regions of the package
that are known to be weaker and less able to withstand an impact
force, such as a periphery of the box, additional moulded
structures may be provided for reinforcement or enhanced
protection. A product to be protected is placed within the
protective packaging such that it is surrounded by the moulded
structures. For example, the protective packaging may form an
end-cap having the moulded structures for protecting a printer or
other hardware component from external impact forces during
transit,
[0029] In an example, the moulded structures are mass produced and
are provided into pre-defined cavities (by hand or dispensers)
along a conveyor-like production line. A half-box may then be
applied on top of the arranged moulded structures as a flat sheet,
The flat sheet is pressed onto adhesive on the attachment surfaces
of the moulded structures, For example, hot-melt glue or
starch-based glue can be applied on the attachment surfaces or
rib-flanges. The flat sheet of the box and the moulded structures
are pressed together. A box can then be formed by folding the flat
sheet into a half-box or an end-cap.
[0030] FIGS. 3A-C show an example of a production line for
providing protective packaging according to an example. In
particular, moulded structures may be placed in depressions as
shown in FIG. 3B before a flat sheet of cardboard is placed over
the moulded structures as shown in FIG. 3C. In this example, there
is shown an assembly process according to an example, in which
cushioning ribs are pre-positioned in an array of assembly trays in
a conveyor system (or a rotary table system). The ribs and the
corrugated sheet may be inserted manually by operators or
automatically by robotic arms or dispensers. FIGS. 3A-C do not show
details of a glue-application step. There are many different ways
to apply the glue, for example the glue may be applied on the
flanges, on the flat sheet or substrate, with a tool (such as a
flexo-printing plate or silk printing plate), or by a robotic
arm.
[0031] A method for moulding a moulded structure comprising a
layer(s) or sheet(s) of paper for protective packaging according to
an example will now be described.
[0032] FIG. 4A is a flow chart of a method for moulding a moulded
structure for protective packaging according to an example. At
block 410 there is a step of providing a moulded structure
comprising an attachment surface, the moulded structure including a
recessed portion defining a shock absorbing region. At block 420
there is a step of applying the moulded structure to a packaging
substrate using the attachment surface, At block 430 there is a
step of configuring the substrate to form the protective packaging
structure, The attachment surface may be provided around a
periphery of the structure. At block 440 the substrate may be
configured whereby to conform to an outer dimension of an article
to be packaged.
[0033] In an example, a pre-defined moulding template may be
provided that is product or packaging specific. The moulded
structure is applied to packaging to form protective packaging for
protecting a product during transportation.
[0034] A plurality of moulded structures may each be manufactured
in a respective pre-defined moulding template on a production line.
The method may further comprise the step of inserting a plurality
of moulded structures into respective pre-positioned depressions in
an assembly tray of a conveyer system or rotary table system. The
moulded structures may be of the same type or can be a combination
of different types or sizes. The moulded structures may be inserted
manually by operators or automatically by robotic arms or
dispensers. The method may further comprise the step of arranging a
flat sheet of corrugated cardboard over the moulded structures. The
flat sheet may be pressed onto adhesive and subsequently onto the
attachment surfaces of the moulded structures. The method may
further comprise the step of folding the flat sheet to form a
half-box having the moulded structures attached thereto. The step
of applying may comprise one or more of: gluing; stapling; and
interconnecting.
[0035] FIG. 5A shows attachment of a moulded structure according to
an example. The moulded structure may be glued on a flange or
stapled at a flange. In the example of FIG. 5A is shown different
methods of how a rib can be connected to a corrugated sheet, for
example using glue or staples or interlocking. The corrugated sheet
may be provided on either side of the flange. The flange may be
sandwiched between two corrugated sheets or a corrugated sheet
having holes and allowing nesting of a plurality of moulded
structures for space-saving storage and delivery. FIG. 5B shows a
rib section that is cut open for better visibility. For example,
two ribs with two different depths inside each other, where the two
ribs add to the total protection in this area can be provided. The
amount of energy which the deformation of two nested ribs can take
on a drop is higher and having the ribs with two different depths
will generate progressive cushion-performance curves.
[0036] FIG. 6 shows non-hinged moulded structures which can be
designed with a specific shape to fit a particular product. In an
example, moulded structures are attached to a flat surface.
[0037] FIGS. 7A and 7B are schematics of a moulded structure 700
for protective packaging according to an example. The moulded
structures may be attached on an inner surface of packaging
adjacent the product to be protected.
[0038] In the example of FIG. 7A is shown the surface of the
moulded structure that receives an external impact force. The
structure comprises a first section 710 and a second section 720
and an intermediate section or region 730 located between the first
and second sections.
[0039] FIG. 7B shows an inner surface of the moulded structure
arranged such that it faces towards the product to be protected.
The moulded structure comprises two shells forming the first and
second sections, The first section comprises a first recessed
region 715 and the second section comprises a second recessed
region 725. The structure comprises an attachment surface 740 which
may be formed at or around a periphery of the first section and
second section.
[0040] FIG. 7C shows a moulded structure 700 for protective
packaging according to an example. The structure comprises a first
section 710 having a recessed region 715 and a second section 720
having a recessed region 725, Each recessed region is provided
facing towards a product to be protected, with a shell forming the
first and second sections facing outwards and away from the product
such that the shell forming the first and second sections are the
point of contact receiving an external impact force. The structure
further comprises an intermediate section 730 disposed between the
first section and the second section. As shown in FIG. 7D, the
first and second sections may be of different lengths or sizes. An
impact force may comprise a shock and/or vibration.
[0041] In an example, the moulded structure comprises an attachment
surface 740. The attachment surface may be formed at or around a
periphery of the first section and second section. The attachment
surface or flange may be provided as a flat surface or flange that
is suitable for attaching the moulded structure onto a package, for
example using adhesive. The attachment surface may extend beyond an
intersection with the shell forming the first and second sections
such that the attachment surface protrudes beyond the shells, This
provides a larger area for applying the moulded structure onto
packaging to provide a more reliable attachment. This also allows
for the application of more pressure during the gluing process
without deforming the ribs.
[0042] In the example of FIG. 7C, the intermediate section also
comprises a recessed region to protect a corner of protective
packaging. An inside corner 745 is provided that may have a surface
that is suitable for conforming to a package or for attachment to a
package, The inside corner may be suitable for hugging the corner
of a package.
[0043] The intermediate section allows the first section to be
arranged at an angle to the second section. The moulded structure
may be substantially L-shaped. For example, the angle between the
first and second sections may be around 90 degrees. The first and
second sections may extend in two directions 750, 760 that are
angled to one another. The moulded structure can be attached to a
corner of packaging. As such, the moulded structure is suitable for
absorbing an impact force at a corner of protective packaging, An
impact of a product drop will have the energy being absorbed by the
deformation of the papers in the recessed regions. The moulded
structure may act like a cushion under an external force to cause
one or more the sections to cave into the recessed region such that
the impact force is absorbed.
[0044] The structure is moulded using paper-plate manufacturing
technology in which a layer(s) or sheet(s) of paper is used. The
paper-plate manufacturing process involves a moulding process
utilizing pressure and heat using sheets of paper (as opposed to
pulp). Paper thicknesses can range from 50 gsm to 1000 gsm. The
tool for the moulding has to consider a maximum depth, angles of
the sides and surfaces of the moulded structure and the flow of
paper from a flat sheet to a moulded shape. The moulding template
may be provided to conform to a packaging onto which the moulded
structures are attached to form the protective packaging.
[0045] The moulded structure shown in FIG. 7C may be attached to
the outside of packaging on an outer surface on an opposite side of
the packaging to the product, The moulded structures may
alternatively or additionally be attached on the inside of
packaging on an inner surface adjacent the product.
[0046] In an example a moulded structure or cushioning rib has six
faces, twelve edges and eight corners. The moulded structure
protects a product from external shock and vibration.
[0047] The protective packaging may comprise moulded structures
that form paper-based ribs in either a fixed shape or an adjustable
shape or a hinged shape. The adjustable moulded structure may be
selected or modified to conform to a package or product shape. The
moulded structures may be generally L-shaped and may comprise at
least one hinge such that the angle of the L-shaped rib is
adjustable. The moulded structures have recessed regions. As such,
the moulded structures or ribs are formed of a shell of a layer or
layers of paper.
[0048] The first section and/or the second section of the moulded
structure may be provided to any desired length to suit the product
to be protected. For example, the first section may be of the same
or a different length to that of the second section. In an example,
the first section may extend along one side of the product and the
second section may extend further than the first section along
another side of the product. In this way, differently shaped
products (for example square or rectangular) can be sufficiently
protected using the moulded
[0049] The moulded structure may be provided as a fixed unit having
a shape formed directly from its moulding template. Alternatively,
the moulded structure may be provided as an adjustable unit, such
that the positions of the first and second sections relative to
each other can be adjusted.
[0050] Whilst the shapes of the moulded structures can be designed
to be product specific, the moulded structures may also be provided
in different designs having different widths, lengths and depths in
different paper thicknesses and paper types. This would allow a
packaging designer to select for each surface or edge of their
product, the moulded structure which is most applicable and
provides the best fit to the product or the best protection. In an
example, the moulded structures are provided as a mix of "standard"
shapes which can be purchased on the open marked like a commodity,
where they may have a product specific design, A packaging design
can optimize the combination of different moulded structures by
having many "standard" shaped moulded structures and a small number
of product-specific designs requiring special mould-tooling. This
would reduce the fixed one-time costs related to launching a new
packaging design, Once the designer has selected the optimum
moulded structure for and dimensions of the boxing for their
product, the protective packaging can be optimised based on drop
testing by changing some parameters, for example by applying
different paper thicknesses or paper types, to find which is most
suitable for the product in question. The moulded structures may be
delivered, with different sizes or properties, as nested moulded
structures. This would reduce the space for transporting the
moulded structures and reduce transportation costs.
[0051] The moulded structures can be attached to paper-based
packaging or a corrugated box to form the protective packaging.
FIGS. 8A and 8B are schematics of protective packaging 800
according to some examples. In an example, the cushioning ribs may
be attached using an interlocking arrangement, for example to form
a cross,
[0052] The packaging to which the moulded structures are attached
may be a half-opened corrugated box used to represent one of two
end-caps for protecting a printer. The product can be provided with
a left and right paper-based cushion to protect it during
transportation or storage. In an example, the cushions can be
attached to the packaging by gluing, stapling, or interlocking.
[0053] The moulded structures may alternatively, or additionally,
be attached to an inner surface of the packaging such that they are
arranged adjacent the product to be protected. FIGS. 8A and 8B show
a protective packaging 800 in which moulded structures 810 are
attached to a package 820. The moulded structures may be arranged
on the inside of the protective packaging next to a product 830
contained within the packaging. An outer layer of packaging 840 may
also be provided for further protection or reinforcement during
storage or shipping,
[0054] The packaging may comprise an end-cap suitable for
protecting a printing product. FIG. 8C is a schematic of an
arrangement of moulded structures 810 for protecting a hardware
product 830 according to an example. In this example, the product
is surrounded by the moulded structures (the box or package to
which the moulded structures are attached is not shown). The
moulded structures protect the product at its edges or corners.
[0055] The moulded structures may be provided to conform to the
shape of a product to be protected, for example as shown in FIG. 9.
For example, a bottle may be packed by attaching two or more ribs
to a corrugated sheet which is then rolled around the bottle. In
this example, the corrugated sheet does not have to be formed and
glued into a box.
[0056] In an example, the first and second sections are adjusted
via a hinged region. In an example, a moulded structure may
comprise more than one hinge.
[0057] FIGS. 10A-D are schematics of a moulded structure for
protective packaging according to an example. As shown in FIG. 10A,
the first and second sections may be of different lengths or sizes.
FIG. 10B shows the moulded structure in an open configuration (as
moulded). FIGS. 10C and 10D show the moulded structure in a closed
configuration (adjusted). In an example, the moulded structure is
moulded to be I-shaped and can be adjusted into an L-shaped
form.
[0058] A shown in FIG. 10B, the structure comprises a first section
1010 having a recessed region 1015 and a second section 1020 having
a recessed region 1025. Each recessed region is provided facing
towards a product to be protected, with a shell forming the first
and second sections facing outwards and away from the product such
that the shell forming the first and second sections are the point
of contact receiving an external impact force. The structure
further comprises an intermediate section 1030 disposed between the
first section and the second section. The moulded structure
comprises an attachment surface 1040. An attachment surface may be
formed at or around a periphery of the first section and second
section. The intermediate section may comprise a hinge 1045 about
which the first and/or second section can pivot. The intermediate
section may comprise a sloped surface 1050 on the first section or
first shell and a corresponding sloped surface 1060 on the second
section or second shell. The attachment surface may comprise the
sloped surfaces. In the example shown, when the first section is
pivoted about the hinge the sloped surfaces 1050, 1060 connect,
hence closing the open V-shape of the intermediate section. The
intermediate section may comprise a recessed region to protect a
corner of protective packaging. Connecting regions 1070, 1080
between the sloped surfaces and the attachment surfaces are
provided and may have a surface that is suitable for conforming to
a package or for attachment to a package, For example, when the
moulded structure is in a closed configuration the inside corner
may be suitable for hugging the corner of a package. In the open
configuration, both the first and second sections extend along the
same direction 1090.
[0059] FIGS. 10C and 10D show the moulded structure in a closed
configuration in which the first section has been rotated about the
hinge 1045. In the closed configuration, the second section extends
along a first direction 1090 and the first section extends along a
second direction 1095. The first direction may be substantially
perpendicular to the second direction. The first section and second
section may be linearly shaped with the intermediate section
forming a corner between the first section and second section.
[0060] Each recessed region may define a hollow shell such that the
moulded structure can be nested within a further moulded structure.
FIGS. 11A and 11B are schematics showing the nesting or stacking of
moulded structures according to examples.
[0061] The present disclosure provides environmental advantages
with reduced manufacturing costs. The recessed regions of the
moulded structures provide for a lighter shock absorber with lower
material costs. Foam and EPS based packaging has already been
banned by some environmental programs of selective countries, e.g.
California, Italy, which push against the use of plastic-based
packaging. Plastics packaging is being replaced by the use of
moulded pulp but moulded pulp is a costly alternative to EPS
because the pulp process starts with paper fibres in large amounts
of water, where the water is sucked or pressed out and the
remaining fibres use a significant amount of hot air drying. The
pulping process is time-consuming and costly and further compounded
by locations in areas with high relative humidity which do not
support the drying process. The manufacturing techniques used for
providing the moulded structures described herein allow for a
reduction in energy used during manufacture, thus enabling a lower
price per unit.
[0062] The present disclosure allows paper-based cushions to be
manufactured or provided at a lower production cost. The cost of
production is reduced because less energy is used during the
manufacturing since the step of drying pulp, as used with existing
methods, is removed. Much less heat energy is used using the
paper-plate manufacturing technology. There is provided a faster
moulding cycle with moulding times of around one second being
achieved per mould (as opposed to one minute as with existing
pulping techniques).
[0063] The present disclosure provides protective packaging that is
more environmentally friendly and easier to recycle, Instead of
using moulded pulp which has high energy consumption and
manufacturing costs, paper-based plate technology is used to
manufacture the moulded structures for protective packaging, where
the moulded structures can be shaped to conform to product
packaging.
[0064] The paper-based moulded structures described herein can
possess similar material characteristics as the packaging to which
they are attached. As such, the similar material used for both the
inner and outer protection makes recycling easier and simpler
because the moulded structures can be recycled with the outer
packaging or corrugated boxing in the same paper recycling stream.
The moulded structures according to the present disclosure
therefore have a higher environmental perception than existing
packaging.
[0065] While the method, apparatus and related aspects have been
described with reference to certain examples, various
modifications, changes, omissions, and substitutions can be made
without departing from the spirit of the present disclosure. In
particular, a feature or block from one example may be combined
with or substituted by a feature/block of another example.
[0066] The word "comprising" does not exclude the presence of
elements other than those listed in a claim, "a" or "an" does not
exclude a plurality, and a single processor or other unit may
fulfil the functions of several units recited in the claims.
[0067] The features of any dependent claim may be combined with the
features of any of the independent claims or other dependent
claims.
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