Method of making an insulation material and an insulated mailer

• US 10,583,977 B2
• Filed: 08/15/2017
• Issued: 03/10/2020
• Est. Priority Date: 08/16/2016
• Status: Active Grant

• Current Assignee: MP Global Products LLC
• Original Assignee: MP Global Products LLC
• Inventors: Collison, Alan B., Borgman, Reid
• Primary Examiner(s): Demeree, Christopher R
• Application Number:
  US15/677,738
• Publication Number:
  US 20180050857A1
• Time in Patent Office: 938 Days
• Field of Search: 229301, 428206, 428327, 428503, 442153, 442412
• CPC Class Codes: B29C 70/08 comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
• CPC Class Codes: B29C 70/12 using fibres of short length, e.g. in the form of a mat non-woven fabrics per se D04H1/00
• CPC Class Codes: B29C 70/508 and first forming a mat composed of short fibres
• CPC Class Codes: B29C 70/545 Perforating, cutting or machining during or after moulding
• CPC Class Codes: B29K 2301/12 Thermoplastic materials
• CPC Class Codes: B29K 2311/12 Paper, e.g. cardboard
• CPC Class Codes: B29L 2031/712 Containers; Packaging elements or accessories, Packages closures therefor B29L2031/56; ink or toner cartridges B29L2031/7678; squeeze tubes B29L2023/20; suitcases B29L2031/7418
• CPC Class Codes: B32B 2250/26 All layers being made of paper or paperboard
• CPC Class Codes: B32B 2260/028 Paper layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/0223 Vinyl resin fibres
• CPC Class Codes: B32B 2262/0253 Polyolefin fibres vinyl or acrylic copolymers B32B2262/0223 or B32B2262/0246
• CPC Class Codes: B32B 2262/0276 Polyester fibres
• CPC Class Codes: B32B 2262/062 Cellulose fibres, e.g. cotton
• CPC Class Codes: B32B 2262/12 Conjugate fibres, e.g. core/sheath or side-by-side
• CPC Class Codes: B32B 2262/14 Mixture of at least two fibres made of different materials
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/50 having particular mechanical properties
• CPC Class Codes: B32B 2307/72 Density
• CPC Class Codes: B32B 2307/7265 : Non-permeable
• CPC Class Codes: B32B 2307/732 : Dimensional properties
• CPC Class Codes: B32B 2398/20 : Thermoplastics
• CPC Class Codes: B32B 2439/62 : Boxes, cartons, cases
• CPC Class Codes: B32B 27/32 : comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 29/005 : next to another layer of paper or cardboard layer
• CPC Class Codes: B32B 29/02 : next to a fibrous or filamentary layer
• CPC Class Codes: B32B 29/08 : Corrugated paper or cardboard
• CPC Class Codes: B32B 3/04 : characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
• CPC Class Codes: B32B 5/02 : characterised by structural features of a fibrous or filamentary layer layer formed of metallic wires B32B15/02; layer formed of natural mineral fibres B32B19/02; layer formed of wood fibres B32B21/02
• CPC Class Codes: B32B 5/06 : characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
• CPC Class Codes: B32B 5/08 : the fibres or filaments of a layer being of different substances , e.g. conjugate fibres, mixture of different fibres
• CPC Class Codes: B32B 7/09 : by stitching, needling or sewing by mechanically connecting fibrous layers to another layer B32B5/06
• CPC Class Codes: B32B 7/12 : using interposed adhesives or interposed materials with bonding properties
• CPC Class Codes: B32B 7/14 : applied in spaced arrangements, e.g. in stripes
• CPC Class Codes: B65B 11/08 : in a single straight path
• CPC Class Codes: B65D 2565/384 : made of recycled material B65D2565/383 takes precedence
• CPC Class Codes: B65D 2565/385 : especially suited for or with means facilitating recycling
• CPC Class Codes: B65D 27/00 : Envelopes or like essentially-rectangular containers for postal or other purposes having no structural provision for thickness of contents with shock-absorbing properties B65D81/03; letter-cards B42D15/00
• CPC Class Codes: B65D 27/005 : Linings
• CPC Class Codes: B65D 5/0227 : with end closures formed by inward folding of flaps and securing them by heat-sealing, by applying adhesive to the flaps or by staples
• CPC Class Codes: B65D 81/3823 : formed of different materials, e.g. laminated or foam filling between walls
• CPC Class Codes: B65D 81/3858 : formed of different materials, e.g. laminated or foam filling between walls; for shock absorbing purposes B65D81/1275
• CPC Class Codes: D21H 13/14 : Polyalkenes, e.g. polystyrene polyethylene
• CPC Class Codes: D21H 15/10 : Composite fibres
• CPC Class Codes: D21H 21/52 : Additives of definite length or shape
• CPC Class Codes: D21H 27/10 : Packing paper packaging materials of special type or form B65D65/38
• CPC Class Codes: Y02W 30/80 : Packaging reuse or recycling, e.g. of multilayer packaging bio-packaging Y02W90/10
• CPC Class Codes: Y02W 90/10 : Bio-packaging, e.g. packing containers made from renewable resources or bio-plastics

Abstract

A method and system for producing an insulated mailer and an insulated box having an insulative paper fiber pad substructure with a density of less than about 10 pounds per cubic foot. The insulative paper fiber pad has entangled reinforcement fibers. A method of forming an insulative paper fiber pad using recycling-compatible or water soluble adhesive and paper layers is provided.

Claims

1. A repulpable insulation material comprising:

a batt formed of a mixture of cellulose fiber and between about 0.5% and about 25% thermoplastic binder fiber distributed substantially randomly within the cellulose fiber, said thermoplastic binder fiber being adhered to the cellulose fiber, wherein the thermoplastic binder fiber has a length of between about 0.5 mm to about 16 mm, and wherein subjecting the repulpable insulation material to a repulpability test produces greater than 85% fiber yield.

2. The repulpable insulation material according to claim 1 wherein the thermoplastic binder fiber is a meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly.

3. The repulpable insulation material according to claim 2 wherein the thermoplastic binder fiber has about a 65/35 percent PE/PP mixture.

4. The repulpable insulation material according to claim 1 having a compression resistance of between about 0.3 psi and about 1.4 psi at thickness compressions of between about 25% and about 50%.

5. The repulpable insulation material according to claim 1 having a compression set at about 25% of between about 5% and about 18%.

6. The repulpable insulation material according to claim 1 wherein the batt is formed of a mixture of the cellulose fiber and about 10% by weight of said thermoplastic binder fiber.

7. The repulpable insulation material according to claim 1 wherein the cellulose fiber includes at least one of paper fiber and cardboard fiber.

8. The repulpable insulation material according to claim 1 wherein the cellulose fiber includes both paper fiber and cardboard fiber.

9. The repulpable insulation material according to claim 1 wherein the repulpable insulation material has a weight of between 1000 and 1600 GSM.

24. The repulpable insulation liner according to claim 1 wherein the cellulose reinforcement fibers include at least one of paper fibers and cardboard fibers.

10. A method for producing an insulation material comprising:

mixing cellulose reinforcement fibers with about 0.5% to about 25% by weight of a meltable PE/PP bi-component thermoplastic binder fiber having a length less than about 16 mm to distribute the PE/PP bi-component thermoplastic binder fiber substantially randomly within the cellulose reinforcement fibers to form a mixture; and

applying heat to the mixture to melt the PE/PP bi-component thermoplastic binder fiber to bind the PE/PP bi-component thermoplastic binder fiber to the cellulose reinforcement fibers to from a batt, wherein subjecting the insulation material to a repulpability test produces a fiber yield of greater than 85%.

11. The method for producing an insulation material according to claim 10 further comprising coupling a first repulpable paper layer to the batt to form an insulative batt assembly.

12. The method for producing an insulation material according to claim 11 further comprising disposing a water soluble adhesive layer between the batt and the first repulpable paper layer.

13. The method for producing an insulation material according to claim 10 wherein the batt has a compression resistance of between about 0.3 psi and about 1.4 psi at compressions of between about 25% and about 50%.

14. The method for producing an insulation material according to claim 10 wherein the batt has a compression set at about 25% thickness compression of between about 5% and about 18%.

15. A repulpable insulation liner for a shipping container, the repulpable insulation liner comprising:

a first paper layer; and

a cellulose fiber pad coupled to the first paper layer, the cellulose fiber pad having cellulose reinforcement fibers interlocked with about 2% to about 25% by weight meltable PE/PP bi-component thermoplastic binder fiber distributed substantially randomly, wherein subjecting the repulpable insulation liner to a repulpability test produces greater than 85% fiber yield.

16. The repulpable insulation liner according to claim 15 wherein the meltable PE/PP bi-component thermoplastic binder fiber is a chopped fiber having a length less than about 24 mm.

17. The repulpable insulation liner according to claim 15 wherein the meltable PE/PP bi-component thermoplastic binder fiber has a length less between 0.5 to about 16 mm.

18. The repulpable insulation liner according to claim 15 further comprising one of a recycling-compatible or water soluble adhesive layer disposed between the first paper layer and the cellulose fiber pad.

19. The repulpable insulation liner according to claim 15 wherein the insulation liner has a weight of between 1000 and 1600 GSM.

20. The repulpable insulation liner according to claim 15 wherein the meltable PE/PP bi-component thermoplastic binder fiber has a plurality of different lengths.

21. The repulpable insulation liner according to claim 20 wherein the meltable PE/PP bi-component thermoplastic binder fiber has a length distribution of about 50% 1 mm length bi-component fiber and about 50% 6 mm length bi-component fiber.

22. The repulpable insulation liner according to claim 15 further comprising a second paper layer coupled to at least one of the cellulose fiber pad and the first paper layer.

23. The repulpable insulation liner according to claim 22 wherein:

the second paper layer is coupled to the first paper layer; and

the cellulose fiber pad is encapsulated between the first and second paper layers.

25. The repulpable insulation liner according to claim 15 wherein the cellulose reinforcement fibers include both paper fibers and cardboard fibers.

26. The repulpable insulation liner according to claim 15 wherein the meltable PE/PP bi-component thermoplastic binder fiber makes up about 5% to about 10% by weight of the cellulose fiber pad.

27. The repulpable insulation liner according to claim 15 wherein the meltable PE/PP bi-component thermoplastic binder fiber makes up about 10% by weight of the cellulose fiber pad.

28. An insulation liner for a shipping container, the insulation liner comprising:

a first paper layer;

a second paper layer coupled to the first paper layer to form an envelope; and

a cellulose fiber batt encapsulated between the first and second paper layers with edges of the first and second paper layers being joined together on all four sides of the cellulose fiber batt, the cellulose fiber batt including cellulose fibers bound together by thermoplastic binder fibers, wherein subjecting the cellulose fiber batt to a repulpability test produces greater than 85% fiber yield.

29. The insulation liner according to claim 28 wherein the thermoplastic binder fibers makeup between about 5% and about 10% by weight of the cellulose fiber batt.

30. The insulation liner according to claim 29 wherein the thermoplastic binder fibers makeup about 10% by weight of the cellulose fiber batt.

31. The insulation liner according to claim 29 wherein the thermoplastic binder fibers are meltable PE/PP bi-component thermoplastic binder fibers.

32. The insulation liner according to claim 28 wherein the cellulose fibers include at least one of paper fibers and cardboard fibers.

33. The insulation liner according to claim 28 wherein the cellulose fibers include both paper fibers and cardboard fibers.

34. The insulation liner according to claim 28 wherein the cellulose fiber batt has a weight of between 1000 and 1600 GSM.