Protective articles having cellulose-based swellable composites

Abstract

The invention relates to a protective article comprising a first and a second wall. Each wall comprises a laminate enclosing an inflation space therebetween, and an inflatable composite material disposed in the inflation space. The inflatable composite material comprises a biodegradable matrix and a plurality of cellulose-based inflatable microspheres. The inflatable microspheres are configured to inflate the biodegradable matrix upon activation of the inflatable microspheres. The invention also relates to an inflatable web comprising a first layer, a second layer, and an inflatable composite material deposited between the first layer and the second layer. The invention also relates to a method for manufacturing an inflatable protective article.

Description

[0001] Cross-reference of related applications

[0002] This application claims priority to U.S. Provisional Application No. 63 / 107,412, filed on October 29, 2020, which is incorporated herein by reference in its entirety. Technical Field

[0003] This disclosure generally relates to cellulose-based expandable composite materials that, upon expansion, provide thermal insulation, sound insulation, cushioning, or a combination thereof. Furthermore, this disclosure relates to methods and apparatus for producing cellulose-based expandable composite materials, as well as methods for using cellulose-based expandable synthetic materials. Background Technology

[0004] Traditional low-density protective packaging is produced in standard, bulky, low-density configurations. These bulky, low-density configurations can include, for example, pre-formed and expanded fluid chambers (e.g., bubble wrap), pre-expanded foam, padding inserts, etc. These bulky, low-density configurations provide packaging support during transportation. However, before they can be used for packaging, they must be transported to the packaging and shipping location.

[0005] Because traditional protective packaging is already produced in a large, low-density configuration, it must be transported in this manner. This increases the overall volume of the packaging material even before it is used for packaging, thereby increasing transportation costs to get the packaging material to the packaging and shipping locations and reducing the amount of product that can be stored at these locations before it is needed.

[0006] For at least these reasons, there is a need for systems and methods for producing packaging materials with low volume and high density configurations, which can then be expanded later. Summary of the Invention

[0007] According to various embodiments of the present disclosure, a protective article is provided. The protective article includes a first wall and a second wall. Each wall includes superimposed layers enclosing an expansion space therebetween, and an expandable composite disposed in the expansion space. The layers can include biodegradable materials, and the protective article as a whole can be made of at least 75% by weight of biodegradable materials. The expandable composite includes a biodegradable matrix and a plurality of cellulose-based expandable microspheres configured to cause the biodegradable matrix to expand when the cellulose-based expandable microspheres are activated. In some embodiments, the microspheres are entrapped in the biodegradable matrix. The first wall and the second wall are superimposed on each other to define a container cavity therebetween, the container cavity being configured and dimensioned to house a product to be transported therein, and the expansion spaces of the respective walls are superimposed on each other around the container cavity. The first wall and the second wall are connected to each other on a plurality of sides of the container cavity. The expandable composite in the pair of expansion spaces is disposed and provided in a sufficient amount to provide cushioning for the product housed in the container cavity.

[0008] According to various embodiments, the respective walls can be unsealed to each other on an open side of the container cavity, the open side being dimensioned to enable the product to be inserted into the container cavity therethrough. The protective article can further include a closure on the first wall, the closure being configured to seal the first wall to the second wall to seal the open side closed to retain the product in the cavity.

[0009] According to various embodiments, the protective article further includes a web including the first walls and the second walls connected to each other at a series of locations across the web to define a plurality of connected protective packaging units, the protective packaging units being configured to be separable from each other, each packaging unit including a pair of expansion spaces superimposed on each other around at least one container cavity.

[0010] According to various embodiments, the biodegradable matrix can include a biodegradable polymer, a biodegradable binder, or a combination thereof. The biodegradable polymer can include a natural starch, a synthetic starch, cellulose, a biopolyester, a protein, a polysaccharide, or a combination thereof. The biodegradable polymer can be selected to be cellulose.

[0011] According to various embodiments, the biodegradable binder includes a starch-based binder, a cellulose-based binder, a biopolyester-based binder, a protein-based binder, a polysaccharide-based binder, or a combination thereof. The biodegradable binder can be selected to be a cellulose-based or starch-based binder.

[0012] According to various embodiments, the cellulose-based expandable microspheres can include a blowing agent. In other embodiments, the microspheres can include a reaction component, a chemical catalyst, or a combination thereof. The cellulose-based expandable microspheres can include a blowing agent including air, carbon dioxide, nitrogen, methane, ethane, propane, isobutane, n-butane, neopentane, inert gases such as argon and helium, or a combination thereof. The cellulose-based expandable microspheres can include an outer shell and an inner core material, the outer shell can include cellulose. The cellulose-based expandable microspheres can include a hydrocarbon, water, or a combination thereof. The cellulose-based expandable microspheres are configured to be heat activated. Activation can cause the cellulose-based expandable microspheres to expand, thereby expanding the biodegradable matrix. The biodegradable matrix is configured to solidify after expansion.

[0013] According to various embodiments, a protective article is provided. The protective article includes a first layer defining an expansion region and an expandable composite material in the expansion region. The expandable composite material includes a biodegradable matrix and a plurality of cellulose-based expandable microspheres configured to expand the biodegradable matrix upon activation of the cellulose-based expandable microspheres.

[0014] According to various embodiments, the first wall can include a second layer superposed on and connected to the first layer, such that a first expansion space is defined between the first layer and the second layer, enclosing the expansion region. The expandable composite material is contained in the first expansion space. The protective article can further include a second wall. The second wall includes opposing base layers superposed on and connected to each other, to define a second expansion space therebetween; and an additional amount of the expandable composite material contained in the second expansion space. The first wall and the second wall are superposed on each other to define a container cavity therebetween, the container cavity being configured and dimensioned to house a product to be transported therein, and the expansion spaces of the walls are superposed on each other around the container cavity. The first wall and the second wall are connected to each other on a plurality of sides of the container cavity.

[0015] According to various embodiments, an expandable web is provided. The expandable web includes a first layer; a second layer; and an expandable composite material in an expansion region. The expandable composite material includes a biodegradable matrix and a plurality of cellulose-based expandable microspheres configured to expand the biodegradable matrix upon activation of the cellulose-based expandable microspheres. The first layer and the second layer can each be made of at least 75% by weight of a biodegradable material.

[0016] According to various embodiments, a method for manufacturing an inflatable protective article is provided. The method includes a step of applying an inflatable composite material to a surface of a first layer. The inflatable composite material includes a biodegradable matrix and a plurality of cellulose-based inflatable microspheres configured to cause the biodegradable matrix to inflate upon activation of the cellulose-based inflatable microspheres. The method further includes a step of applying a second layer on the first layer such that the inflatable composite material is sandwiched between the first layer and the second layer. BRIEF DESCRIPTION OF DRAWINGS

[0017] The above and other features of the present disclosure will become more apparent by describing in detail some embodiments thereof with reference to the attached drawings in which:

[0018] Figure 1 is a perspective view of a web of packaging units in a fan-folded configuration according to one embodiment of the present disclosure;

[0019] Figure 2 and 3 is a top perspective view of a web of one layer for manufacturing a protective article in the system of Figure 1

[0020] Figure 4 and Figure 5 are respectively Figure 2 and Figure 3 a top perspective view of a web of one layer for manufacturing a protective article in the system of

[0021] Figure 6 is a perspective cross-sectional view of a web of protective packaging units formed by the system of Figure 2 and Figure 3 after folding the web of Figure 5 itself;

[0022] Figure 7 is a top cross-sectional view of an embodiment of a web for producing a protective article;

[0023] Figure 8 is a perspective cross-sectional view of a web of Figure 7 folding itself;

[0024] Figure 9 is a cross-sectional view of the folded web of Figure 2 and Figure 3 in the system of Figures 5-6 as viewed along section X-X of Figure 3 ;

[0025] ​Figure 10 is Figure 2 and Figure 3 in the system Figures 5-6 a cross-sectional view of the folded web along Figure 2 a cross-sectional plane XI-XI;

[0026] Figure 11 is a perspective view of a packaging unit web in a fan-folded configuration according to another embodiment of the present disclosure;

[0027] Figure 12 is a perspective cutaway view of an embodiment of a supply roll of protective packaging units of a web using Figure 1

[0028] Figure 13 is a perspective view of another embodiment of a protective packaging unit having a closed flap;

[0029] Figure 14 is a perspective cutaway view of a bagging machine including an inflation device according to one embodiment of the present disclosure; and

[0030] Figures 15-16 are, respectively, front and rear perspective views of a bagging machine according to another embodiment of the present disclosure. DETAILED DESCRIPTION

[0031] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols typically identify similar components, unless context dictates otherwise. The illustrative examples described in the detailed description, drawings, and claims are not meant to be limiting. Other examples can be utilized, and other changes can be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein, and illustrated in the Figures, can be arranged, substituted, combined, separated, and designed in a wide variety of different configurations, all of which are implicitly contemplated herein.

[0032] Figure 1 An embodiment of a web of protective articles 100 as a series of connected, separable protective packaging units 110 in a supply configuration 150 is shown. The protective articles can be selected to provide cushioning and / or insulation. For example, in one embodiment, the protective articles are provided as cushioning material to be inserted into a structure to provide structural stability to the structure such that the structure can better withstand mechanical forces with the aid of the cushioning material. In another embodiment, the protective articles are provided as insulation material to be inserted into a structure to provide at least one of thermal and / or acoustic insulation to the structure such that the insulation material can minimize the transfer of heat and / or sound through the structure.

[0033] ​The protective article can be divided into a plurality of protective packaging units. As described above, each protective packaging unit can be provided as a single unit of cushioning material to provide cushioning and / or insulation. For example, in one embodiment, the protective packaging unit is a cushion that is inserted into a structure to provide structural stability to the structure. In this embodiment, the cushion is a cushion wall that provides structural stability to the structure. In another embodiment, the protective packaging unit is a packaging container having a protective packaging wall that defines a container having a cavity provided for receiving an object (e.g., a product for shipping) therein. The packaging container can be a bag, a mailer, a box, or other packaging container that is provided for containing an object, for example, during shipping. In other embodiments, the packaging container is a food container having an insulating wall that defines a food container cavity provided to receive food such that hot food or beverage can be placed in the food container cavity without unduly increasing the temperature of the outer surface of the food container and minimizing the risk of burns associated with hot containers.

[0034] The protective article can be provided as a web. A web is a generally flat material structure having a large surface area with a thin thickness relative to the surface area.

[0035] For example, Figure 1 The packaging unit 110 described in the illustrated embodiment is a packaging container web. The packaging unit 110 is made from protective packaging walls 118, 120. The wall portions 118, 120 are two portions of a wide wall of a folded web such that the longitudinal sides 124 and the transverse sides 128 of each wall portion 118 and 120 are sealed together to define a container cavity 198 therein. The sides 124, 128 are sealed together by a sealing material applied to at least one of the inner surfaces of the walls 118, 120 corresponding to these sides 124 and 128, as described below. The walls 118, 120, the sides 124, 128, the edges 126, and the edges 130 define a container cavity 198 therebetween. In particular, the walls 118, 120 define the top and bottom boundaries of the container cavity 198, while the sides 124, 128, the edges 126, and the edges 130 define the perimeter of the container cavity 198. The container cavity 198 is in communication with the opening 197 such that the container cavity 198 can receive an object inserted through the opening 197.

[0036] The wall 118 is cut along the edge 130, defining an opening 197 between the walls 118, 120, the edge 130 of the wall 118, and the longitudinal sides 124, 126. The opening 197 is in communication with a container cavity 198 and is configured to allow insertion of an object into the packaging unit 110. In this manner, the object can be inserted longitudinally into the packaging unit 110 in a top-loading configuration. A top-loading configuration refers to an opening into which an object can be inserted that faces an adjacent packaging unit. In other embodiments, the opening is cut along a portion of the packaging unit that is adjacent to and parallel to the transverse sides, such that the object is inserted laterally into the packaging unit in a side-loading configuration, with the opening facing away from an adjacent packaging unit. In still other embodiments, the opening is cut along a wall from an edge or transverse side of the packaging unit for a distance. In this embodiment, another wall extends beyond the opening for a distance to allow the other wall to act as a flap that is subsequently closed over the wall into which the opening is cut to receive the object (e.g., the flap 630 as shown in FIG. 6). In yet another embodiment, the opening is a perforation line, score line, or other suitable structure. Figure 13

[0037] The packaging units 110 are secured to adjacent packaging units 110 along the weakened regions 116. The weakened regions 116 are perforation or slit lines, score lines, or other suitable structures that allow each packaging unit 110 to be separated from an adjacent packaging unit 110 along the web 100.

[0038] The packaging units 110 are cut from the transverse sides 124, 126 along the edges 130 to form transverse slits 122 along each side of the weakened regions 116. Such transverse slits 122 facilitate easier opening of the openings 197 and easier separation of the packaging units 110 from one another. In other embodiments, the packaging units do not have transverse slits, but rather have weakened regions along the entire edges of the packaging units.

[0039] The web can be manipulated to form a supply configuration so that the web can be conveniently extracted from the supply configuration at a later time. For example, in one embodiment, the supply configuration is in the form of a roll configuration, in which the web is wound up and the web can be subsequently pulled from the roll. In another embodiment, the supply configuration is in the form of a fan-fold configuration, such as the supply configuration 150 shown in FIG. 5, in which the web is accordion-folded to form a stack of webs that can be later pulled from the stack. Figure 1

[0040] ​​The protective article can include a wall that defines an inflation space for receiving an inflatable composite material. In one embodiment, the inflatable composite material is provided as inflatable such that the inflatable composite material can be activated to inflate under certain conditions (e.g., heat or pressure). In this embodiment, the protective article is an inflatable protective article having an inflatable form that can inflate after the inflatable composite material is activated. In another embodiment, the inflatable composite material is inflated such that the inflatable composite material has already been activated and has inflated within the wall. In this embodiment, the protective article is an inflated protective article having an inflated form after the inflatable composite material has been activated. In this embodiment, the inflated wall serves as a filler wall for a packaging container or as a cushion. In other embodiments, the protective article does not have an inflatable composite material such that the protective article is not inflatable.

[0041] For example, Figure 1 The protective article 10 of the illustrated embodiment is an inflatable protective article having an inflatable composite material that has not yet inflated. In this embodiment, the walls 118, 120 can include an inflatable composite material that can be inflated at a later time such that the walls 118, 120 form inflated walls. In the case where the packaging unit 110 is a container, such inflated walls can act as filler walls for the container to help protect an object contained within the container from impact. In other embodiments, only one of the walls 118, 120 is inflatable such that only one of the walls 118, 120 inflates when the inflatable composite material is subsequently inflated. The inflatable composite material will be discussed in further detail below.

[0042] In one embodiment, the supply configuration can be a high density configuration in which the inflatable composite material in the walls of the web of protective articles is inflatable, but is not provided in an inflated configuration, thus allowing for a more dense configuration of the web within the supply configuration. In this embodiment, the inflatable web of protective articles is a web of inflatable, connected, and separable protective article units. In this manner, a user can receive a high density configuration and inflate the web of the supply configuration at a later time. In an alternative embodiment, the supply configuration is a low density configuration in which the inflatable composite material in the walls of the web of protective articles is inflated, resulting in a lower density configuration of the web within the supply configuration. In this embodiment, the inflated web of protective articles is a web of inflated, connected, and separable protective article units. In this manner, a user can receive a low density configuration without having to inflate the web of the supply configuration at a later time.

[0043] For example, Figure 1The supply configuration 150 described in the illustrated embodiment is a high-density fan-fold configuration in which the protective articles are inflatable but not yet inflated. The packaging units 110 are folded along the weakened regions 116 such that the packaging units 110 are stacked on one another in the inflatable supply configuration 150.

[0044] With reference to Figure 2 and Figure 3 In the illustrated embodiment, the system 200 is configured to process the raw material into a web of protective articles, which in this embodiment is provided as a supply configuration 150 of a series of connected, separable protective article units 110. The system 200 pulls the substrate from a substrate supply, which in this embodiment is a substrate spool 102, 104 of individual substrates 106, 108 provided as a web. Each substrate 106, 108 is pulled from the supply as a web in a downstream direction 210. In other embodiments, other supply configurations can be used, and the separate webs can be combined into fewer webs and folded on one another to provide the layers described below. Alternatively, other embodiments use additional webs to provide the layers described below.

[0045] The substrate in this embodiment is made of paper. These paper substrates are permeable to air or water to allow vapor to be expelled from the expandable composite as it expands to be expelled through the paper substrate. In other embodiments, the substrate has vents defined along at least one of the surfaces in the substrate to expel vapor from the expandable composite. The paper substrate can be paperboard, kraft paper, fiberboard, pulp-based paper, recyclable material (e.g., recyclable paper or plastic), paper, newsprint. In other embodiments, the paper substrate includes a coating along the substrate such that the paper substrate is not air or water permeable, but allows the paper substrate to be heat sealable. For example, the coating can be wax, plastic, water resistant material, and / or stain resistant material. In such embodiments, the paper substrate can have a thickness between 20 microns and 90 microns, preferably about 30 microns. Further, the paper substrate can be 20-90 pounds per ream (or 20-90 pounds per 500 substrates). In other embodiments, the substrate can be made of a polymer (e.g., polyolefin, polyethylene, polypropylene, polyester, or other suitable polymer), foil, poly or synthetic material, and / or other suitable material having a suitable thickness, weight, and size. The substrate can also be made of a biodegradable material (e.g., paper, natural starch, synthetic starch, cellulose, biopolyester, protein, polysaccharide, or other suitable biodegradable material). As used herein, the term “biodegradable” refers to a substance that decomposes upon exposure to light, air, water, or any combination thereof, or upon the action of naturally occurring microorganisms such as bacteria, fungi, and algae. In some embodiments, the paper substrate is made primarily of biodegradable material. For example, in such embodiments, the paper substrate is made of at least 75%, 85%, or 95% by weight, or substantially entirely of biodegradable material. In some embodiments, the raw material used to convert the substrate into a packaging unit is made primarily of biodegradable material. In another embodiment, the protective article is made primarily of biodegradable material as a whole. For example, in such embodiments, the protective article is made of at least 75%, 85%, or 95% by weight, or substantially entirely of biodegradable material. Preferably, the protective article is recyclable. For example, in such embodiments, the protective article is recyclable for at least 80%, 85%, 90%, 95% by weight, or substantially all of the protective article.

[0046] The system 200 processes the substrate webs 106, 108 to provide the substrate webs 106 and 108 as a layer 140. As the substrate 140 is drawn downstream, the expandable composite applicator 212 applies an expandable composite 220 to the substrate 140. The expandable composite 220 can be configured to expand upon the application of certain expansion conditions, such as heat, pressure, or chemical reaction, or other suitable means.

[0047] The expandable composite material 220 is typically applied in a manner including regular shapes (e.g., circles, ellipses, squares, rectangles, triangles, polygons, lines, etc.), irregular shapes (such as arbitrary or random shapes), or other methods required to provide the expandable composite material along the substrate. For example, the expandable composite material 220 may be applied in a pattern that allows the expandable composite material to form continuous layers when pressure is applied in subsequent steps. In one embodiment, the expandable composite material covers most or all of the expansion area along the layer and subsequently defines an expansion space (e.g., expansion space 117, such as...) between the substrates. Figure 6 (As shown). For example, the expandable composite material is applied to the entire surface of the layer. In other embodiments, the expandable composite material 220 is applied to the layer as a continuous layer along most or all of the layer. In another embodiment, the expandable composite material 220 is applied to a portion of the layer such that the expandable composite material is applied along the layer at a distance from the edge of the layer. In some suitable embodiments, the expandable composite material 220 is applied such that some regions along the expansion area of ​​the layer have less or no expandable composite material 220, so as to facilitate easier folding along the natural hinge region in a later step of the process. For example, the linear portion of the layer includes less expandable composite material 220 relative to other portions of the layer, or the expandable composite material 220 may be absent along this portion, thus forming a natural region that allows for easier folding in subsequent steps when the expandable composite material 220 expands (e.g., region 492, as shown). Figure 7 (As shown). Alternatively or additionally, pressure may be applied along certain linear regions after the application of the expandable composite material 220, and before or after the expansion of the expandable composite material 220, to form hinges along these regions. In yet another alternative, the expandable composite material 220 may be applied with a uniform or varying thickness or width.

[0048] The expandable composite material 220 may include a matrix. The matrix may be a fluid matrix, such as a gel or liquid, thereby allowing immediate application onto the first layer 140. Alternatively or additionally, the matrix may be a solid matrix that can pass through a gel or fluid phase. The matrix may be a mixed matrix comprising a gel or liquid and a solid, such that solid particles are entrained within the gel or fluid.

[0049] The matrix can be made of a polymer, including an emulsion-based polymer. The polymer can be thermoplastic. The polymer can be at least one of ethyl vinyl acetate-ethylene, polyvinyl acetate, polyvinyl alcohol, polyvinyl acetate copolymer, polyvinyl alcohol copolymer, dextrin stabilized polyvinyl acetate, vinyl acetate copolymer, ethylene copolymer, vinyl acrylic, styrene-acrylic acid, styrene butyl rubber, polyurethane, polyolefin, biodegradable materials (e.g., cellulose and starch), and / or other suitable expandable composites.

[0050] In some embodiments, the matrix includes polyurethane, and the matrix contains more than 50%, 75%, 90%, or 95% polyurethane, based on the total weight of the matrix.

[0051] The matrix can alternatively include a polyolefin dispersion. Preferably, the matrix contains more than 50%, 75%, 90%, or 95% polyolefin, based on the total weight of the matrix. The polyolefin dispersion can be polyethylene and / or polypropylene, a vinyl thermoplastic polymer, a propylene thermoplastic polymer, a polyethylene film or foam, a polymer stabilizer including at least one polar polymer, water, and / or other suitable polyolefin dispersions. The vinyl thermoplastic polymer can include high density polyethylene (HDPE), linear low density polyethylene (LLDPE), low density polyethylene (LDPE), or combinations thereof. As used herein, the term "vinyl polymer" refers to a polymer that includes a majority of polymerized ethylene monomer (based on the total weight of the polymer), and optionally can include at least one polymerized comonomer. In some embodiments, the vinyl polymer contains more than 50%, 75%, 90%, or 95% ethylene moieties, based on the total weight of the polymer. The propylene thermoplastic polymer is an optionally oriented polypropylene (OPP). As used herein, the term "propylene polymer" refers to a polymer that includes a majority of polymerized propylene monomer (based on the total weight of the polymer), and optionally can include at least one polymerized comonomer. In some embodiments, the propylene polymer contains more than 50%, 75%, 90%, or 95% propylene moieties, based on the total weight of the polymer. Suitable polyolefin dispersions can be, for example, HYPOD® from Dow Chemical, or other suitable polyolefin dispersions. TM

[0052] ​The matrix can alternatively comprise a polyolefin-based adhesive. An adhesive is a material that can adhere to opposing surfaces without relying on the opposing surfaces having the same or complementary material to form a seal between the surfaces. An adhesive can be a liquid adhesive, which typically requires water to form a seal between the surfaces. Alternatively, an adhesive can be a dry adhesive, which typically does not require activation with water, solvents, or heat to form a seal between the surfaces. Further, an adhesive can be a pressure sensitive adhesive, which can seal surfaces together upon application of slight initial external pressure. Examples of these adhesives include water-based, acrylic, pressure sensitive adhesives, similar to the adhesives applied to packaging tape, which material secures two surfaces together with only surface contact, typically under slight initial external pressure. Examples can include dry adhesives, which typically do not require activation with water, solvents, or heat, and adhere firmly to many different surfaces. Pressure sensitive adhesives can be selected to have aggressive and / or permanent tack at room temperature. The application and use of pressure sensitive adhesives can be automated. When used in assembly, pressure sensitive adhesives can be used to save time compared to using typical liquid adhesives, which require setup or long curing times. Pressure sensitive adhesives preferably bond immediately, enabling the manufacturing process to continue uninterrupted, which can result in significant time and labor savings. Examples of water-based, acrylic pressure sensitive adhesives include those known as RHOPLEX N-1031 emulsion, RHOPLEX-N-580 emulsion, RHOPLEX-N-619 emulsion, or other suitable types of pressure sensitive adhesives. Other emulsion polymer or acrylic polymer blend adhesives are also known, and other suitable types of adhesives and / or contact adhesives can be used.

[0053] Alternatively, the matrix can be a water-based adhesive. The water-based adhesive can include a water-based polymer. In yet another alternative, the matrix can be based on starch in natural or synthetic form. The starch can be in the form of a ground microstarch powder. The ground starch particles can have a diameter between about 12 microns and about 20 microns. The starch-based matrix can include at least one of water or other solvents, surfactants, polar adhesives, or other fillers. For example, the starch-based matrix can contain up to 50% water. In some embodiments, the matrix contains 25%-80% or 30%-40% starch. Such a starch-based matrix can be biodegradable. In other suitable embodiments, the biodegradable matrix includes a starch-based adhesive.

[0054] In another alternative embodiment, the expandable composite material may be made of multiple materials separated by barriers that, when mixed or in contact with each other, cause the expandable composite material to expand into an expanded configuration. For example, the barriers may be microsphere shells, such as those disclosed in U.S. Provisional Application No. 62 / 706,110. Such microspheres may be expandable and / or ruptureable, for example, when sufficient heat is applied. The microspheres may have an outer shell and an inner core. Suitable outer shells may be made of, for example, thermoplastic polymers, including but not limited to polyacrylonitrile or PVC, as well as glass, rubber, starch, cellulose, ceramics, or other suitable materials. In other suitable embodiments, the plurality of thermally expandable microspheres comprises a solid, liquid, or gaseous core made of hydrocarbons, water, or other suitable chemicals that can be activated to cause the microsphere shell to expand or rupture. In other suitable embodiments, the microspheres may be made of biodegradable materials, such as cellulose. Cellulose-based microspheres have an outer shell that may be made of cellulose. The term "cellulose-based microsphere" as used herein refers to a microsphere whose total weight comprises a majority of cellulose. In some embodiments, the cellulose-based microspheres contain more than 50%, 75%, 90%, or 95% cellulose based on the total weight of the microspheres. In some embodiments, the expandable composite material itself is a cellulose-based expandable composite material. As used herein, the term "cellulose-based expandable composite material" refers to an expandable composite material containing a majority of cellulose based on the total weight of the expandable composite material. The cellulose-based expandable composite material preferably contains more than 50%, 75%, 90%, or 95% cellulose based on the total weight of the expandable composite material.

[0055] Microspheres can be mixed with the matrix before being applied to the web, or, for example, provided on the matrix after the matrix is ​​applied to the web by mixing the microspheres after they are applied to the web or by forcing the microspheres into the matrix, for example when the layers are pressed together.

[0056] Microspheres have an expansion temperature (T) exp ) and maximum temperature (T max At the expansion temperature, the microspheres begin to expand. If the microspheres are heated to T... max Above all, they will break. The T-cell structure of the microspheres. exp There are no particular restrictions, but the temperature range is typically between approximately 60°C and up to approximately 250°C. The T value of the microspheres... max Typically between approximately 80°C and up to approximately 300°C. In other suitable embodiments, T max Above 300℃. The microspheres are selected based on their maximum expansion temperature, depending on whether the microspheres need to rupture. maxThe heat can be generated by suitable means, such as radio frequency radiation or other suitable means, as further described below with reference to the inflation device. In other suitable embodiments, the radio frequency radiation is applied to the inflatable composite 220 at about 10-45 MHz or at a frequency appropriate for the microsphere component and the matrix material. In other embodiments, other frequencies can be used. The heating parameters selected depend on the inflatable composite or composites 220 used. In such techniques, the inflatable composite can be dispensed into a container, such as a bag, where the inflatable composite is activated and expands to fill the void of the bag. If a product is present in the container, the inflatable composite, when activated, will expand and form itself around the product.

[0057] The system 200 can include an inflation device to inflate the inflatable composite 220. In embodiments where the inflatable composite includes an emulsion polyolefin dispersion, the microspheres inflate the emulsion polyolefin dispersion when the inflatable microspheres are activated. In some embodiments, the microspheres are entrained in the emulsion polyolefin dispersion. The inflation device can include a heating element, a heating coil, a hot air applicator, a radio frequency radiation generator, an ultraviolet light applicator, a chemical reaction applicator, a pressure mechanism, or other suitable device for inflating the inflatable composite 220. The inflatable composite can include a blowing agent. In such embodiments, the inflatable microspheres, including the blowing agent, inflate themselves and cause the emulsion polyolefin dispersion to inflate once activated. In other embodiments, the inflatable composite can include a reactive component, a chemical catalyst, and a heating agent (which can apply heat to and / or raise the temperature of the inflatable composite) and / or other suitable inflation device. In this manner, the inflation device can activate the inflatable composite 220 to inflate by at least one of heat treatment, mechanical treatment, chemical treatment, or other suitable means of activating the inflatable composite 220 to inflate. For example, the inflation device can provide at least one of heat, pressure, or a chemical reaction.

[0058] Examples of blowing agents include air, carbon dioxide, nitrogen, argon, helium, methane, ethane, propane, isobutane, n-butane, neopentane, and the like. In some embodiments, the blowing agent can generally be an inert gas or any suitable material. The expandable composite can include a blowing agent. In other embodiments, the expandable composite can include a reaction component, a chemical catalyst, and a heating agent (which can apply heat to and / or increase the temperature of the expandable composite) and / or other suitable expansion means. In some embodiments, a gas or gas mixture is added to the expandable composite by mechanical means. Examples of mechanical means include agitating or foaming the expandable composite to beat air or other gas into the expandable composite and increase its volume. In other embodiments, the gas or gas mixture can also be encapsulated in microspheres. When the microspheres are activated, they expand. The expansion of the microspheres causes the expansion of the expandable composite.

[0059] The chemical reaction can include the mixing of two reaction components that react to produce a foam. In some embodiments, a catalyst is used to increase the rate of the chemical reaction. In some embodiments, the two reaction components are separated by a barrier prior to mixing and expansion. The barrier separating the reaction components can be the outer shell of a microsphere, where the core of the microsphere includes one or more reaction components, and the rupture of the microsphere releases its contents into one or several other reaction components, causing the reaction that produces the foam. Other barriers can also be used, such as walls, capsules, or other barrier-forming containers. An example of reaction components that cause expansion include mixing an isocyanate in liquid form with a multi-component liquid mixture known as a polyurethane resin. When these ingredients are brought together, carbon dioxide and water vapor are released, producing a polyurethane foam. Other reaction components that form a foam when mixed can be used.

[0060] The sealing material applicator 214 applies a sealing material 216 to the exposed surfaces of the layers 140 and / or 160. The sealing material applicator 214 can apply the sealing material 216 using a tape (such as double-sided tape) or other suitable method of applying a sealing material. In some embodiments, the sealing material includes polyethylene.

[0061] The sealing material 216 is configured to provide a seal strong enough so that when the layers 140, 160 are connected together, the sealed portions of the layers 140 and 160 are able to withstand the expansion of the expandable composite 220 without the expanding material escaping along these sealed portions. The sealing material 216 can be a strip seal, a coated configuration, or other suitable configuration for sealing the layers 140, 160 together. The sealing material 216 can be applied as a continuous layer or as a pattern of discrete strip seals.

[0062] The sealing material can be activated to form a seal under certain conditions, for example upon the application of heat or pressure. The sealing material can be made of a cold glue. The sealing material can be made of an adhesive element that provides a sealing surface. The adhesive element can be an adhesive that provides an adhesive surface as described above. Alternatively, the adhesive element can be a tacky substance that provides a tacky surface. The tacky substance can seal one surface to an opposing surface by bringing one tacky substance on the first surface into contact with the same or a complementary tacky substance along the opposing surface. While a tacky substance will not typically adhere sufficiently to other substances to adhere to them; or, in other suitable cases, the tackiness is very weak compared to the bond formed by their mutual adhesion to each other, certain tacky substances (e.g., latex tacky substances) can be mixed with water to adhere to non-tacky surfaces such that the tacky substance can remain adhered to the non-tacky surface when dried.

[0063] With reference to Figure 4 The layer 140 includes sealing material 216 applied along the longitudinal regions 144, along the longitudinal edges 142, transverse regions 146. In other embodiments, the sealing material 216 can be applied along the longitudinal regions 144 adjacent to but distanced from the longitudinal edges 142. In Figure 4 In the illustrated embodiment, the sealing material 216 is applied along the transverse regions 146 that are longitudinally spaced apart from each other as well as between the longitudinal regions 144. In other embodiments, the sealing material 216 is applied along the layer 140 parallel to the longitudinal regions 144. In another embodiment, the sealing material 216 is applied only along the longitudinal regions 144. In this embodiment, the layer 160 is free of sealing material. The layer 160 defines regions configured to correspond to the portions of the layer 140 that include the sealing material 216, such that when the layers 140, 160 are subsequently joined together, the regions 144, 146 of the layer 140 having the sealing material 216 are joined with corresponding regions of the layer 160 that are free of sealing material. In particular, the layer 160 defines longitudinal regions 164 and edges 162 configured to correspond to the longitudinal regions 144 and edges 142, and transverse regions 166 configured to correspond to the transverse regions 146 when the layers 140, 160 are joined together. In preferred embodiments, the layers 140, 160 are biodegradable materials, and the protective article is biodegradable as a whole. Biodegradable protective articles include, for example, biodegradable layers, biodegradable composite materials including a biodegradable matrix, and a plurality of cellulose-based swellable microspheres. The biodegradable layer can include a plastic matrix, for example a polyolefin, such as a polyethylene film or foam.

[0064] In other embodiments, the second layer 160 also includes a sealing material along the regions 164, 166 to provide a stronger seal between the layers 140, 160. In this embodiment, a longitudinal sealing material is applied along the longitudinal regions 164 and a transverse sealing material is applied along the transverse regions 166, such that the sealing material along the regions 164, 166 corresponds to the sealing material along the regions 144, 146 when the layers 140, 160 are joined together. For example, the one or more longitudinal seals and the one or more transverse seals can include pressure-activated adhesive, cold glue (e.g., collagen-based glue, polyvinyl acetate-based glue, or other suitable glue), and / or other suitable sealing material.

[0065] The expandable composite 220 is applied along an expansion region 148 on the layer 140. The expansion region 148 is bounded by the longitudinal regions 144 and the transverse regions 146 to define a perimeter around the expansion region 148. The layer 160 defines an expansion region 168 that is configured to correspond to the expansion region 148 when the layers 140, 160 are joined together. The expansion region 168 is bounded by the longitudinal regions 164 and the transverse regions 166 to define a perimeter around the expansion region 168. When the layers 140, 160 are subsequently joined together, the expansion regions 148, 168 can define an expansion space (e.g., the expansion space 117, as shown) between them to accommodate the expandable composite 220 therebetween. Figure 6

[0066] In other embodiments, the layers include a sealing material along only one of the regions, such that the expansion region is joined along only one of the longitudinal or transverse perimeters to allow the expandable composite 220 to expand therein. In another embodiment, no sealing material is applied along the layers, such that the expandable composite 220 is not bound by a sealing material. In other embodiments, the expandable composite is applied only on a portion of the expansion region.

[0067] In other embodiments, there is no sealing material applicator, as the layers can be configured to join to each other without a sealing material. For example, in one embodiment, the expandable composite 220 is used as an adhesive that can join the layers together. In this embodiment, the expandable composite 220 is applied along the layers, such that pressure can be applied to the layers to spread the expandable composite 220 evenly between the layers. For example, the expandable composite 220 is pressed between the layers to expand near the edges of the layers. In another embodiment, the layers include a coating along the layers that can heat seal the layers together. In another embodiment, the roller includes an adhesive that can be activated upon heating.

[0068] Referring again to Figures 3-4 ​After the expandable composite 220 and the sealing material 216 are applied, the pressure applicator 222 applies pressure to the layers 140 and 160 at the areas where the sealing material 216 of the layers 140, 160 is applied between the layers (e.g., along the areas 144, 146, 164, 166) to join the layers 140 and 160 together such that the webs of the layers 140, 160 cumulatively form the protective packaging wall 170. The joined layers 140, 160 define an expansion space between them to contain the expandable composite 220 (e.g., the expansion space 117, as shown). Figure 6 In some embodiments, the lamination together can cause the expandable composite 220 to expand to form a continuous layer.

[0069] The system 200 includes sealing applicators 224, 226 that each apply a different sealing material. For example, the sealing applicator 224 can apply the sealing materials 274, 276, and the sealing applicator can apply a different sealing material 278 to the outer surface of the wall 170. In other embodiments, any combination of sealing materials are applied by the sealing applicators. In further embodiments, each sealing applicator applies the same sealing material. In yet another embodiment, there can be only one sealing applicator. The sealing applicators 224, 226 are similar to the sealing applicator 214, and the sealing materials 274, 276, 278 can be similar to the sealing materials described for the sealing material 216, or other suitable sealing materials can be used.

[0070] Figure 5 An embodiment of the wall 170 is shown after the sealing applicators 224, 226 have applied the sealing materials 274, 276, 278 to the outer surface of the wall 170. The sealing material 274 is applied along the longitudinal area 180. In this embodiment, the sealing material 274 is applied along the longitudinal area 180 adjacent to the longitudinal edge 172, however, in other embodiments the sealing material 274 is applied along a longitudinal area a distance from the longitudinal edge. The sealing materials 276, 278 are applied along the transverse areas 182, 184, respectively, which are longitudinally spaced apart from each other and between the longitudinal areas 180. However, in other embodiments, either of the sealing materials 276, 278 are applied parallel to the other. In further embodiments, the sealing materials are applied only along the longitudinal areas of the wall. The sealing materials 276, 278 are separated by a gap 186 having a distance 188. The gap 186 can be configured to provide a space in which an opening or a weakened area can be cut.

[0071] When sealing materials 274, 276, and 278 are condition sealing materials with different conditions (e.g., temperature or pressure), some sealing materials are selected to be activated under one condition, while others are selected to be activated under different other conditions. For example, in one embodiment, sealing materials 274 and 276 may be selected to be activated at a temperature or pressure different from the temperature or pressure required to activate seal 278 to form a seal. In this way, sealing materials 274 and 276 may form a seal along regions 180 and 182, while sealing material 278 does not form a seal along region 184. However, in other embodiments, sealing materials are selected to have similar conditions for producing a seal. In other embodiments, sealing materials may be selected to have other combinations of conditions for each sealing material.

[0072] Sealing materials 274, 276, and 278 can be applied along the folded wall 190, having the same or different widths or lengths to control the size and shape of the container cavity formed by the folded web 170 in subsequent steps. For example, the longitudinal sealing material can be applied with a thicker width adjacent to the transverse sealing material, while smoothly transitioning to a thinner width between the transverse sealing materials. In such a configuration, the expansion space can be defined with a curved side adjacent to the longitudinal sealing material.

[0073] like Figures 2-3 As shown, system 200 includes a folding device 228 that folds the wall 170 onto itself after sealing materials 174, 276, 278 are applied to the outer surface of the wall 170 to form a folded wall 190. The folded wall 190 includes overlapping protective walls that surround a container cavity therebetween (e.g., container cavity 398, as shown). Figure 6 (As shown). In this embodiment, the folding device 228 folds the wall 170 around the folding mechanism 234, and tension is applied to the wall 170 during folding using the tension mechanism 230. For example, in one embodiment, the folding mechanism 234 is a folding rod, and the tensioning mechanism 230 is a wheel. In this embodiment, the wheel pulls the wall 170 into tension around the folding rod to fold the wall 170, such that the longitudinal regions 174 correspond to each other. The folding mechanism 234 may have a suitable shape for folding the wall 170, such as a V-shape. The folding device 228 further includes a flattening mechanism 190 configured to flatten the folded wall 190. The flattening mechanism 190 may be a flattening rod configured to apply pressure to the folded wall 190 and flatten it. Other suitable folding mechanisms known in the art may be used.

[0074] The sealing apparatus then seals the walls 170 such that the sealing material 174, 276 forms a seal along the regions 180, 182. The sealing apparatus is configured to apply conditions to activate the sealing material 174, 276 (e.g., heat, pressure, and / or other suitable means of activating the sealing material 174, 276). In other suitable embodiments, the planarization mechanism 190 functions as the sealing apparatus. In other embodiments, the system 200 incorporates a separate sealing apparatus along different portions of the process.

[0075] Referring to Figure 5 , the walls 170 define regions 192 along which the folding apparatus 228 folds the walls 170. The walls 170 include wall portions 118, 120 such that when the walls 170 are folded, the wall portion 118 meets the wall portion 120. In particular, the sealing regions 180, 182, 184 of the wall portion 118 meet the sealing regions 180, 182, 184 of the wall portion 120. Referring to Figure 6 , the folded walls 190 are generally substantially flat, however, for illustrative purposes, the folded walls 190 are described as having a substantially open container cavity 398. As described further below, this meeting of the sealing regions 180, 182, 184 allows the sealing material 174, 276 to be sealed together at a later stage to form a boundary of the protective packaging unit, while the sealing regions 184 of the wall portions 118, 120 are unsealed at this point in the process. Such unsealed regions can then be used as an opening of the packaging unit (e.g., the packaging unit 110) to receive an object prior to the sealing region 184 having the sealing material 278 being used as a closure of the packaging unit after the sealing material 278 forms a seal along the sealing region 184. For example, the sealing region 184 can be a portion of a flap that does not have another layer on top of the sealing material 278. In this example, the sealing material 278 is a water-activated adhesive such that a user can lick the flap to activate the adhesive. In yet another embodiment, the sealing region 184 is free of sealing material such that a user subsequently applies adhesive along the sealing region 184. Although Figure 6 , the embodiment shown in FIG. 4 depicts the longitudinal edges 172 of each wall portion 118, 120 meeting, in other embodiments, the longitudinal edges of each wall portion do not meet, and one edge of one wall portion extends beyond the edge of the other wall portion.

[0076] Referring to Figure 6The folded wall 190 defines a container cavity 398 between the wall portions 118, 120, which can store one or more objects after the wall 170 is folded along the region 192. The container cavity 398 is further bounded on one side by a seal formed by the regions 180 of the wall portions 118, 120 meeting one another, and on the other side by the layer 160 folded around the region 192. As will be further described below, the container cavity 398 will be further bounded by other sealing regions as the protective packaging unit 110 is defined along the web 100. The expandable composite 220 can be expanded at a later stage to expand the folded wall 170 (as a separate packaging unit 110 or prior to forming such a packaging unit 110) such that the wall portions 118, 120 expand to provide protection to the objects contained within the cavity 398 from impact (e.g., during transport of the objects).

[0077] In other embodiments, the system does not include a folding apparatus, and thus the walls can be fed to later stages of the process without being folded. For example, in such embodiments, another wall is layered on the initial wall such that the sealing regions of each wall can correspond to one another and define a container cavity therebetween. An example of such a configuration can be seen in Figure 11 , where the web 300 of protective articles 30 includes two walls 318, 320 layered on one another and defining a container cavity 398.

[0078] Although Figure 4 The wall 170 is depicted as having a single region 192 about which the wall 170 can be folded, other embodiments of the wall can include multiple folding regions. For example, Figures 8-9 The embodiment of FIG. 48 has a wall 470 with linear regions 55 having a reduced amount of expandable composite 220 or no expandable composite 220. Due to the reduction or absence of expandable composite, these regions have a lower thickness and less internal structure than the pad portions 494, 496, thereby providing a natural hinge line 499 to facilitate folding of adjacent portions 494 and 496 of the wall 470 on one another. In particular, with reference to Figure 1The liner portion 494 is folded along line 498 onto the liner portion 496 such that the sealing regions 480 of each liner portion 494 (with sealing material 474 applied to the sealing regions 480) meet each other on the liner portion 496 to form a folded wall 490. In this embodiment, the sealing regions 480 of each liner portion 494, 496 meet, are then folded onto the liner portion 494 and flattened, such that the sealing regions 480 engage to form a folded ridge along the length of the web 490 on the central portion of the liner portion 496. However, in other embodiments, the sealing region of one liner portion is located on the outer surface of the liner portion (e.g., along the edge of the liner portion), such that engaging the sealing region on the inner surface of one liner portion with the outer surface of another liner portion can join the liner portions together to form a container cavity without forming a central folded ridge along the length of the web. The sealing material 174 can then form a seal to join or otherwise secure the sealing region 480, such that the filling portions 494, 496 form a container cavity 498 therebetween. The container cavity 498 is further defined between lines 499, and can be further defined at a later stage when the sealing regions 482, 484 are joined or otherwise secured to each other by the sealing materials 276, 278 forming the seal.

[0079] System 200 is also configured to have openings along the folded wall 190 and into the container cavity 398 of the folded wall 190 (e.g., opening 117, as shown). Figure 13 As shown, a weakened region 116 is formed. In this embodiment, the weakened region 116 extends along the folded wall 190 in a direction transverse to the longitudinal edge 172 to define the length of a single protective packaging unit and to facilitate the separation of packaging units 110 from one another, for example by tearing one unit 110 from the next unit.

[0080] The weakened region 116 and the opening can be configured as perforations or slits, scribing, or other suitable structures. System 200 may include a cutting device 240 for perforation, scribing, and / or cutting, or other suitable means for creating the weakened region. The weakened region and the opening can be applied before, during, or after other parts of the process. The cutting device 240 can also be used to remove the longitudinal length of one layer to create a flap extending from one wall of the packaging unit (e.g., as shown in the image). Figure 2 (as shown in wing 630).

[0081] refer to Figure 3 , Figure 9 , Figure 10 and Figure 10The cutting device 240 of system 200 includes a blade holder 250 for holding a blade 244 and an anvil, such as a roller 242, which may be slotted to receive the blade 244 or made of an elastomer or other backing material that can be penetrated or pressed by the blade to make the desired cuts and / or notches. Other cutting devices may include a fixed or rotating blade, a thermal cutter, and / or known mechanisms for cutting the folded wall 190. In the illustrated embodiment, the blade 244 includes a series of spaced teeth 246 configured to completely pierce all wall portions 118, 120 of the folded wall 190. The blade 244 completely penetrates the wall portion 120 to form an opening 197 along the wall portion 118 transverse to the longitudinal edge of the folded wall 190. However, because the teeth 246 of the blade 244 include gaps 248 between each tooth, the blade 244 does not completely penetrate the wall portion 120. The teeth 246 and the gaps 248 form perforation lines, serving as a weakening region 116 along the longitudinal edge of the folded wall 190, transverse to the wall portion 120. Thus, the folded web 190 is cut to form the cut web 100 of the connected separable packaging unit 110.

[0082] although Figure 1 The embodiments described in the text depict the cutting device 240 cutting the opening 117 and the weakened region 116 through the gap 186. However, in other embodiments, the cutting device cuts the opening and weakened region through different portions of the folded web, such as along a portion of the folded web with a sealing material (e.g., along the folded web 190 with sealing material 278), because this sealing material has not yet been activated and can form the top side of the packaging unit. In other embodiments, the blade may cut through the entire folded wall to separate the folded wall into packaging units. In another alternative, the teeth of the blade may be configured to cut a perforation line through the entire folded wall to create weakened regions along two portions of the wall. In yet another embodiment, the cutting device may include one blade to form an opening along a portion of the folded wall, and another blade to form a weakened region along another portion of the folded wall at different times or locations during the process.

[0083] System 200 includes a merging device 252 configured to merge cut webs 100 into a supply configuration 150, such as the fan-shaped folded configuration in this embodiment (or... Figure 11In other embodiments, the merging device 252 includes an inflation device. Figure 2 shows one example of a supply configuration as a fan-fold configuration 150. In this example, the fan-fold configuration 150 includes a web 100 of high-density configuration of inflatable, connected, separable packaging units 310. The packaging units 310 are made of protective packaging walls 318, 120 that are stacked on top of each other along the longitudinal sides 324, 326 and the transverse side 328 of the packaging units 310. The sides 324, 326, 328 are portions of the packaging units 310 in which the walls 318, 320 are sealed together with a sealing material applied on at least one inner surface of the walls 318, 320 corresponding to these sides 324, 326, 328, as further described below. The walls 318 are cut along the edges 330 such that openings 397 are defined between the walls 318, 320, the edges 330 of the walls 318, and the longitudinal sides 324, 326. The openings 397 are provided to allow insertion of objects into the packaging units 310 in a top-loading configuration. The packaging units 310 are secured to adjacent packaging units 310 along the weakening regions 316. The packaging units 310 are cut from the transverse sides 324, 326 along the edges 330 to form a transverse slit 322 along each side of the weakening region 316. Such transverse slits 322 facilitate easier opening of the openings 397 and easier separation of the packaging units 310 from each other. In other embodiments, the web does not have transverse slits, but rather has a weakening region along the entire edge of each packaging unit.

[0084] Figure 12 Figure 2 shows one example of a supply configuration as a fan-fold configuration 150. In this example, the fan-fold configuration 150 includes a web 100 of high-density configuration of inflatable, connected, separable packaging units 310. The packaging units 310 are made of protective packaging walls 318, 120 that are stacked on top of each other along the longitudinal sides 324, 326 and the transverse side 328 of the packaging units 310. The sides 324, 326, 328 are portions of the packaging units 310 in which the walls 318, 320 are sealed together with a sealing material applied on at least one inner surface of the walls 318, 320 corresponding to these sides 324, 326, 328, as further described below. The walls 318 are cut along the edges 330 such that openings 397 are defined between the walls 318, 320, the edges 330 of the walls 318, and the longitudinal sides 324, 326. The openings 397 are provided to allow insertion of objects into the packaging units 310 in a top-loading configuration. The packaging units 310 are secured to adjacent packaging units 310 along the weakening regions 316. The packaging units 310 are cut from the transverse sides 324, 326 along the edges 330 to form a transverse slit 322 along each side of the weakening region 316. Such transverse slits 322 facilitate easier opening of the openings 397 and easier separation of the packaging units 310 from each other. In other embodiments, the web does not have transverse slits, but rather has a weakening region along the entire edge of each packaging unit.

[0085] Figure 13 Figure 2 shows one example of a supply configuration as a fan-fold configuration 150. In this example, the fan-fold configuration 150 includes a web 100 of high-density configuration of inflatable, connected, separable packaging units 310. The packaging units 310 are made of protective packaging walls 318, 120 that are stacked on top of each other along the longitudinal sides 324, 326 and the transverse side 328 of the packaging units 310. The sides 324, 326, 328 are portions of the packaging units 310 in which the walls 318, 320 are sealed together with a sealing material applied on at least one inner surface of the walls 318, 320 corresponding to these sides 324, 326, 328, as further described below. The walls 318 are cut along the edges 330 such that openings 397 are defined between the walls 318, 320, the edges 330 of the walls 318, and the longitudinal sides 324, 326. The openings 397 are provided to allow insertion of objects into the packaging units 310 in a top-loading configuration. The packaging units 310 are secured to adjacent packaging units 310 along the weakening regions 316. The packaging units 310 are cut from the transverse sides 324, 326 along the edges 330 to form a transverse slit 322 along each side of the weakening region 316. Such transverse slits 322 facilitate easier opening of the openings 397 and easier separation of the packaging units 310 from each other. In other embodiments, the web does not have transverse slits, but rather has a weakening region along the entire edge of each packaging unit.

[0086] Figure 14An exemplary protective packaging unit 610 in the form of a packaging container, such as a mailbox, is shown that is configured to receive an object for shipping. In contrast to the packaging unit 110, the walls of the packaging unit 610 are not folded over one another to define a container cavity. Rather, the protective packaging unit 610 is formed by walls 618, 620 that are sealed to one another along the interior surfaces of the regions 624, 626, 628 to define a container cavity 698 for storing an object. For example, the regions 624, 626, 628 of the walls 618, 620 are sealed to one another such that the edges of the walls 618 and 620 coincide with one another to define a perimeter of the packaging unit 610. However, in other embodiments, the edges of one wall can extend beyond the edges of the other wall.

[0087] The edges 640 of the wall 618, the region 628 opposite the wall 618, and the wall 620 define an opening 697 between one another such that an object can be loaded into the container cavity 698 from the top. The wall 620 includes a flap 630 that extends past the edge 640. In the present embodiment, the flap 630 includes an adhesive surface 634 and a release layer 632 made of a material that is not strongly adhesive to the adhesive surface 634. In other embodiments, the flap has an abutment surface on the flap and the opposing shorter wall to seal the closed flap rather than an adhesive surface. In use, after an object is inserted into the container cavity 698 through the opening 697, the release layer 632 can be peeled and the flap 630 folded over the opening 697 after which the adhesive surface 634 can be sealed to the exterior of the wall 620. After the flap 630 is sealed to the wall 618, the protective packaging unit 610 is closed over the object contained in the container cavity 698, thereby preventing the object from escaping.

[0088] Reference is made to Figure 11 The bagger 700 is configured to receive a web of packaging units connected in series, such as the web 300 of Figure 14 protective packaging units 310 in their still expandable state. The bagger 700 is configured to receive the web 300, move the web 300 in a downstream direction, expand the web 300 to form an expanded web 380, open each expanded packaging unit 381 along the opening 387 to access the container cavity 388, and insert an object into the container cavity 388.

[0089] The bagger 700 includes an expansion device 706 that is configured to expand the expandable composite material 220 contained within the walls 318, 320 of the web 300 to form the expanded web 380. Although Figure 14The display inflation device 706 is positioned immediately downstream of the fan-fold configuration 350, but in other embodiments, the inflation device is placed at a different point in the process (e.g., after the inflation package unit is opened, during insertion of the object into the inflation package unit, or after the object is inserted into the inflation package unit). In other embodiments, the bagger does not include an inflation device, where the web from the supply configuration is already inflated. In yet another embodiment, the bagger does not include an inflation device, and the web is fed through the bagger without inflation.

[0090] To assist in opening the opening 387, the bagger 700 can include opening assist devices. As shown, the opening assist devices include a plurality of fingers 702 to grip a portion of the inflation package unit 381, a telescoping protrusion 704 to pull a portion of the inflation package unit 381, a suction cup 712 to suction a portion of the inflation package unit 381, and a blower 714 to apply air pressure to the opening 387. Although Figure 10 the embodiment shown depicts the bagger 700 including all of the fingers 702, the telescoping protrusion 704, the suction cup 712, and the blower 714 as opening assist devices, other embodiments can have any combination of the opening assist devices or only one opening assist device. Figures 15-16

[0091] Once the opening 387 is opened, the object can be loaded into the container cavity 398 from the top. The filled package unit can then be sealed by a sealing device 716, which activates the sealing material 274, 276, 278 to enclose the filled package unit around the object, as described above. The sealing device 716 can also separate the filled package unit from the adjacent inflated package unit 380 by cutting, melting, pulling, tearing, or other suitable manner of separating the package unit along the weakened region 386. However, in other embodiments, the bagger 700 includes a separation device to separate the filled package unit from the adjacent package unit.

[0092] Figure 15 Another example bagger 800 is shown that is fed a web 900 of inflatable walls of a supply configuration 950. The bagger 800 is configured to receive the web 900, move the web 900 in a downstream direction, inflate the folded web 900 to form an inflated web 980, fold the inflated web 980 to define an interior container cavity 986, and insert an object into the interior cavity 986.

[0093] The bagger 800 includes an inflation device 806 configured to inflate the inflatable composite material 220 contained within the walls of the web 900 to form the inflated web 980. Although Figure 7 ​The display inflation device 806 is positioned directly downstream of the supply configuration 950, but in other embodiments, the inflation device 806 can be placed at a different point in the process (e.g., after folding, during insertion of the object into the container cavity, or after insertion of the object into the container cavity).

[0094] As shown, the inflated web 980 includes regions 992 that are configured to facilitate folding of the inflated web 980 along these sections. The regions 992 can be portions of the inflated web 980 where there is less or no expandable composite material 220, creating a natural hinge to facilitate folding of the inflated web 980, similar to the regions 492 shown. Figure 7 In another embodiment, the bagger includes a device that applies pressure to the web during or after inflation to form regions of the inflated web that have more compressed regions of inflated material to facilitate folding of the inflated web. In other embodiments, a natural hinge is provided, for example, with a uniform amount of expandable composite material that extends laterally across the inflation space, and the device folds the wall web around its center or other desired location only to place wall portions (e.g., cushion portions 494, 496 as shown) on top of one another, defining the container cavity. ​

[0095] The bagger 800 includes a folding device 806 that is configured to fold the inflated web 980. The folding device 806 can include bars 808, 810 or other suitable mechanisms that fold the inflated web 980 to define an interior container cavity 986 within the inflated web 980. The folding device 806 makes a C-fold in the web 980, but other known types of folds can also be employed. The bagger 800 includes a hold-open member, such as fingers 814 or other suitable device, that holds the container cavity open within opposing walls of the folded inflated web, providing a laterally-facing container cavity 312 for side-loading of the object.

[0096] The bagger 100 includes a sealing device 816 for activating the sealing material 274, 278 to seal the inflated packaging unit 981. The sealing device 116 is configured to apply heat, pressure, and / or other suitable means of setting the sealing material 274, 278 to form a complete bag. For example, where the sealing material is a tape seal, the sealing device applies heat to activate the sealing material.

[0097] ​The sealing apparatus 816 includes a transverse sealing apparatus 820 and a longitudinal sealing apparatus 818. The transverse sealing apparatus 820 is configured to activate the sealing material 278 to seal a bottom side of one inflated packaging unit 981 (defining a bottom boundary of the container cavity 986) and a top side of an adjacent inflated packaging unit 981 after the inflated packaging unit 981 is folded. The longitudinal sealing apparatus 818 is configured to activate the sealing material 274 to seal the side boundaries of the inflated packaging unit 981 and define the side boundaries of the container cavity 986. In this way, the longitudinal sealing apparatus 818 seals the closed finished pouch 999 after the object is inserted within the container cavity 986.

[0098] In other embodiments, the bagging machine does not include an inflation device, where the web from the supply configuration is already inflated. In yet another embodiment, the bagging machine does not include an inflation device, and the web is fed through the bagging machine without inflation.

[0099] The bagging machine 800 includes a separation mechanism 818 configured to facilitate separation of the finished pouch from the inflated web 980, similar to the separation device discussed above with respect to the bagging machine 700. In one embodiment, the sealing apparatus can melt through the top boundary of the finished pouch, and the separation mechanism can pull the finished pouch away from the adjacent packaging unit.

[0100] Although the bagging machines 700, 800 are described as being fed from a particular un-inflated high-density configuration (e.g., the folded stack configuration 150 or the roll configuration 550), it can be appreciated that either of the machines 700, 800 can be fed from any type of consolidated configuration. In other embodiments, the web can be fed entirely through the bagging machines 700, 800 without inflation.

[0101] The present disclosure is not limited to the particular examples described in this application, which are intended to illustrate various aspects. Numerous modifications and embodiments can be devised by those skilled in the art without departing from the spirit and scope of the present disclosure. In addition to the methods and apparatuses recited in this document, functions equivalent to those within the scope of the present disclosure will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and examples are intended to fall within the scope of the claims that follow. The present disclosure is limited only by the terms of the claims as encompassed within the full scope of equivalents that the claims enjoy. It is also to be understood that the terminology used herein is for the purpose of describing particular examples only, and is not intended to be limiting.

[0102] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate the plural in the singular and / or singular in the plural, depending on the context and / or application. For example, where a singular term is used, it is intended to include plural of that term (e.g., where a singular term is used, it is intended to include a plurality of that term) unless the context clearly indicates otherwise. For clarity, various singular / plural permutations can be explicitly set forth herein.

[0103] While various aspects and examples are disclosed herein, other aspects and examples will be apparent to those skilled in the art. The various aspects and examples disclosed herein are for purposes of illustration and are not intended to limit the true scope and spirit of the claimed subject matter, which is indicated by the following claims.

Claims

1. A protective article comprising: The first wall and the second wall, each wall includes: Stacked layers, with expansion spaces between the layers, and An expandable composite material disposed in the expansion space, the expandable composite material comprising: Biodegradable matrix, and Multiple cellulose-based expandable microspheres are configured to cause the biodegradable matrix to expand upon activation. The cellulose-based expandable microspheres comprise more than 50% cellulose based on the total weight of the cellulose-based expandable microspheres, and The expandable composite material comprises more than 50% cellulose based on the total weight of the expandable composite material. The first wall and the second wall are stacked on top of each other to define a container cavity therebetween, the container cavity being constructed and sized to accommodate a product to be transported therein, and the expansion spaces of the walls are stacked on top of each other around the container cavity. The first wall and the second wall are connected to each other on multiple sides of the container cavity, and The expandable composite material in a pair of expansion spaces is provided and supplied in sufficient quantities to provide cushioning for the product to be contained in the container cavity.

2. The protective article according to claim 1, wherein: The walls are unsealed from each other at the opening side of the container cavity, the size of which is set to allow the product to be inserted into the container cavity through the opening; and The protective article also includes a closure on the first wall, the closure being configured to seal the first wall to the second wall to seal the closed opening side to retain the product in the cavity.

3. The protective article of claim 2 further includes a web comprising a first wall and a second wall connected to each other at a series of locations transversely through the web to define a plurality of connected protective packaging units configured to be separate from each other, each packaging unit including a pair of expansion spaces stacked on top of each other around at least one container cavity.

4. The protective article of claim 1, wherein the biodegradable matrix comprises a biodegradable polymer, a biodegradable adhesive, or a combination thereof.

5. The protective article of claim 4, wherein the biodegradable polymer comprises natural starch, synthetic starch, cellulose, biopolyester, protein, polysaccharide, or a combination thereof.

6. The protective article of claim 5, wherein the biodegradable polymer comprises cellulose.

7. The protective article of claim 4, wherein the biodegradable adhesive comprises starch-based adhesives, cellulose-based adhesives, biopolyester-based adhesives, protein-based adhesives, polysaccharide-based adhesives, or combinations thereof.

8. The protective article of claim 7, wherein the biodegradable adhesive is a cellulose-based adhesive.

9. The protective article of claim 7, wherein the biodegradable adhesive is a starch-based adhesive.

10. The protective article of claim 1, wherein the cellulose-based expandable microspheres comprise a foaming agent.

11. The protective article of claim 1, wherein the cellulose-based expandable microspheres comprise a reactive component, a chemical catalyst, or a combination thereof.

12. The protective article of claim 10, wherein the cellulose-based expandable microspheres comprise a foaming agent comprising air, carbon dioxide, nitrogen, methane, ethane, propane, isobutane, n-butane, neopentane, an inert gas, or a combination thereof.

13. The protective article of claim 1, wherein the cellulose-based expandable microspheres comprise a shell and an inner core material, the shell comprising cellulose.

14. The protective article of claim 1, wherein the cellulose-based expandable microspheres comprise hydrocarbons, water, or a combination thereof.

15. The protective article of claim 1, wherein the cellulose-based expandable microspheres are configured to be thermally activated.

16. The protective article of claim 1, wherein the activation causes the cellulose-based expandable microspheres to expand, thereby causing the biodegradable matrix to expand.

17. The protective article of claim 1, wherein the biodegradable matrix is ​​configured to solidify after expansion.

18. The protective article of claim 1, wherein the layer comprises a biodegradable material, and the protective article is made wholly of at least 75% by weight of a biodegradable material.

19. The protective article of claim 1, wherein the microspheres are encased in the biodegradable matrix.

20. A protective article comprising a first wall, the first wall comprising: The first layer that defines the expansion region, and The expandable composite material in the expansion region, the expandable composite material comprising: Biodegradable matrix, and Multiple cellulose-based expandable microspheres are configured to cause the biodegradable matrix to expand upon activation. The cellulose-based expandable microspheres comprise more than 50% cellulose based on the total weight of the cellulose-based expandable microspheres, and The expandable composite material contains more than 50% cellulose based on the total weight of the expandable composite material.

21. The protective article according to claim 20, wherein, The first wall includes a second layer stacked on and connected to the first layer, such that the first and second layers define a first expansion space between them that surrounds the expansion region, wherein the expandable composite material is contained in the first expansion space.

22. The protective article of claim 21, further comprising a second wall, the second wall comprising: Opposite base layers, which are stacked and connected to each other to define a second expansion space therebetween; and An additional amount of the expandable composite material contained in the second expansion space; The first wall and the second wall are stacked on top of each other to define a container cavity between them, the container cavity being constructed and sized to accommodate a product to be transported therein, and the expansion spaces of the walls are stacked on top of each other around the container cavity. The first wall and the second wall are connected to each other on multiple sides of the container cavity.

23. An expandable web, comprising: First layer; Second layer; and An expandable composite material in an expansion region between the first layer and the second layer, the expandable composite material comprising: Biodegradable matrix; and Multiple cellulose-based expandable microspheres are configured such that the biodegradable matrix expands upon activation of the cellulose-based expandable microspheres. The cellulose-based expandable microspheres comprise more than 50% cellulose based on the total weight of the cellulose-based expandable microspheres, and The expandable composite material contains more than 50% cellulose based on the total weight of the expandable composite material.

24. The expandable web of claim 23, wherein each of the first layer and the second layer is made of at least 75% by weight of a biodegradable material.

25. A method for manufacturing an expandable protective article, comprising: An expandable composite material is applied to the surface of a first layer, the expandable composite material comprising: Biodegradable matrix, and Multiple cellulose-based expandable microspheres are configured to cause the biodegradable matrix to expand upon activation of the cellulose-based expandable microspheres. The cellulose-based expandable microspheres comprise more than 50% cellulose based on the total weight of the cellulose-based expandable microspheres, and The expandable composite material comprises more than 50% cellulose based on the total weight of the expandable composite material; and A second layer is applied on top of the first layer, such that the expandable composite material is sandwiched between the first and second layers.

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