Biodegradable packaging for shipping

Abstract

A biodegradable, thermally insulated mailer and cooler, and method of making them, are disclosed. The thermally insulated packaging material are made from laminated starch foam and bio-plastic film. The lamination can be performed by heat bonding, without the use of an adhesive bonding agent, to produce biodegradable packaging materials that can pass ASTM and other certifications for home compostability and marine environment safety.

Description

TECHNICAL FIELD OF THE INVENTION[0001]The present invention generally relates to biodegradable packaging for shipping, and, more specifically, to biodegradable shipping envelopes, coolers, and the like for shipping temperature-sensitive materials.BACKGROUND OF THE INVENTION[0002]The shipping and mailing industry offers a wide range of products and services today in order to provide efficient and effective transportation of a wide range of cargoes via both private carriers and the federal postal system. These products include a large variety of packaging designed to protect valuable cargoes, from impact, crushing, spoilage, and so forth.[0003]Cargoes that are thermally sensitive have been a substantial and growing portion of the cargoes being shipped. Such cargoes include, for example, food products, such as sea foods, and a variety of medical products, including insulin or insulin replacements. The ability to package such cargoes so that the shipper can be assured that the products ...

AI Technical Summary

Benefits of technology

The present invention is directed to providing biodegradable packaging for shipping thermally sensitive cargoes, such as food products and medical products, that do not pose environmental problems. The technical effect of the invention is to provide an alternative to traditional packaging materials, such as expanded polystyrene and foam made from corn starch, that are commonly used but cause environmental concerns. The invention provides biodegradable packaging that can decompose properly in typical composting conditions, allowing for more efficient and cost-effective shipping.

Problems solved by technology

Unfortunately, existing products that have facilitated the shipping of temperature-sensitive cargoes tend to be especially problematic for the environment.

For example, expanded polystyrene (e.g. Styrofoam®) packaging, a common insulating material, is problematic in terms of both its production and disposal (it includes benzene; furthermore, it outgases, which can be dangerous in and of itself, and causes it to loose R-value).

It requires nearly 700 gallons of oil to produce one ton of expanded polystyrene, it generally cannot be economically recycled, it is generally lethal to any creature that ingests a significant quantity, and, in the absence of expensive procedures (which, as a practical matter, are never employed) it does not decompose in any reasonable time period.

Biodegradable alternatives to expanded polystyrene have been developed, but they remain generally unacceptable alternatives.

However, it will biodegrade only in commercial facilities, and it suffers from manufacturing inconsistencies, especially in the manufacturing of thicker sheets, which render it unacceptable for many packaging applications.

For another example, foam made from corn starch exists, but it is generally unacceptable as shipping material, both because contact with moisture causes the material to degrade, and because the material in its dry form “sands,” i.e., it abrades, damaging the structural integrity of the material and producing small particulate waste.

In addition to the resulting structural degradation, the resulting waste is problematic, both aesthetically and from a practical perspective.

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