Paper-based packaging pad for packaging assembly

Abstract

A packaging assembly for a household appliance may include a corrugated frame defining an encapsulation portion. The packaging assembly may further include a paper-based packaging pad fully encapsulated within the encapsulation portion of the corrugated frame. The paper-based packaging liner may include a molded paper composite. The molded paper composite is a wet molded paper composite formed via a wet molding process.

Description

Paper-based packaging liners for packaging components Technical Field

[0001] The present subject matter relates generally to a packaging assembly and, more particularly, to a packaging assembly for a household appliance. Background Art

[0002] Household appliances (e.g., dishwashers, refrigerators, ovens, etc.) are available in a variety of configurations. Often, for shipping household appliances, robust packaging components are required. These packaging components can be configured to protect the appliance during shipping and handling. For example, packaging components often include some type of padding to help absorb shock (e.g., from drops or impacts) that may occur during shipping and handling.

[0003] Typically, expanded polystyrene (EPS) is used as a liner for packaging components of household appliances. However, there are challenges with using EPS as a liner. For example, while EPS is recyclable, it is typically only recyclable at specific drop-off locations. This can be inconvenient for users because EPS is not typically recyclable through household recycling streams. Additionally, EPS is typically bonded to the frame of the packaging component (e.g., a cardboard frame). In this case, even if the packaging components are taken to a drop-off location, they may still end up in a landfill where they cannot be recycled because separating the EPS from the frame can be difficult and time-consuming. Furthermore, EPS is susceptible to breaking or cracking during transport. Since EPS is typically not enclosed within a frame, loose pieces can create a mess when users unpack their household appliances.

[0004] Therefore, it would be useful to have a packaging assembly for a household appliance that obviates one or more of the above-mentioned disadvantages. Summary of the Invention

[0005] Aspects and advantages of the invention will be set forth in part in the following description, or may be obvious from the description, or may be learned through practice of the invention.

[0006] In one exemplary aspect of the present disclosure, a packaging assembly is provided. The packaging assembly may include a corrugated packaging frame. The corrugated frame may include a first panel and a second panel. The packaging assembly may further include a paper-based packaging liner encapsulated within the first and second panels of the corrugated packaging frame. The paper-based packaging liner may include a molded paper composite material.

[0007] In another exemplary aspect of the present disclosure, a packaging assembly for a household appliance is provided. The packaging assembly may include a corrugated frame defining an encapsulation portion. The packaging assembly may further include a paper-based packaging liner completely encapsulated within the encapsulation portion of the corrugated frame. The paper-based packaging liner may further include a molded paper composite material. The molded paper composite material is a wet-molded paper composite material formed via a wet molding process.

[0008] These and other features, aspects and advantages of the present invention will become better understood with reference to the following description and appended claims.The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] With reference to the accompanying drawings, a complete and enabling disclosure of the invention, including the best mode thereof, is set forth in the specification to those skilled in the art.

[0010] FIG. 1 provides a perspective view of a package according to one or more exemplary embodiments of the present disclosure.

[0011] 2 provides a perspective view of the packaging assembly of FIG. 1 with the top gasket removed.

[0012] 3 provides a perspective view of a top pad of a packaging assembly according to one or more exemplary embodiments of the present subject matter.

[0013] FIG. 4 provides an exploded view of the packaging assembly of FIG. 1 .

[0014] Repeat use of reference characters in the present specification and drawings is intended to represent the same or analogous features or elements of the invention. DETAILED DESCRIPTION

[0015] Reference will now be made in detail to embodiments of the present invention, one or more examples of which are illustrated in the accompanying drawings. Each example is provided by way of explanation of the present invention and is not intended to limit the present invention. In fact, it will be apparent to those skilled in the art that various modifications and variations may be made to the present invention without departing from the scope of the present invention. For example, a feature shown or described as part of one embodiment may be used together with another embodiment to produce yet another embodiment. Therefore, the present invention is intended to cover such modifications and variations within the scope of the appended claims and their equivalents.

[0016] As used herein, the terms "first," "second," and "third" can be used interchangeably to distinguish one component from another and are not intended to represent the position or importance of the various components. The terms "comprise" and "contain" are intended to be inclusive in a manner similar to the term "comprises." Similarly, the term "or" is generally intended to be inclusive (i.e., "A or B" is intended to mean "A or B or both"). In the context of, for example, "at least one of A, B, and C," the term "at least one" refers to only A, only B, only C, or any combination of A, B, and C. In addition, here and throughout the specification and claims, range limitations can be combined or interchanged. Such a range is definite and includes all subranges contained therein, unless the context or language indicates otherwise. For example, all ranges disclosed herein include endpoints, and the endpoints can be combined independently of each other. The singular forms "a," "an," and "the" include plural references unless the context clearly states otherwise.

[0017] The approximate language used throughout the specification and claims herein can be used to modify any quantitative representation that is allowed to vary without causing a change in the basic function associated therewith. Therefore, the value modified by one or more terms, such as "roughly," "approximately," and "substantially," is not limited to the precise value specified. In at least some cases, the approximate language can correspond to the accuracy of the instrument used to measure the value, or the accuracy of the method or machine used to construct or manufacture a component or system. For example, the approximate language can refer to within a range of 10 percent, that is, including values ​​within a range of 10 percent greater than or less than the value being described. In this regard, for example, when used in the context of an angle or direction, these terms include within a range of ten degrees greater than or less than the angle or direction being described, for example, "roughly vertical" includes forming an angle of up to ten degrees with the vertical direction V in any direction, such as clockwise or counterclockwise.

[0018] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Furthermore, reference to "one embodiment" or "an embodiment" does not necessarily refer to the same embodiment, although it may. Any implementation described herein as "exemplary" or "embodiment" is not necessarily to be construed as preferred or advantageous over other implementations.

[0019] According to one or more exemplary embodiments of the present subject matter, a packaging assembly for household appliances is provided. The exemplary packaging assembly can advantageously include a paper-based packaging liner for absorbing shock or vibration during the transportation and handling of the household appliance. It will be appreciated that the paper-based packaging liner can advantageously be molded from waste paper, such as shredded paper. A wet molding process can advantageously be used to mold the paper-based packaging liner into a desired shape and size. In addition, once molded, the paper-based packaging liner can advantageously be encapsulated in a corrugated packaging frame. The corrugated packaging frame can also be paper-based (e.g., can be composed of a paper material such as cardboard). In this regard, when the packaging assembly reaches its final location, the combination of the packaging assembly can be recycled as a whole.

[0020] With reference now to the accompanying drawings, an exemplary packaging assembly 100 for household appliances 102 is provided. Specifically, Fig. 1 has depicted a perspective view of the packaging assembly 100 for household appliances 102, and Fig. 2 has depicted a perspective view of the exemplary packaging assembly 100 of Fig. 1, with top pad frame 104 wherein removed, and Fig. 3 has depicted an exploded view of the exemplary packaging assembly 100 of Fig. 1. The term " household appliances " used herein can describe an electrical appliance that is typically used for or is intended to be used for common household tasks. According to other embodiments, these " household appliances " can include but are not limited to refrigerators, dishwashers, microwave ovens, stoves, ovens, washing machines, dryers, water heaters, water filters or water purifiers, air conditioners, space heaters and any other suitable household or household appliances.

[0021] As best shown in FIG1 , an exemplary packaging assembly 100 generally defines an interior chamber 101 that can be complementary to a predetermined household appliance (e.g., a refrigerator, a dishwasher, etc.). The packaging system can include a corrugated packaging frame that can include one or more frame components. For example, in some embodiments, the corrugated packaging frame of the packaging assembly includes a top mat frame 104, a skid or base mat frame 106, a plurality of sidewall frames 108, and a plurality of corner post frames 110. Each of the top mat frame 104, the base mat frame 106, the plurality of sidewall frames 108, and the plurality of corner post frames 110 can be constructed from one or more sheets of corrugated sheet 112 (see, e.g., FIG3 ).

[0022] Alternatively, in some other embodiments, each of the top mat frame 104 , the base mat frame 106 , the plurality of side wall frames 108 , and the plurality of corner post frames 110 may be constructed from one or more sheets of corrugated board, fiberboard, or paperboard.

[0023] The corrugated board 112 can include one or more liners, such as the flat surface of the corrugated board 112. Furthermore, the corrugated board 112 can include media attached to the one or more liners. For example, single-faced corrugated board 112 can generally refer to a corrugated board 112 having one liner and media attached thereto. As another example, single-walled corrugated board 112 can generally refer to a corrugated board 112 having two liners and fluted media attached therebetween. It should be understood that both the one or more liners and the media can be constructed from a paper-based material, such as paperboard. In this regard, the corrugated packaging frame can be a paper-based corrugated packaging frame.

[0024] The media can be a fluted layer of a corrugated sheet 112. For example, the media can define a fluted pattern (e.g., a wavy, undulating, or serpentine pattern). In particular, the media can impart rigidity and strength to the corrugated sheet 112 and help prevent or mitigate crushing of the corrugated sheet 112. For example, a cornstarch-based adhesive can be used to bond the media to the adjacent liner. Furthermore, each corrugated packaging frame (e.g., the top mat frame 104, the base mat frame 106, the plurality of sidewall frames 108, or the corner post frames 110) can include one or more corrugated sheets 112 that together define the shape of the corrugated packaging frame.

[0025] Referring now to Figures 2-4, the top mat frame 104 of the packaging assembly 100 will be described in greater detail. For purposes of brevity and clarity, only the top mat frame 104 is described herein. Those skilled in the art will appreciate that the subject matter described herein can be applied to any suitable corrugated frame (e.g., the base mat frame 106, the plurality of sidewall frames 108, or the corner post frames 110), and is not intended to be limited to only the top mat frame 104.

[0026] As shown, the exemplary top mat frame 104 includes a single piece of corrugated sheet 112. The exemplary corrugated sheet 112 of the top mat frame 104 can be folded so that the top mat frame 104 forms six main panels. For example, the top mat frame 104 can include a top panel 114, a bottom panel 116, a front panel 118, a back panel 120, a first side panel 122, and a second side panel 124. The bottom panel 116 can be formed so that a top portion 126 of the household appliance 102 can be placed therein. For example, the bottom panel 116 can include a recessed portion 117 (e.g., as best shown in FIG. 3 ) so that the top portion 126 of the household appliance 102 can fit therein.

[0027] It should be understood that in some other embodiments, each major panel of the corrugated packaging frame can be a separate corrugated sheet 112. For example, in some such embodiments, the top mat frame 104 can include six separate corrugated sheets 112, each of which forms a separate panel of the top mat frame 104 (e.g., the top panel 114, the bottom panel 116, the front panel 118, the back panel 120, the first side panel 122, or the second side panel 124). In some such embodiments, each corrugated sheet 112 can include attachment features (e.g., tabs, hooks, slots, etc.) that can be used to attach the major panels together in a desired shape.

[0028] Each corrugated packaging frame (e.g., the top mat frame 104, the base mat frame 106, the plurality of sidewall frames 108, or the corner post frames 110) can encapsulate one or more paper-based packaging liners 130 therein. As used herein, "encapsulate" (when used as a verb, including its cognates, such as "encapsulated") can generally refer to a corrugated packaging frame that surrounds or encloses one or more paper-based packaging liners 130 on all sides. More specifically, in some embodiments, the panels of the corrugated packaging frame can completely encapsulate or enclose one or more paper-based packaging liners 130. That is, the panels can surround, encase, or protect one or more paper-based packaging liners 130 within or as in a package. Furthermore, in some embodiments, each panel of the corrugated frame can define an encapsulation portion 132 within which the paper-based packaging liners 130 can be encapsulated.

[0029] In some other embodiments, the top mat frame 104 can define a plurality of encapsulation portions 132 surrounding the recessed portion 117. For example, as shown in FIG3 , the top mat frame 104 can include five encapsulation portions surrounding the recessed portion 117. In some such embodiments, a discrete paper-based packaging liner 130 can be encapsulated within a respective encapsulation portion 132.

[0030] In some embodiments, the paper-based packaging liner 130 includes or is formed as a molded paper composite material. The molded paper composite material can include shredded paper material formed into a predetermined shape via a wet molding process. The shredded paper material can include any suitable paper material that has been shredded (e.g., torn or cut into strips or fine particles). For example, the shredded paper material can be waste paper or recycled paper material, such as newspaper, which has been shredded into a desired size or shape.

[0031] Generally, the wet molding process can include three steps. The first step is a soaking step, the second step is a molding step, and the third step is a drying step. The soaking step can include soaking the shredded paper material in a liquid solution, such as a water-based solution, for a predetermined amount of time. The predetermined amount of time that the shredded paper material is soaked can correspond to the consistency of the paper. For example, it is generally understood that when the shredded paper material is soaked in a liquid solution, the fibers of the paper begin to separate. Generally, the longer the paper is soaked in the liquid solution, the more the fibers separate. Ultimately, if the shredded paper material is soaked in the liquid solution for a sufficient period of time, the shredded paper material can achieve a pulp-like consistency.

[0032] After the shredded paper material has been soaked in the liquid solution for a predetermined amount of time, a certain amount of soaked shredded paper material can be placed in the mold. The mold can limit the predetermined shape of the molded paper composite material. For example, the predetermined shape can be any suitable shape in the corrugated frame (for example, top pad frame 104, base pad frame 106, multiple sidewall frames 108 or corner column frame 110) that can be encapsulated in the packaging component 100. For example, the predetermined shape can directly correspond to the shape of the corrugated frame in which it can be encapsulated. In other words, the predetermined shape can be the shape roughly the same as the corresponding corrugated frame, but slightly smaller than the corresponding corrugated frame so that it can be encapsulated in the corrugated frame. For example, the predetermined shape of the molded paper composite material can directly correspond to the shape of the top pad frame 104.

[0033] In addition, the molding step may include pressing or compacting the soaked shredded paper material within the mold. For example, a press or compactor (e.g., a pneumatic or hydraulic press or compactor) may be used to press or compact the shredded paper material within the mold. Pressing the soaked shredded paper material may compact the shredded paper material into a desired shape. In addition, the force used when pressing the soaked shredded paper material or the amount of shredded paper material placed within the mold may correspond to the density of the molded paper composite. For example, it is generally understood that the more shredded paper material is placed in the mold during the molding step, or the greater the force applied by the press or compactor, the denser the molded paper composite. After the molding step, the molded paper composite may be removed from the mold. The molded paper composite may then be dried for a predetermined amount of time in any suitable manner. For example, the molded paper composite may be air-dried, fan-dried, or dried for a predetermined amount of time in a low-heat conveyor oven. In this regard, moisture may be removed from the molded paper composite.

[0034] It should be understood that the molded paper composite material of the paper-based packaging liner 130 can be formed into any shape. For example, as described above, the predetermined shape can correspond to the shape of the corrugated frame within which the paper-based packaging liner 130 can be enclosed. However, in some other embodiments, the predetermined shape can be a regular geometric shape, such as a sphere or a cube. In such embodiments, the paper-based packaging liner 130 can be a paper-based packaging liner 130, and more specifically, a plurality of paper-based packaging liners 130 having regular geometric shapes.

[0035] In addition to or in lieu of a paper-based packaging liner 130 that may correspond to the shape of a corrugated frame in which the paper-based packaging liner can be encapsulated, a plurality of paper-based packaging liners 130 having regular geometric shapes may be used. For example, a plurality of paper-based packaging liners having regular geometric shapes may be used to fill gaps or spaces that may exist between a corrugated frame and an encapsulated paper-based packaging liner 130 (which may correspond to the shape of the corrugated frame in which the paper-based packaging liner can be encapsulated). As another example, a plurality of regular paper-based packaging liners may be encapsulated within a corrugated frame to provide cushioning or protection (e.g., to a household appliance 102 held within the packaging assembly).

[0036] Embodiments of the present subject matter advantageously provide a packaging assembly comprising a paper-based packaging liner. The exemplary packaging assembly is advantageously recyclable in its entirety because it is composed entirely of a paper-based material. For example, the packaging assembly can be composed entirely of a paper-based material, which is different from traditional packaging assemblies comprising synthetic liners (e.g., packaging assemblies that may include expanded polystyrene). The exemplary paper-based packaging liner advantageously comprises a shredded paper material that is formed into a molded paper composite material via a wet molding process. The paper-based packaging liner is enclosed in a corrugated packaging frame and used as a base frame, wall frame, or corner post frame of a household or home appliance packaging assembly. Enclosing the paper-based packaging liner completely within the corrugated frame can advantageously maintain the shape of the paper-based packaging liner and provide cushioning during transportation and handling of the packaging assembly.

[0037] This written description uses examples to disclose the invention, including its best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or components and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. If other examples include structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims, then these other examples are intended to fall within the scope of the claims.

Claims

1. A packaging assembly, comprising: a corrugated packaging frame comprising a first panel and a second panel; as well as A paper-based packaging liner enclosed within the corrugated packaging frame of the corrugated packaging frame comprises a molded paper composite material.

2. The packaging assembly according to claim 1, wherein: The corrugated packaging frame further includes a third panel, a fourth panel, a fifth panel, and a sixth panel, wherein the first panel, the second panel, the third panel, the fourth panel, the fifth panel, and the sixth panel together completely encapsulate the paper-based packaging liner.

3. The packaging assembly according to claim 1, wherein The paper-based packaging liner is a plurality of paper-based packaging liners enclosed within the corrugated packaging frame.

4. The packaging assembly according to claim 1, wherein The corrugated packaging frame is a paper-based corrugated packaging frame.

5. The packaging assembly according to claim 1, wherein The molded paper composite material includes shredded paper material.

6. The packaging assembly according to claim 5, wherein: The shredded paper material is waste paper or recycled paper.

7. The packaging assembly according to claim 1, wherein: The molded paper composite is a wet molded paper composite formed via a wet molding process.

8. The packaging assembly according to claim 1, wherein: The corrugated packaging frame defines an interior cavity complementary to a predetermined household appliance.

9. The packaging assembly according to claim 8, wherein: The corrugated packaging frame includes a top mat frame positioned above the predetermined home appliance, a base mat frame positioned below the predetermined home appliance, a side wall frame positioned beside the side of the predetermined home appliance, or a corner column frame positioned at the edge of the predetermined home appliance.

10. The packaging assembly according to claim 1, wherein The first and second panels at least partially define an encapsulation portion, and wherein the paper-based packaging liner is encapsulated within the encapsulation portion.

11. A packaging assembly for a household appliance, the packaging assembly comprising: a corrugated packaging frame defining a package portion; and a paper-based packaging liner completely encapsulated within the encapsulation portion of the corrugated packaging frame, the paper-based packaging liner comprising a molded paper composite material, The molded paper composite material is a wet-molded paper composite material formed via a wet-molding process.

12. The packaging assembly according to claim 11, wherein The corrugated packaging frame further includes a first panel, a second panel, a third panel, a fourth panel, a fifth panel, and a sixth panel, and wherein the first panel, the second panel, the third panel, the fourth panel, the fifth panel, and the sixth panel together define the packaging portion.

13. The packaging assembly according to claim 11, wherein: The paper-based packaging liner is a plurality of paper-based packaging liners enclosed within the corrugated packaging frame.

14. The packaging assembly according to claim 11, wherein The corrugated packaging frame is a paper-based corrugated packaging frame.

15. The packaging assembly according to claim 11, wherein The molded paper composite material includes shredded paper material.

16. The packaging assembly according to claim 15, wherein: The shredded paper material is waste paper or recycled paper.

17. The packaging assembly according to claim 11, wherein: The corrugated packaging frame defines an interior cavity complementary to a predetermined household appliance.

18. The packaging assembly according to claim 17, wherein: The corrugated packaging frame includes a top mat frame positioned above the predetermined home appliance, a base mat frame positioned below the predetermined home appliance, a side wall frame positioned beside the side of the predetermined home appliance, or a corner column frame positioned at the edge of the predetermined home appliance.

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