Method for manufacturing a packaging product and packaging product

Abstract

Packaging products can consist of paper and biodegradable materials containing cushioning to protect goods from damage during transport. However, a common problem is that such paper packaging is often large and bulky. Since the packaging itself doesn't represent the value of the goods but is intended to be part of the most cost-effective yet efficient packaging solution, the packaging industry aims to make the storage and shipping of such packaging sustainable, yet still affordable and effective. This is achieved by producing a paper packaging product that is only expanded shortly before use, allowing for space-saving and efficient storage and transport until needed. A solid foaming agent is sandwiched between two layers of paper. When activated, this agent releases a liquid that saturates the paper layers, making them flexible. The space created by the expansion of the foaming agent can be contained within the expanded space.

Description

[0001] The present invention relates to a method for producing a packaging product comprising a flat first paper web and a flat second paper web, wherein, in a preparatory step, a solid foam former is applied to at least the first paper web in a patterned section, and the first paper web and the second paper web are bonded with the solid foam former interposed. The invention also relates to such a packaging product.

[0002] It is already known in the art to produce packaging products from paper consisting of bag-shaped sleeves filled with organic filling material, such as cardboard chips. Such packaging products are frequently used as filling material for parcels and are very popular due to their environmental compatibility. The problem here, however, is not so much that the material itself creates waste, but rather that it takes up a lot of space and one package containing such packaging materials can be used for perhaps four parcels to be sent. Storage and transport are correspondingly inefficient. A truck full of the familiar packaging material hardly carries any weight and is therefore effectively driving empty. A comparatively large amount of space must be reserved in the warehouse for the storage of such packaging products.

[0003] Compared to other solutions, such packaging products have so far played a subordinate role. More often, paper that can be kept on a roll is cut and crumpled, so that a shaped body is only created during packaging. This requires some strength and skill during packing, but is considerably more efficient. In terms of waste, paper from the roll represents a more or less comparable easily degradable product.

[0004] Due to their portionability and good spring properties, film bags are also known in the state of the art. These bags can also be filled and sealed on-site during packaging, making them easy to store. However, these either require a suitable machine on-site for filling and sealing, or the film air cushions are delivered ready-made. In this case, they offer no advantage in storage. In any case, these films must be disposed of for waste separation so that they can be fully recycled. Most films practically do not decompose.

[0005] Against this background, the present invention is based on the object of producing a method for producing a packaging product and a corresponding packaging product which, on the one hand, is portionable and has good cushioning properties, but on the other hand is also easy to store.

[0006] This object is achieved by a method for producing a packaging product according to the features of independent claim 1 and a corresponding packaging product according to the features of independent claim 12. Useful embodiments of both the production method and the packaging product can be found in the respective subsequent dependent claims.

[0007] In this respect, a method is provided for producing a packaging product, comprising a flat first paper web and a flat second paper web, wherein, in a preparatory step, a solid foam former is applied in a pattern section at least to the first paper web and the first paper web and the second paper web are bonded with the solid foam former interposed. Such a method is characterized according to the invention in that, due to activation of the solid foam former in an activation step, a liquid is released, with which the first paper web and / or the second paper web are impregnated, so that the first paper web and / or the second paper web become stretchable and allow expansion of the solid foam former to form a cushion.

[0008] The two paper webs form a sandwich with the solid foam former in between, which is connected in such a way that the connection is at least largely gas-tight, so that the reaction gases produced during the activation of the solid foam former, which enter the formed foam, cannot escape. Conversely, despite the mutual connection, the paper webs must be able to continue to absorb the expanding solid foam former, even when the foam expands. By separating a liquid from the solid foam former, for example water, the paper around the solid foam former can be saturated with the liquid and thus become soft and pliable. As the solid foam former expands, the paper gives way and can provide a larger internal volume.

[0009] This allows the unactivated product to be initially stored and transported as a flat material, so that the unactivated packaging product takes up as little space as possible. Activation can then be performed on-site. Once the activation period has expired, the packaging product, with the solid foam former expanded into a cushion, can be used like a standard bubble wrap bag.

[0010] In a first embodiment, such a method can provide that, before applying the solid foam former, a preferably gas-tight adhesive layer is applied to the first paper web and / or the second paper web to bond the first paper web to the second paper web. This adhesive layer can be detached using the liquid released in the activation step, after which the solid foam former is applied to the adhesive layer. The paper webs can be coated or impregnated with waxes, dissolved salts, or similar substances, for example, thereby obtaining a protective layer that protects against pest infestation and rot. Furthermore, it can be impermeable to moisture, grease, and gases, as well as flame-resistant. Such a coating serves several purposes.On the one hand, it ensures that the paper layers can be bonded together by adhesive, and on the other hand, it makes it possible to create a gas-tight surface so that the reaction products formed when the solid foaming agent is activated cannot escape. If the coating or impregnation can initially be dissolved by the liquid escaping from the solid foaming agent, this allows deformation, in particular expansion of the paper, as a result of the increasing pressure in an enclosed interior space between the paper webs. If the liquid later dries out, the adhesive layer solidifies again and becomes gas-tight and solid again. Between the sample sections, the adhesive layer can be used in the conventional way to adhesively bond the paper webs together.

[0011] Various methods can be used to apply the adhesive layer to the at least one paper web. First, an adhesive can be sprayed or printed on to apply the adhesive layer to the first paper web and / or the second paper web. A second possibility provides that, to apply the adhesive layer to the first paper web and / or the second paper web, an adhesive is melted in an extrusion process and applied via a nozzle to one side of each of the first paper web and / or the second paper web, where it hardens to form a solid adhesive layer. Furthermore, it can be provided that, to apply the adhesive layer to the first paper web and / or the second paper web, an adhesive is heated and vapor-deposited onto the first paper web and / or the second paper web.Finally, it is possible to apply the adhesive layer to the first paper web and / or the second paper web by depositing an adhesive onto the first paper web and / or the second paper web using static charging. The use of a suitable process depends on the adhesive and paper selected, as well as the solid foaming agent to be reacted with it. In extrusion coating, for example, molten thermoplastic can be applied to the paper web through a horizontal slot die. The end product is a permanently coated web material. The paper webs can also be coated by heating the coating molecules and vaporizing them, ideally in a vacuum, onto the paper webs until a continuous layer is applied.

[0012] In a preferred embodiment, the activation of the solid foam former can be carried out by supplying energy, in particular in the form of heat and / or microwave radiation, or by mechanical triggering, for example by ultrasound. For this purpose, a packaging product prepared in the preparation step can be used, in which the solid foam former is still in a non-activated state. Depending on the type of activation, such a product can then be placed in an oven or microwave oven, associated with an ultrasound source, or, in the case of activation by mechanical energy, bent or pressed, for example. The solid foam former will then expand and secrete liquid, which softens the paper and / or temporarily detaches the adhesive layer.

[0013] In a further embodiment, it can be provided that, prior to the application of the solid foam former, semi-open embossings are added to the first paper web and / or the second paper web using corresponding embossing means of an embossing press, and that, after embossing, these are pressed flat again, preferably rolled. These compressed semi-open embossings facilitate the expansion of the solid foam former, since the paper is thus already prepared from the outset to be expanded. The paper then simply returns to the shape predetermined by the embossing. This effect can be further supported if the first paper web and / or the second paper web are moistened with a liquid, preferably water, prior to embossing. This softens the paper so that it does not tear under the mechanical stress of the embossing press.

[0014] In a further preferred embodiment, the first paper web and / or the second paper web can be crumpled in a crumpling machine prior to embossing and then flattened, preferably by rolling. This also makes the paper more resistant to tears and damage during embossing and pressing.

[0015] There are various options for bonding the two paper webs together, with a preferred bond being one that prevents the solid foam former from escaping after activation, as well as its reaction products such as liquid and foaming gas. For example, the bond between the first paper web and the second paper web can be achieved by embossing, by bonding by local activation, or by applying an adhesive layer and pressing the first paper web and the second paper web together. The same adhesive layer that allows the paper web to bond at the contact points can improve the impermeability of the paper webs to prevent the reaction products from escaping on both sides of the pattern sections to which the solid foam former is applied.

[0016] In addition to the method for producing a packaging product, the packaging product itself is also provided, comprising a flat first paper web and a flat second paper web, wherein a solid foam former is assigned to the first flat paper web in a pattern section and the first paper web is connected to the second paper web with the solid foam former interposed. According to the invention, this is characterized in that, due to the activation of the solid foam former, a liquid is present with which the first paper web and / or the second paper web are impregnated, wherein the first paper web and / or the second paper web are stretchable in the impregnated state and thereby allow expansion of the solid foam former to form a cushion.

[0017] In a preferred embodiment, it can be provided that an adhesive layer is arranged between the solid foam former and the first paper web and / or between the solid foam former and the second paper web, which adhesive layer is produced by applying an adhesive.

[0018] In a specific embodiment, the adhesive can be made at least substantially from biodegradable components. Biodegradable materials such as biopolymer dispersions or proteins and waxes with bio-based additives are preferably used for this purpose.

[0019] Finally, the adhesive may comprise a resin, preferably a melamine or a phenolic resin.

[0020] The invention described above is explained in more detail below using an exemplary embodiment.

[0021] It shows Fig. 1 a flow diagram of a method for producing a packaging product, Fig. 2 the packaging product after the preparation step, but before the activation step in a lateral cross-sectional view, and Fig. 3 the packaging product according to Fig. 2 in an activated state in a lateral cross-sectional view.

[0022] Fig. Figure 1 shows a method for producing a packaging product 1. This essentially comprises a first paper web 2 and a second paper web 3, which are joined together with the interposition of a solid foam former 5. The solid foam former 5 expands after activation 20 to form a cushion 7.

[0023] An essential aspect of the invention is that the packaging product 1 as in Fig. 2, can be kept in a flat state. The cushions 7 have not yet been formed, the solid foam former 5 is in a non-activated state. Only upon activation 20 of the solid foam former 5 will it expand as shown in Fig. 3 and thereby form cushions 7 with which products can be protected during postal shipment.

[0024] In order for the cushion 7 to form inside the packaging product 1, the first paper web 2 and / or the second paper web 3 must be able to expand spatially so that extensive pockets form between the paper webs 2 and 3. This is particularly successful if, in a first step, the paper webs 2 and 3 to be prepared are first watered and pre-crumpled in a common step 8 and 9 so that the paper becomes soft and, in places, may also be present in multiple layers. It is also possible to subsequently carry out embossing so that the later desired bulge is first embossed but then rolled flat again. This makes it easier for the material to bulge again at the later time of activation 20.

[0025] As a further step, an adhesive application is carried out in point 10. The first paper web 2 and / or the second paper web 3 is preferably coated over its entire surface with an adhesive to create an adhesive layer 4. This serves to bond the two paper webs 2 and 3 to one another, but also to make the area occupied by the solid foam former 5 liquid-tight and / or gas-tight. Ideally, an adhesive is applied that can be dissolved using a liquid, preferably water, emerging from the solid foam former 5 after activation 20, to become flexible and, after the paper has expanded, to dry again and once again become a liquid and / or gas barrier.

[0026] The adhesive is applied 10 in one of the following ways. First, a simple spraying or printing 11 can be provided, in which either a broad jet of adhesive is directed over the paper webs 2, 3. Application by means of a printer is also possible, although this is sometimes particularly useful if only certain pattern sections 6, such as a bonding edge around the areas covered with the solid foaming agent 5, are to be provided with adhesive. Extrusion 12 occurs by liquefying the adhesive and then distributing it onto the paper webs 2 and / or 3. During vapor deposition 13, the adhesive is dissolved in steam, which is applied to the paper webs 2 or 3, onto which the adhesive then deposits. During deposition 14, a static voltage is required, whereby the adhesive adheres to the paper due to an electric field.

[0027] This is followed by a preparation step 15 in which the solid foam former 5 is applied to the first and second paper webs 2 and 3, which are preferably coated with an adhesive layer 4. Before its activation 20, the paper webs 2 and 3 are joined together, optionally by embossing or the like, but preferably by means of the interposed adhesive layer 4, which takes place in steps 16 and 17. A pressing process 18 compacts the packaging product, and the surfaces coated with the adhesive are pressed together.

[0028] The packaging product 1 produced in this way can thus be stored in a space-saving manner and transported efficiently. During storage 19, the packaging product 1 remains in this prepared state. Activation 20 only takes place when it is to be used. For this purpose, for example, the packaging product can be placed in a microwave oven or under a heat lamp and exposed to activation energy. Due to the activation energy, the solid foam former 5 is activated, forms a gas with which the solid foam is formed, as well as preferably a liquid, ideally water, which escapes and wets or saturates the paper. This makes the paper more stretchable and flexible, and also dissolves the adhesive, if present. The Fig.3, while the paper webs 2 and 3 can expand due to the preparation and form pockets into which the cushions 7 can expand.

[0029] After expansion, the liquid finally dries, and the cushions 7, as well as the paper webs 2 and 3, become solid. The adhesive, which then dries again, solidifies the outer shell of the packaging product and ensures gas tightness again. In the area of ​​the cushions 7, the packaging product 1 is now flexible due to the solid foam, for example, a foam. Separating the packaging product 1 into several separate or connected sample sections 6 with cushions 7 can be made possible, for example, by perforating the paper webs 2 and 3 between the cushions 7.

[0030] The above describes a method for producing a packaging product and a corresponding packaging product which, on the one hand, is portionable and has good cushioning properties, but, on the other hand, is also easy to store. LIST OF REFERENCE SYMBOLS 1 packaging product 2 first paper web 3 second paper web 4 adhesive layer 5 solid foaming agents 6 Sample section 7 cushions 8 waterings 9 balls 10 Adhesive application 11 Spraying / Printing 12 Extrusion 13 Evaporation 14 Separation 15 Preparation step 16 Joining 17 Connect 18 presses 19 Storage 20 Activation

Claims

[1] Method for producing a packaging product, comprising a flat first paper web (2) and a flat second paper web (3), wherein in a preparation step (15) a solid foam former (5) is applied in a pattern section (6) at least to the first paper web (2) and the first paper web (2) and the second paper web (3) are joined with the solid foam former (5) interposed, characterized by that due to an activation (20) of the solid foam former (5) in an activation step, a liquid is released with which the first paper web (2) and / or the second paper web (3) are impregnated, so that the first paper web (2) and / or the second paper web (3) become stretchable and allow an expansion of the solid foam former (5) to form a cushion (7). [2] Method according to claim 1, characterized bythat on the first paper web (2) and / or the second paper web (3) before the application of the solid foam former (5) a preferably gas-tight adhesive layer (4) for connecting the first paper web (2) to the second paper web (3) is applied over the surface, which adhesive layer is detachable with the aid of the liquid released in the activation step, after which the solid foam former (5) is applied to the adhesive layer (4). [3] Method according to claim 2, characterized by that an adhesive is sprayed or printed onto the first paper web (2) and / or the second paper web (3) to apply the adhesive layer (4). [4] Method according to claim 2, characterized byin that, in order to apply the adhesive layer (4) to the first paper web (2) and / or the second paper web (3), an adhesive is melted in an extrusion process (12) and is applied via a nozzle to one side of each of the first paper web (2) and / or the second paper web (3) and hardens there to form a solid adhesive layer (4). [5] Method according to claim 2, characterized by in that, in order to apply the adhesive layer (4) to the first paper web (2) and / or the second paper web (3), an adhesive is heated and vapor-deposited onto the first paper web (2) and / or the second paper web (3). [6] Method according to claim 2, characterized by in that, for applying the adhesive layer (4) to the first paper web (2) and / or the second paper web (3), an adhesive is deposited on the first paper web (2) and / or the second paper web (3) by means of static charging. [7] Method according to one of the preceding claims, characterized bythat the activation (20) of the solid foam former (5) takes place by supplying energy, in particular in the form of heat and / or microwave radiation, or by mechanical triggering, for example by ultrasound. [8] Method according to one of the preceding claims, characterized by that, before the application of the solid foam former (5), semi-open embossings are added to the first paper web (2) and / or the second paper web (3) by means of corresponding embossing means of an embossing press and, after the embossing, these are pressed flat again, preferably rolled. [9] Method according to claim 8, characterized by that the first paper web (2) and / or the second paper web (3) is wetted with a liquid, preferably with water, before embossing. [10] Method according to one of claims 8 or 9, characterized bythat the first paper web (2) and / or the second paper web (3) are crumpled in a crumpling machine before embossing and then pressed flat, preferably rolled. [11] Method according to one of the preceding claims, characterized by that the connection (17) between the first paper web (2) and the second paper web (3) is effected by embossing or by bonding by local activation or application of an adhesive layer (4) and pressing of the first paper web (2) and the second paper web (3). [12] Packaging product, comprising a flat first paper web (2) and a flat second paper web (3), wherein a solid foam former (5) is assigned to the first flat paper web (2) in a pattern section (6) and the first paper web (2) is connected to the second paper web (3) with the solid foam former (5) interposed, characterized bythat due to the activation (20) of the solid foam former (5) a liquid is present with which the first paper web (2) and / or the second paper web (3) are impregnated, wherein the first paper web (2) and / or the second paper web (3) are stretchable in the impregnated state and thereby allow an expansion of the solid foam former (5) to form a cushion (7). [13] Packaging product according to claim 12, characterized by that an adhesive layer (4) is arranged between the solid foam former (5) and the first paper web (2) and / or between the solid foam former (5) and the second paper web (3), which adhesive layer is produced by applying an adhesive. [14] Packaging product according to claim 13, characterized by that the adhesive is made at least essentially from biodegradable components. [15] Method according to claim 13 or 14, characterized bythat the adhesive comprises a resin, preferably a melamine or a phenolic resin.

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