Method of manufacturing thermal insulation and thermal insulation envelope

Abstract

A method and system for producing an insulated envelope and an insulated box having an insulated paper fiber pad structure, wherein the density of the insulated paper fiber pad is less than about 10 pounds per cubic foot. The insulated paper fiber pad has wrapped reinforcing fibers. The invention provides a method of forming an insulated paper fiber pad using a recyclable compatible or water soluble binder and paper layers.

Description

[0001] This invention application is a divisional application of the invention patent application filed on November 7, 2017, with application number 202110728997.2 and title "Method for Manufacturing Thermal Insulation Material and Thermal Insulation Sheath". This invention patent application is a divisional application of the invention patent application filed on November 7, 2017, with application number 201780081689.7 and title "Method for Manufacturing Thermal Insulation Material and Thermal Insulation Sheath" (based on PCT International Application No. PCT / US2017 / 060403). Technical Field

[0002] The present invention relates to a method and system for producing a thermal insulation material and a container using the thermal insulation material, and more specifically, to a method and system for producing a resizing thermal insulation material, and a recyclable container using the resizing thermal insulation material. Background Technology

[0003] Thermal insulation boxes are widely used in many transportation applications. They are needed when transporting materials that need to withstand decreasing or increasing temperatures and when shock absorption is required. Similarly, they are needed when transporting materials that need to avoid large temperature fluctuations. These boxes also reduce impact stress on the product, thereby extending the lifespan of the transported product and / or making it appear more durable and of higher quality. Unfortunately, the insulation material is usually made of a different material than the one used to form the box, making it non-recyclable. Summary of the Invention

[0004] This section provides a general overview of the invention and does not fully disclose its entire scope or all its features.

[0005] According to the teachings of the present invention, a method for forming a transport container is disclosed. The method includes mixing paper fibers with recyclable compatible fibers to form a material mixture. The mixture is placed on a surface to form a mixture layer. Heat and at least one of heat and pressure are applied to the mixture layer to form paper fiber batts. The paper fiber batts are then trimmed to have a fixed width and a fixed length. The paper fiber batts are positioned adjacent to a corrugated box, and the transport container has a repulpingability greater than 85%.

[0006] According to another teaching, the above or below method includes mixing paper fibers with a two-component thermoplastic fiber of fusible polyethylene and polypropylene (“PE / PP”).

[0007] According to the teachings of the present invention, a method for manufacturing a thermal insulation material is disclosed. The method includes mixing paper reinforcing fibers with about 0.5% to about 25% by weight of fusible PE / PP bicomponent thermoplastic adhesive fibers with a length less than about 16 mm. The PE / PP bicomponent thermoplastic adhesive fibers are substantially randomly distributed within the paper reinforcing fibers to form a mixture. Heat is applied to the mixture to melt the PE / PP bicomponent thermoplastic adhesive fibers, thereby bonding the PE / PP bicomponent thermoplastic adhesive fibers to the paper reinforcing fibers to form a fibrous structure. The thermal insulation material has a physical property of a repulping rate greater than 85%.

[0008] According to another teaching, in the above or below method, the method includes joining a repulpable paper layer with wadding to form an insulating wadding assembly.

[0009] According to another teaching, in the above or below method, the method includes forming a repulpable paper fiber pad having a compression resistance of about 0.3 psi to about 1.4 psi at a compression of about 25% to about 50%.

[0010] According to another teaching, in the above or below method, the method includes forming a repulpable paper fiber pad having a compression stability of about 5% to about 18% at a compression of about 25%.

[0011] According to another teaching, in the above or below method, the method includes forming a layer of water-soluble binder between a paper fiber pad and a first paper layer.

[0012] According to the teachings of the present invention, a method for manufacturing an insulating material is disclosed. A mixture of paper fibers and 0.5% to 25% thermoplastic adhesive fibers, substantially randomly distributed within the paper fibers, is formed. The mixture is heated so that the thermoplastic adhesive fibers are above their glass transition temperature or melting point, thereby bonding the thermoplastic adhesive fibers to the paper fibers, forming a wadding with a density of less than 5 psi. The fiber web of the paper fibers is tightly bonded to the thermoplastic adhesive fibers, and then the wadding is brought to a temperature below the glass transition temperature of the thermoplastic fibers to form an insulating pad with a resizing property greater than 85%. This pad is disposed within one of the inner surfaces of a resizing corrugated cardboard box or a resizing outer wrapping to form an assembly with a resizing property greater than 85%.

[0013] According to another teaching, in the above or below method, the mixture of paper fiber and thermoplastic adhesive is formed by forming a mixture of paper fiber and about 0.5% to about 25% of PE / PP bicomponent thermoplastic fibers with a length of less than about 24 mm.

[0014] According to another teaching, in the above or below method, forming a mixture of paper fibers and thermoplastic adhesive fibers is forming a mixture of paper fibers and about 5% to about 10% of PE / PP bicomponent thermoplastic adhesive fibers of varying lengths and with an average length of less than about 16 mm.

[0015] According to the teachings of the present invention, containers, transport containers, insulation materials, and insulation structures produced by the methods described above or below, or using the methods described above and below, have a re-sizing capacity greater than 85%, and have a re-sizing paper layer and a re-sizing paper fiber mat bonded to said paper layer. The paper fiber mat has paper reinforcing fibers that are tightly bonded to fusible PE / PP bicomponent thermoplastic adhesive fibers, which are substantially randomly distributed therein, at a weight of about 2% to about 25%.

[0016] According to the teachings of the present invention, in containers, transport containers, insulation materials and insulation structures produced by the methods described above or below, or using the methods described above or below, the fusible thermoplastic fibers are short-cut fibers with a length of about 0.5 mm to about 16 mm.

[0017] According to the teachings of the present invention, in containers, transport containers, insulation materials and insulation structures produced by the methods described above or below, or using the methods described above or below, the fusible thermoplastic fibers may be short-cut PE / PP bicomponent fibers with a length of about 0.5 mm to about 16 mm.

[0018] According to the teachings of the present invention, containers, transport containers, insulation materials and insulation structures produced by the methods described above or below, or using the methods described above or below, also have repulpable corrugated cardboard placed adjacent to the paper layer.

[0019] According to the teachings of the present invention, containers, transport containers, insulation materials and insulation structures produced by the methods described above or below, or using the methods described above or below, further have a recyclable compatible or water-soluble adhesive layer disposed between the paper layer and the corrugated cardboard.

[0020] According to another teaching, in the method described above or below, the method involves placing loose, ground fibrous cellulose paper or ground paperboard material on a moving conveyor belt. The fibers in the cellulose paper or cellulose material can be tightly bound together by methods such as needle punching or by using molten adhesive fibers, bioabsorbable binders, recycled compatible water-soluble binders, plant-based (sugar or pectin) binders (from, for example, beets, corn, or sugarcane, or starch). The ground cellulose paper or paperboard material is formed into a blank or wadding by passing a continuous layer of material between a pair of tapered edge plates, which form the width and thickness of the uncompressed wadding. The material can have a thickness and density that can be adjusted using pressure rollers capable of applying heat.

[0021] According to another teaching, in the methods described above or below, the method includes cutting the wadding into individual pieces using a cutter after compression. Optionally, a movable cutter or blade can be used to cut the wadding in half along its thickness. Once the wadding is formed into a rectangular shape and thickness, the material is ready to be attached to an inner corrugated box or sleeve, or placed in an inner corrugated box or outer wrapping.

[0022] According to another teaching, in the methods described above or below, the method involves removing the inner surface of a corrugated box from a suitable roll of material. The inner surface material of the corrugated box is cut to a specific length and width. For example, the width and length of the inner surface material of a cardboard box may be greater than the width and length of the fiber wadding.

[0023] According to the teachings of the present invention, containers, transport containers, insulation materials, and insulation structures produced using the methods described above or below include a paper layer that can be arranged above the wadding and overlap the extended portion of the wadding below all four sides. The ends of the paper layer can be wrapped around and tucked under the ends of the wadding. Heat or a recyclable or water-soluble binder can be applied to secure the inner paper layer to the wadding.

[0024] According to another teaching, in the method described above or below, the method includes bonding an inner paper layer to a wadding on the outer surface of the inner paper layer, the inner paper layer being foldable to form a bag. The folded wadding is then placed through an end-sealing device to close the sides of the inner paper layer, thereby forming the bag. The edges of the folded wadding can be sewn together using an industrial sewing machine.

[0025] According to another teaching, in the methods described above or below, the method includes placing another paper layer around the outside of the folded wadding. The outer paper layer may surround the wadding placement on the inner paper layer in a manner that forms a closable fold. The closable fold may include a recyclable or water-soluble adhesive in the form of double-sided tape.

[0026] According to another teaching, in the methods described above or below, the method includes encapsulating an insulating wadding material between an inner paper layer and an outer paper layer. In this case, a thermally or recyclable compatible or water-soluble adhesive or stitching can be used to connect the edges of the outer paper layer to the inner paper layer. Excess material at the edges can be removed.

[0027] According to the teachings of the present invention, the insulating materials and structures manufactured using the methods described above or below may include forming cellulose fibers by passing recycled paperboard through a hammer mill. These fibers are mixed with paper and a recycled compatible fiber. The recycled compatible fiber may be a fusible thermoplastic fiber. Insulating paper fiber wadding with a first width and a first length is formed from the recycled paper fibers. A first paper layer is bonded to the paper fiber wadding. The paper fiber wadding is bonded to a corrugated box.

[0028] Other applicable fields will become apparent from the description provided herein. The descriptions and specific examples in this invention are for illustrative purposes only and are not intended to limit the scope of the invention. Attached Figure Description

[0029] The accompanying drawings described herein are for illustrative purposes only for selected embodiments and not all possible implementations, and are not intended to limit the scope of the invention.

[0030] Figure 1 This refers to the formation of insulating fibers or pads used in thermal insulation sheaths;

[0031] Figure 2 This indicates that the recyclable paper layer is placed... Figure 1 On the heat insulation pad shown;

[0032] Figure 3 Indicates cutting as Figure 2 The recyclable paper layer shown is located on the pad;

[0033] Figure 4 This indicates that the paper layer surrounds the edge of the pad;

[0034] Figure 5 This indicates that heat is applied to bond the paper layers to the pad;

[0035] Figure 6 Indicates will Figure 5 The structure is folded into a bag;

[0036] Figure 7 Indicates suturing Figure 6 The sides of the structure are designed to form a bag;

[0037] Figure 8 Indicates the application of adhesives;

[0038] Figure 9 Indicates encirclement Figure 8 Application of the outer paper layer in the structure;

[0039] Figure 10 Indicates heat sealing and cutting Figure 9 The structure consists of an inner paper layer and an outer paper layer;

[0040] Figure 11 Indicates use Figures 1 to 10 Envelopes formed by methods and systems;

[0041] Figure 12 This refers to a system for forming the lining of a box according to another teaching of the present invention;

[0042] Figures 13A to 13B This indicates the cutting and forming of insulation wadding or padding;

[0043] Figures 14A to 14CThis indicates the application of the upper paper layer according to the teachings of the present invention;

[0044] Figures 15A to 15B Indicates the application of any optional backing paper layer;

[0045] Figure 16A and Figure 16B This indicates a side seal where the paper layer surrounds the insulation component;

[0046] Figure 17 This indicates a thermal channel used to form a thermal insulation component according to the teachings of the present invention; and

[0047] Figures 18A to 18B This refers to the insulation floss connected to the corrugated box.

[0048] In the various views of the accompanying drawings, the corresponding reference numerals denote the corresponding parts. Detailed Implementation

[0049] Exemplary embodiments will now be described more fully with reference to the accompanying drawings.

[0050] In Figures 1-12 The description describes the formation of insulation materials and insulation sheaths or transport containers. For example... Figure 1 As shown, fiber paper or cellulose material 2 is placed on a moving conveyor belt 4. The fibers can be tightly bonded by methods such as needle punching or using a molten adhesive, wherein the molten adhesive comprises approximately 2% to approximately 25% (by weight) of the fibers and is mixed in the fiber paper or cellulose material. Alternatively, recycled compatible or water-soluble binders can be used to bond the fibers. The fiber paper or cellulose material 4 is formed into a blank 10 by passing a continuous layer of material 2 between a pair of tapered edge plates 11 (only one shown) forming the wavy width. The thickness of the uncompressed blank 10 can be defined by an upper rake or block 14. The material can then have a thickness and density adjusted using a compression roller 16. Figure 3 ).

[0051] After compression, the board 10 is transformed into paper fiber insulation flocs 22. Figure 2 The paper fiber wadding 22 can be a manufactured fibrous composition formed by passing recycled paperboard through a mill such as a hammer mill. The wadding 22 may contain a small amount of water-soluble binder or fusible fibers, such as polypropylene fibers. Optionally, randomly distributed natural fibers such as cotton and binder fibers with a length of about 1 / 16 inch to about 1.5 inches and a denier of about 5 to about 12 are used to form the paper fiber wadding 22, wherein the paper fiber wadding 22 is processed to form an insulating pad 46. Figure 3 ).

[0052] Alternatively, the bonding fiber can be a water-soluble PVOH fiber with a denier of about 0.02 to about 3.0, a water temperature greater than about 100°C, and a cut length of about 2 mm to about 8 mm. The bonding fiber can be, for example, chopped strand fiber from the KURALON(tm) brand. As a bonding fiber, the recyclable PVOH fiber used for insulation can be a fiber with a denier of about 0.4 to about 1.0 denier and a length of about 3.0 mm to about 4.0 mm.

[0053] Insulating material 22 is continuously fed onto a conveyor belt between a pair of side guides, which define a pair of sides for a continuous strip of insulating material. The side guides define a predetermined width for the pad. Once aligned, the continuous strip of material lies beneath a cutting mechanism that cuts the continuous strip 22 into predetermined lengths to form an insulating pad 46.

[0054] like Figure 2 As shown, the wadding 22 is conveyed to a second position via conveyor belt 4, where the inner paper layer 25 covers the pad 46. The length and width of the inner paper layer 25 are greater than the length and width of the pad 46. The first and second ends 26 of the inner paper layer 25 can be tucked under the first and second ends 28 of the pad 46.

[0055] like Figure 3 As shown, the floss 22 can then be cut into individual pieces using a cutter 12, which can be a rotary blade or a circular blade. Optionally, the cutter 12 can be used to cut the floss 22 in half along its thickness. Once the floss 22 is formed into a rectangular shape and thickness, the material can be attached to or placed adjacent to the inner surface of the inner corrugated box.

[0056] Remove the inner paper layer 25 from a roll of suitable material, which may be, for example, pre-perforated or waterproof. Figure 3 and Figure 4 As shown, the inner surface material of the cardboard box is located above the insulation layer and is cut to a specific length and width. For example, the width and length of the inner surface material of the cardboard box can be greater than the width and length of the fiber pad 46.

[0057] like Figure 4 As shown, the inner paper layer 25 is placed on the pad 46, overlapping it on all four sides. The end 26 of the inner paper layer 25 wraps around and tucks under the end 28 of the pad 46. Figure 5 As shown, heat or a recyclable, compatible, or water-soluble adhesive can be applied to secure the inner paper layer 25 to the pad 46. The inner paper layer 25 is then folded in half, and the pad 46 is placed on the outer surface of the inner paper layer 25 relative to its own configuration, thereby forming a sub-assembly.

[0058] like Figure 6As shown, the folded pad 46 is then passed through the end-sealing device on the side of the inner paper layer 25 to form a bag 31. Figure 7 As shown, the edges can be sewn using an industrial sewing machine 80 or, if necessary, heat-fused. A row of smaller stitches 84 extends from the top to the bottom of the sub-assembly along each side and is adjacent to the lateral edge 82 of the pad 46. Slightly inward in space from the stitches 84 is a second row of larger stitches 86, which surrounds the pad 46 and the paper layer 25 on the inner side of the pad 46, and includes the portion 78 on the outer side of the pad 46. The second row of stitches 86 extends longitudinally downward only from the top of the sub-assembly and terminates at the portion 78.

[0059] Figure 8 This indicates the application of a recyclable or water-soluble adhesive to help bond the outer paper sheet or outer paper layer 32 to the inner paper layer 25. For example... Figure 9 As shown, the outer paper layer 32 can then be positioned to surround the outside of the folded pad 46. The outer paper layer 32 can be positioned to surround the pad 46 on the inner paper layer 25 in a manner that forms a closable flap 56. This closable flap 56 can be made of a recyclable or water-soluble adhesive 36 in the form of double-sided tape.

[0060] Then the outer paper layer 32 is connected to the inner paper layer 25, and thermal insulation material or a pad 46 is encapsulated between the inner paper layer 25 and the outer paper layer 32 to form a transport container or sleeve 40. Figure 11 In this regard, heat-, recyclable, or water-soluble adhesives or stitching can be used to attach the edges of the outer paper layer 32 to the inner paper layer 25. Excess material at the edges can be removed.

[0061] The outer paper layer 32 forming the outer surface of the envelope or transport container 40 can be recyclable and can be processed to be waterproof or water-resistant. Optionally, the outer paper layer 32 extends laterally, such that its lateral edges or edges 44 can be heat-sealed together, as... Figure 10 As shown. At the bottom of the sleeve 40, the paper layer 32 is folded at 52. At the top of the sleeve 40, the front top edge 58 terminates at the opening 54 of the sleeve, and the back continues upward to form a flap 56, thereby sealing the sleeve 40 by folding the flap 56 over the front top edge 58 of the sleeve 40 to close the opening 54. The flap 56 has transverse strips of a recyclable or recyclable compatible or water-soluble adhesive 30, which is covered with a removable protective paper 62.

[0062] As can be clearly seen from the above description, the pad 46 is covered on the inside by the inner paper layer 25, which extends laterally beyond the pad 46 and extends together with the edge 44 of the outer paper layer 32, thus allowing all edges to be heat-sealed together. The inner paper layer 25 surrounds the longitudinal ends of the pad 46, such that when the pad 46 is located in the sleeve 40, the ends 82 of the inner paper layer 25 are located between the pad 46 and the outer paper layer 32. These portions 82 allow the inner paper layer 25 to be heat-sealed together with the outer paper layer 32 around the sleeve opening 54, thereby enclosing the pad 46. The portion of the opening 54 opposite the fold 56 has a pressure-sensitive, biodegradable strip 59 (covered with a protective strip 64) to seal the top edges of the inner paper layer 25 together before sealing the fold 56 to the front of the sleeve 40. The pad 46 is not attached to the outer paper layer 32 except for the stitching and heat sealing between the outer paper layer 32 and the inner paper layer 25.

[0063] The fibers of mat 46 may be, for example, about 75% of recyclable paperboard and paper fibers and about 25% of adhesive fibers, i.e. (75 / 25), at a weight of about 1600 g / m² (GSM). Other fiber material compositions can be approximately 1500 GSM of approximately 80 / 20 recycled paperboard / paper fibers and bonding fibers; approximately 1400 GSM of approximately 80 / 20 recycled paperboard / paper fibers and bonding fibers; approximately 1600 GSM of approximately 85 / 15 recycled paperboard / paper fibers and bonding fibers; approximately 1500 GSM of approximately 85 / 15 recycled paperboard / paper fibers and bonding fibers; approximately 1400 GSM of approximately 85 / 15 recycled paperboard / paper fibers and bonding fibers; and approximately 1500 GSM of approximately 90 / 10 recycled paperboard / paper fibers and bonding fibers. The first number is the fraction of paperboard fibers, and the second number is the fraction of bicomponent bonding fibers (80 / 20 means approximately 80% paper fibers and approximately 20% bicomponent). The paperboard / paper fiber composition is made from a blend of approximately 50 / 50 fiberized paperboard / paper to a maximum of approximately 75 / 25 fiberized paperboard / paper.

[0064] The flocculant material can have a content of approximately 25 g / m³ to approximately 40 g / m³ (kg / m³). 3 The density of the pad 46 is approximately 12.5 mm to approximately 75 mm, and it has fibers (cardboard and adhesive) with a denier range of approximately 1 denier to approximately 3 denier. The density of the pad 46 is related to the compression of the wadding 22 and the percentage of the bonding fibers.

[0065] Preferably, the material can be formed from about 10% bicomponent fibers and about 90% recycled paperboard fibers. The bicomponent fibers can be chopped and have a length of less than about 24 mm, less than about 16 mm, or from about 0.5 mm to about 16 mm, and can be a mixture of two or more lengths, preferably from about 1 mm to about 16 mm. In the mixture of two or more lengths, the ratio of one fiber length to another fiber length can be from about 10% to about 90%, and the average length can be less than about 16 mm.

[0066] The results showed that for a sample of approximately 1300 GSM, approximately 90% paperboard and approximately 10% adhesive (approximately 50% of 1 mm long bicomponent fibers and approximately 50% of 6 mm long bicomponent fibers), over 93% of the material was repulpable and therefore recyclable. It should be noted that a repulpability greater than 85% is a “qualified” level for recyclability. The bicomponent fibers can be polyethylene and polypropylene (“PE / PP”) bicomponents from approximately 0.5 mm to approximately 16 mm; and can be formed from approximately 65% / 35% PE / PP blends. Optionally, the PE / PP ratio can be from approximately 65 / 35 to approximately 50 / 50. As a non-limiting example, these fibers can be ESFIBERVISIONS® polyethylene / polypropylene fibers, including EAC, EPS, ESC, ESE, EDC, Herculon T426, and Herculon T457 type fibers.

[0067] It has been found that, when tested for repulping resizing, the insulation material samples according to the teachings of the present invention are repulping and therefore recyclable. The insulation material is repulping according to the requirements of the revised version of "Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor" provided by the Fibre Box Association of Elk Grove Village, IL, dated August 16, 2013 (the entire contents of which are incorporated herein by reference). In this respect, the insulation material is recyclable according to the requirements of the revised version of "Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor" provided by the Fibre Box Association of Elk Grove Village, IL, dated August 16, 2013. The container containing the insulation material can be single-flow recyclable, wherein all materials contained in the container can be recycled through a single processing system without the need to separate any materials or components of the container. The results of the repulpability test are as follows:

[0068]

[0069] The results showed that for a sample of approximately 1300 GSM filaments (approximately 90% cardboard and approximately 10% 1 mm bicomponent fiber adhesive), over approximately 98% of the material was resizing and therefore recyclable. The insulation material containers and transport containers taught in this invention are over 85% resizing, and 85% resizing is a “pass grade” for recyclability. The resizing test results are as follows:

[0070]

[0071] The provided thermoplastic bonding fiber weighs less than about 0.2 lbs / sq ft, more particularly, preferably about 0.1875 lbs / sq ft. The remaining reinforcing fiber weighs more than about 0.8 lbs / sq ft, preferably about 1.0625 lbs / sq ft. The bonding fiber is preferably a mixture of fiber and paper components obtained by hammer milling.

[0072] Materials according to the teachings of the present invention can have a compressibility of about 0.3 psi to about 1.4 psi for a compression thickness of about 25% to about 50%. For example, a 1 / 8” thermal insulation pad has a compressibility of about 0.451 psi at a compression thickness of about 25%. The same 1 / 8” pad has a compressibility of about 0.564 psi at a compression thickness of about 30%. The same 1 / 8” pad has a compressibility of about 1.81 psi at a compression thickness of about 50%. A 1 / 4” pad has a compressibility of about 0.425 psi at a compression thickness of about 25%. The same 1 / 4” pad has a compressibility of about 0.547 psi at a compression thickness of about 30%. The same 1 / 4” pad has a compressibility of about 1.566 psi at a compression thickness of about 50%. A 1 / 2” pad has approximately 0.356 psi of compression resistance at approximately 25% compression thickness. The same 1 / 2” pad has approximately 0.458 psi of compression resistance at approximately 30% compression thickness. The same 1 / 2” pad has approximately 1.36 psi of compression resistance at approximately 50% compression thickness. The same 1 / 2” insulation pad can have a tear resistance of approximately 8.4 psi to approximately 8.8 psi.

[0073] When the thermal insulation pad of the present invention is tested according to ASTM C518-15 at approximately 50% relative humidity, the material has an elastic modulus of approximately 2.64 psi. Under a load of approximately 0.020 psi, approximately 5% strain is observed. Under a load of approximately 0.29 psi, approximately 10% strain is observed, and under a load of approximately 0.4 psi, approximately 15% strain is observed. The density of the material can be less than approximately 5 psi, and preferably approximately 3.5 psi. The thermal conductivity of the material can be approximately 0.254 (BTU in / h ft^2Temp F), the thermal resistance can be approximately 1.577 (Temp F Ft^2H / BTU), and the thermal resistance can be approximately 3.943 (Temp F Ft^2h / BTU in). When tested according to ASTM C518-15, the tested pad also has an R-value of approximately 1.577.

[0074] The insulating pad 46 is formed by heating the paper fiber wadding 22 in an oven to a temperature greater than about 350°F, and more preferably to about 362°F. This heating melts the bonding fibers and bonds them to the non-bonded fibers, thereby bonding the fibers together and solidifying them during cooling. Once cooled, the bonding fibers solidify and act as a link to the non-bonded reinforcing fibers, and also serve as reinforcement themselves.

[0075] The insulating paper fiber wadding 22 is heated to form an insulating pad 46, so that its density is less than about 10 pounds per cubic foot. The density of the insulating pad 46 is preferably less than about 10 pounds per cubic foot, and more preferably about 8.3 pounds per cubic foot, and its thickness is about 1 / 4 inch.

[0076] Figure 12 This illustrates a system 140 for forming an insulating liner 142 for a folding box according to another teaching of the invention. Typically, the system 140 utilizes multiple connected conveyor belts 144 to move the insulating pad 46 as described above through a series of processes to form the insulating liner 142. The system 140 uses a cutting device 150 to separate the insulating pad 4 from a continuous feed of wadding 22. An upper paper layer 154 and a lower paper layer 156 are then positioned around the insulating pad 46 using a series of rollers 152. A second cutting device 185 may be used to separate the upper paper layer 154 and the lower paper layer 156 from the continuous paper layer supply. Alternatively, a sealing and cutting device 186 may be used to cut and seal the edges of the upper and lower paper layers surrounding the insulating pad 46. A thermal channel may be positioned to surround the conveyor belts to connect the paper layers 154, 156 surrounding the insulating pad 46 to form the insulating liner 142.

[0077] Figures 13A to 13B This indicates that the insulation pad 46 is formed by cutting from continuous tufts 22. As shown, the tufts 22 and the pad 46 are conveyed along multiple connected conveyor belts 144. The cutting device 150 can be a circular blade. Alternatively, the cutting device 150 can be a strip blade.

[0078] Optionally, the pad 46 can be transversely cut to form two waddings with partial thicknesses, which can have equal thicknesses (i.e., the fabric insulation pad is divided in half) or unequal thicknesses. The present invention is capable of forming waddings with partial thicknesses of about 1 / 16 inch or more. The initial insulation pad can be longitudinally separated to provide two, three, or more waddings with partial thicknesses.

[0079] In this invention, it has been found that the heat insulation pad 46 can be separated controllably and precisely if the feed roller is within a predetermined distance from the cutting blade. This distance is important due to the compressibility and flexibility of the heat insulation pad. In a preferred embodiment, the predetermined distance is from about 0 to about 2 mm.

[0080] The thermoplastic bonding fibers and reinforcing fibers are laid out randomly and uniformly along the xyz axes. The reinforcing fibers are typically bonded together by heating the bonding fibers to above their glass transition temperature. Typically, less than about 20% (by weight) of bonding fibers is used, and preferably about 10% of bonding fibers are used to form the insulation pad.

[0081] The provided thermoplastic bonding fibers weigh less than about 0.2 pounds per square foot, more particularly, preferably about 0.1875 pounds per square foot. The remaining reinforcing fibers weigh more than about 0.8 pounds per square foot, preferably about 1.0625 pounds per square foot. The bonding fibers are preferably a mixture of thermoplastic polymers, including polyethylene / polyester or polypropylene / polyester or combinations thereof.

[0082] Figures 14A to 14C This illustrates the application of the upper paper layer according to the teachings of the present invention. A series of rollers 152 are then used to position the upper paper layer 154 and the lower paper layer 156 surrounding the heat insulation pad 46. As shown, the rollers 152 can be positioned at an angle not perpendicular to the direction of the moving conveyor belt. Preferably, this angle can be approximately 45 degrees to the flow direction of the conveyor belt.

[0083] Figures 15A to 15B This indicates the application of the bottom paper layer 156; once the top paper layer 154 is above the pad 46, the roller 152 can position the bottom paper layer 156 below the pad 46 at the intersection of the two conveyor belts 144. The second cutting device 185 is used to separate the top paper layer 154 and the bottom paper layer 156 from the continuous paper supply.

[0084] Figure 16A and Figure 16B This refers to the side sealing of the paper layers 154, 156 surrounding the insulation member. In this regard, a series of cutting and sealing rollers 186 cut and seal the sides of the paper layers 154, 156 using a recycled compatible or water-soluble adhesive. The cutting and sealing rollers 186 are biased onto the paper layers 154, 156 using a load such as a spring.

[0085] Figure 17 The thermal channel 110, which is optionally used to form the box insulation member or insulation wadding according to the teachings of the present invention, should use a heat-sensitive recyclable or water-soluble adhesive. Once the structure is sealed on all sides, the sub-assembly is sealed through the thermal channel 110, which surrounds the insulation pad 46 with the upper paper layer 154 and the lower paper layer 156.

[0086] like Figure 18A and Figure 18B As shown, the insulation wadding 22 is attached to the corrugated box 158. Optionally, the insulation wadding 22 can be directly attached to the box or the intermediate paper layer 160 before the box is cut into the form of a folded box. When used to form the pad 46, the adhesive material in the form of a recyclable or water-soluble binder or fusible fiber can preferably be recyclable or biodegradable, and can preferably be selected from the group consisting of polyethylene, polyester, polypropylene, and mixtures thereof.

[0087] The insulating floc 22 can be used in containers with polymer capsules for containing liquids or storing gases, or in packaging boxes of photosensitive or similar materials. In this respect, the insulating floc 22 can be used to maintain the temperature of the aforementioned materials above or below the ambient temperature.

[0088] Optionally, the box 158 can be, for example, a flat box with heat-insulated top and bottom surfaces (e.g., a pizza box). The container is envisioned as a means of regulating temperature changes within the box. For example, the container can contain a device such as a recyclable cold pack, which utilizes insulation to provide a specific environment for the contents, for example, a temperature above or below ambient temperature. In this respect, the cold pack can be a recyclable component that is perforated and contains, for example, dry ice. The container can be formed by folding or standing the cardboard blank upright. The closure inside the container can be a removable or non-permanently fixed component. The container may include a shock-absorbing insulation layer.

[0089] Containers, packaging elements, or packages using insulating materials according to the teachings of the present invention can be used to protect organisms, articles, or materials facing specific transportation environmental challenges. In this regard, insulated boxes can be used to transport live plants or animals. Containers may include integral connecting or dispensing features to allow the filling or dispensing of carried materials into the insulated container.

[0090] Paper and insulating structures are particularly suitable for protecting the contents from mechanical damage. In this regard, containers can have a polygonal cross-section with an internal protective layer for the contents. Containers or packaging can have special mechanisms, such as foldable members or funnels (including formed pouring spouts) for dispensing the contents, or dispensing devices incorporated into removable or non-permanently fixed container closures.

[0091] According to the teachings of the present invention, a method for forming an insulated box is proposed. The method includes: forming paper fibers by passing recycled paperboard through a hammer mill; and mixing the paper fibers with recyclable compatible adhesive fibers to form a mixture of 2% to 25% recyclable compatible fibers and the remainder being paper and paperboard fibers. The material is then formed from the recycled paper fibers into paper fiber wadding having a first width and a first length, and a weight of 1000 gsm to 1600 gsm. Optionally, a first recyclable paper layer is attached to the paper fiber wadding on a first surface of the wadding. The fiber wadding can be placed inside or attached to the corrugated box. The paper layer can be attached to a corrugated paper element, or the wadding can be directly attached to a surface layer of the paperboard. Optionally, a second recyclable paper layer can be attached to the paper fiber wadding on a second surface of the wadding.

[0092] Flocs can be formed by melting the aforementioned adhesive fibers. The first paper layer can be bonded to the paper fiber flocs by heating the paper layer or by placing one of a recyclable compatible or water-soluble adhesive between the first paper layer and the flocs. A first and second layer of recyclable paper can be arranged around the insulation material to form a bag. The first and second layers can be bonded to the opposite sides of the fiber paper layer by sewing or by bonding a pair of opposite sides with one of a recyclable compatible or water-soluble adhesive. The adhesive fibers are selected from the group consisting of PVOH, polyethylene, polyester, polypropylene, bicomponents, and mixtures thereof. The thickness of the insulation pad is from about 1 / 4 inch to about 1 inch.

[0093] An insulating sleeve can be formed by the following steps: cutting a first sheet of paper and attaching a first side of a paper fiber pad having a fiber web of substantially randomly distributed paper fibers to the first sheet. The fiber web of paper fibers can be tightly bonded to the first sheet. The insulating pad is attached to a portion of the inner surface of the corrugated box. After attaching the fiber web to the inner surface of the box, the process includes stamping the perimeter of the box and folding the corrugated box. Heat radiated through rollers or steam can be used to tightly bond the fibers to the paper and paperboard fibers to achieve a density of less than about 10 psi.

[0094] To recycle the insulated containers according to the teachings of the present invention, clean, used insulated corrugated containers are collected, in many cases as part of a mixed recyclable stream (such as single-stream recycling). To optimize recyclability, the containers should be free of contaminants such as food, metal foil, wax, etc. The collected insulated corrugated containers are sorted, compacted, and bundled with non-insulated corrugated containers for space-saving storage and handling, whether at end-use (shop or commercial) or at a recycling center. The bundles are unpacked, and the insulated corrugated containers are placed in a resizing tank. The resizing tank is a large vat with an agitator that stirs the containers containing hot water. The water may preferably have a temperature above about 100 degrees Fahrenheit. They are stirred to form a liquid slurry (pulp) of fiber and water.

[0095] The repulper may have a chain or rope that hangs into a rotating drum of material and can subsequently be removed from the repulper. This chain or rope is used to remove larger contaminants that would become entangled in the chain, such as long, thick ropes, thin cords, strips, plastics, and metal strips. The remaining liquid pulp passes through various filters (where additional metal falls to the bottom for removal), screens, cyclone separators, or even large tanks (where contaminants float to the top and can be scraped off). The cleaned pulp is then fed to the paper machine.

[0096] In a typical paper machine, a highly diluted fiber solution is poured onto a moving screen, which allows water to drain away, forming a continuous fiber mat. The continuous fiber mat is pressed between rolls to remove even more water. The wet, continuous fiber web is then passed through a dryer, where the top and bottom of the web alternately contact the heated surfaces of a drying drum to remove any remaining moisture from the paper. At the end of the paper machine, the paper is wound onto a large roll.

[0097] Corrugated board is made from three or more sheets of paperboard. The outer surface is a facing paper, and the inner grooved paper is called the medium. The paper sheet that will become the corrugated medium can be softened with steam and then fed through a machine called a facer. The medium passes between two large toothed metal rollers, giving it wavy ridges or "grooves". A starch binder is applied to the grooved medium, which is then sandwiched between two flat sheets of paper (the facing paper). As described above, insulation material can be attached to the paperboard to form a recyclable insulation structure. In this respect, the insulation material can be directly attached to the box or to the recyclable paper surrounding the insulation structure.

[0098] The assembled 3± layers of boards with relevant insulation material are then passed through the curing section of a continuous mesh, then scored, cut into blanks (sheets) of appropriate size, and stacked. To manufacture new boxes, the corrugated sheets are processed by printing, scoring, die-cutting, and folding machines. The side seams of the box (manufacturer's joints) are secured by adhesive, tape, or stitching.

[0099] This invention provides exemplary embodiments to enable a thorough understanding of the invention and to fully convey the scope of the invention to those skilled in the art. Numerous specific details, such as examples of particular components, devices, and methods, are set forth in this invention to provide a thorough understanding of embodiments thereof. It will be apparent to those skilled in the art that these specific details are not necessary, that the exemplary embodiments may be implemented in many different ways, and that neither should be construed as limiting the scope of the invention. In some exemplary embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail.

[0100] The terminology used herein is for the purpose of describing particular exemplary embodiments only and is not intended to limit the invention. As used herein, the absence of a quantifier before a pronoun may be intended to include one or more pronouns unless the context clearly specifies otherwise. The terms “comprising,” “including,” “comprises,” and “having” are inclusive and therefore specifically indicate the presence of the stated feature, integer, step, operation, element, and / or component, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Unless specifically stated as a sequence of implementation, the method steps, processes, and operations described herein should not be construed as requiring them to be performed in the particular order discussed or described. It should also be understood that additional or alternative steps may be employed.

[0101] When an element or layer is referred to as “on,” “joined to,” “connected to,” or “linked to” another element or layer, it may be directly on, joined to, joined to, or linked to the other element or layer, or there may be intermediate elements or layers present. Conversely, when an element is referred to as “directly on,” “directly joined to,” “directly connected to,” or “directly linked to” another element or layer, there may be no intermediate elements or layers present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations of one or more of the associated listed items.

[0102] Although the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or parts, these elements, components, regions, layers, and / or parts should not be limited by these terms. These terms may be used only to distinguish one element, component, region, layer, or part from another. Unless the context clearly indicates otherwise, terms such as “first,” “second,” and other numerical terms used herein do not refer to a sequence or order. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or part discussed below may be referred to as a second element, component, region, layer, or part.

[0103] As shown in the figure, for ease of description, spatial relative terms such as "inside," "outside," "below," "under," "lower," "above," "upper," etc., are used to describe the relationship of one element or feature to another. In addition to the orientations shown in the figure, spatial relative terms may be intended to cover different orientations of the device during use or operation. For example, if the device in the figure is flipped, an element described as "below" or "under" other elements or features would be oriented as "above" other elements or features. Therefore, the exemplary term "below" can include orientations of "above" and "below." The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptors used herein can be interpreted accordingly.

[0104] The foregoing description of embodiments has been provided for illustrative and descriptive purposes. It is not intended to be exhaustive or limiting of the invention. Various elements or features of a particular embodiment are generally not limited to that particular embodiment, but are interchangeable where applicable and can be used in selected embodiments, even if not specifically shown or described. Variations are also possible in many ways. These variations should not be considered as departing from the invention, and all such modifications are intended to be included within the scope of the invention.

Claims

1. A box assembly, comprising: A box formed from paper blank, the box including a plurality of side box panels and a bottom box panel defining the interior and the bottom; The heat insulation pad located inside the box is composed of a section of wadding assembly, the wadding assembly including heat insulation wadding that contacts the first paper layer and the second paper layer. The heat insulation pad defines multiple sections. Wherein, at least one portion of the heat insulation pad contacts one of the plurality of side box panels, and wherein another portion of the plurality of portions of the heat insulation pad contacts the bottom box panel; and The insulating wadding is formed of a mixture of paper reinforcing fibers and thermoplastic adhesive fibers randomly distributed within the paper reinforcing fibers, wherein the thermoplastic adhesive fibers account for 0.5% to 25% of the weight of the insulating wadding, and the insulating wadding has a thickness of at least 1 / 16 inch. The thermoplastic adhesive fiber is composed of two components: polyethylene (PE) and polypropylene (PP). The ratio of PE to PP ranges from 50 / 50 to 65 / 35.

2. The box assembly according to claim 1, wherein, The first paper layer is sealed to the second paper layer, such that the heat-insulating wadding is encapsulated between the paper layers.

3. The box assembly according to claim 2, wherein, Each edge of the first paper layer is heat-sealed to one edge of the second paper layer.

4. The box assembly according to claim 1, wherein, The second paper layer is part of the paper blank, such that the insulating wadding is in contact with at least a portion of the surface of the box.

5. The box assembly according to claim 1, wherein, The insulating fibers are adhered to at least a portion of the box.

6. A box assembly, comprising: A box formed from paper blank, the box including a plurality of side box panels and a bottom box panel defining the interior and the bottom; The heat insulation pad located inside the box is composed of a section of wadding assembly, the wadding assembly including heat insulation wadding that contacts the first paper layer and the second paper layer. The heat insulation pad defines multiple sections. Wherein, at least one portion of the heat insulation pad contacts one of the plurality of side box panels, and wherein another portion of the plurality of portions of the heat insulation pad contacts the bottom box panel; and The insulating fiber is formed from a mixture of paper fibers and thermoplastic adhesive fibers randomly distributed within the paper fibers. The thermoplastic adhesive fibers account for 0.5% to 25% of the weight of the insulating fiber. The thickness of the insulating fiber is greater than or equal to 1 / 16 inch. The thermoplastic adhesive fibers are adhered to the paper fibers by melting.

7. The box assembly according to claim 6, wherein, The thermoplastic adhesive fiber includes at least one of polyethylene, polyester, polypropylene and polyvinyl alcohol (PVOH).

8. The box assembly according to claim 7, wherein, The thermoplastic adhesive fiber is composed of a two-component fiber comprising polyethylene (PE) and polypropylene (PP).

9. The box assembly according to claim 8, wherein, The ratio of PE to PP ranges from 50 / 50 to 65 / 35.

10. The box assembly of claim 6, wherein, The first paper layer is sealed to the second paper layer, such that the heat-insulating wadding is encapsulated between the paper layers.

11. The box assembly of claim 10, wherein, Each edge of the first paper layer is heat-sealed to one edge of the second paper layer.

12. A box assembly, comprising: A box formed from paper blank, the box including a plurality of side box panels and a bottom box panel defining the interior and the bottom; The heat insulation pad located inside the box is composed of a section of wadding assembly, the wadding assembly including heat insulation wadding that contacts the first paper layer and the second paper layer. The heat insulation pad defines multiple sections. Wherein, at least one portion of the heat insulation pad contacts one of the plurality of side box panels, and wherein another portion of the plurality of portions of the heat insulation pad contacts the bottom box panel; and The insulating fiber is formed from a mixture of paper fibers and thermoplastic adhesive fibers randomly distributed within the paper fibers, comprising 0.5% to 25% by weight of the insulating fiber. The thermoplastic adhesive fibers are adhered to the paper fibers, and the length of the thermoplastic adhesive fibers is between 0.5 mm and 16 mm. The thermoplastic adhesive fiber is composed of two components: polyethylene (PE) and polypropylene (PP). The ratio of PE to PP ranges from 50 / 50 to 65 / 35.

13. The box assembly of claim 12, wherein, The first paper layer is sealed to the second paper layer, such that the heat-insulating wadding is encapsulated between the paper layers.

14. The box assembly of claim 13, wherein, Each edge of the first paper layer is heat-sealed to one edge of the second paper layer.

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