Protective packaging product and method for its manufacture

Abstract

A protective packaging product (10) having a first layer (12) and a second layer (14), the first layer (12) comprising a foamed Polysaccharide material being adjacent and connected to the second layer (14), characterized in that the second layer (14) comprises a honeycomb layer made of a paper material, wherein a longitudinal axis (24) of the honeycombs (18) of the second layer (14) is essentially orthogonal to a plane of the first layer (12).

Description

[0001] Title : Protective packaging product and method for its manufacture

[0002] Specification

[0003] The present invention relates to a protective packaging product and a method for its manufacture according to the preambles of independent claims .

[0004] It is known from the market to manufacture speci fically shaped protective packaging products by stacking polyethylene layers one above the other, and by fixing the polyethylene layers to each other by heat welding . Such protective packaging products are used to receive an obj ect in order to protect this obj ect for example against shock loads during transport . Such obj ects may be TV screens and other fragile obj ects . WO 2022 / 171714 Al discloses a protective packaging product comprising a plurality of corrugated and stacked layers , at least some layers comprising a foamed polysaccharide material , and at least some layers being adhered to an adj acent layer .

[0005] It is an obj ect of the present invention to provide a protective packaging product having good protection and environmental characteristics .

[0006] This obj ect is achieved by means of a protective packaging products having the features of claims 1 or 8 and a method for its manufacture according to claim 10 . Further embodiments are given in the dependent claims .

[0007] The invention has the advantage that it provides a very good shock absorption . The inventive protective packaging product absorbs a shock even several times compared to classic honeycomb cardboard pads . Furthermore , only a comparatively small amount of material is required to protect a product from shocks . The packaging product can be relatively small and only placed where protection is actually necessary .

[0008] This is achieved by a protective packaging product with a first layer and a second layer . Typically, the second layer is signi ficantly thicker than the first layer, for example at least about 3-4 times as thick . A typical value for the thickness of the first layer is in the region of 5- 15 mm, but can be even greater . A typical value for the thickness of the second layer is in the range of 10-50 mm, but the thickness can also be smaller or greater . The first layer comprises a foamed polysaccharide material . For example , the first layer can consist exclusively of a foamed polysaccharide material . However, it is also possible that the main component of the first layer is a foamed polysaccharide material , but that the first layer also comprises a polyvinyl alcohol ( PVA) additive and / or other additives . As a result of the foaming, the polysaccharide material comprises a large quantity of evenly distributed bubble-like small voids , as is usual in a foamed material , whereby the first layer comprises a comparatively low density . It is understood that the material of the first layer is in a cured or dry state .

[0009] The first layer is arranged directly adj acent to the second layer, i . e . in contact with it and firmly bonded to it . In this way, the two layers form a composite layer or laminate .

[0010] The second layer comprises a honeycomb layer made of a paper material . The individual honeycombs of the second layer are typically hexagonal . In principle , however, other suitable cross-sections or shapes are also possible . The individual honeycombs of the second layer can, for example , be bonded together by a polyvinyl alcohol ( PVA) adhesive . It is understood that the term "paper material" is to be understood relatively broadly . It includes , for example and particularly preferably, kraft paper, but can also include , for example , cardboard, high-yield paper, recycled paper and combination of such papers . A longitudinal axis of the honeycombs of the second layer is substantially orthogonal to a plane of the first layer .

[0011] Thus , a layered material is created with a honeycomb layer of paper covered by the first layer of foamed polysaccharide material .

[0012] In a further embodiment , the foamed polysaccharide material of the first layer comprises foamed starch or is substantially foamed starch . The first layer is thus at least substantially created by a foamed material made substantially of or comprising starch, optionally with an additive of PVA and / or other additives . Preferably, the first layer comprises at least approx . 75 percent by weight starch . Such a material is inexpensive and can be easily produced, and it can be disposed of in an ecologically completely safe manner . However, other polysaccharides are also conceivable , for example chitin, alginates , HPMC, lignine and all components of wood ( cellulose , hemicellulose , lignine ) .

[0013] In a further embodiment , the packaging product comprises a third layer of a material which is similar or identical to the material of the first layer, according to the examples given above . The third layer thus comprises at least one foamed polysaccharide material . The third layer is further arranged relative to the first layer on an opposite side of the second layer, whereby a classic sandwich composite of three layers ( one core plus two cover layers ) is created .

[0014] In this respect , the third layer is also directly adj acent to the second layer and firmly connected to it . The longitudinal axes of the honeycombs of the second layer are essentially orthogonal to a plane of the third layer . Such a packaging product can be particularly good at keeping shock loads away from an obj ect to be protected .

[0015] In a further embodiment , the first layer and / or the third layer are each connected to the second layer by a bonding means , which preferably comprises at least one of following materials : dispersion and / or emulsion of synthetic or natural polymers ; synthetic or natural polymers applied in hot melt ; natural polymers , such as starch, dextrin, casein, Arabic gum; synthetic polymers , such as ethylene- vinylacetat-copolymers , polyurethane , polyethylene , styrenic basis , epoxy, latex, polyvinyl alcohol ; the foregoing materials , at least one of which being biobased . Particularly preferred are starch and polyvinyl alcohol . Such a bonding means can be produced very simply, for example , by spraying the surface of the first layer and / or the third layer facing the second layer with a liquid, preferable a water based liquid or and still more preferred water, before the layers are j oined together . The advantage of this further embodiment is therefore that it is technically simple , inexpensive and ecologically neutral .

[0016] In a further embodiment , at least some of the walls of the honeycombs of the second layer penetrate a distance into the first layer and / or the third layer . This increases the surface area via which the first layer and / or the third layer is respectively connected to the second layer and ultimately increases the stability of the packaging product .

[0017] In a further embodiment , an outer surface of the first layer and / or the third layer is covered by a paper layer . The outer surface is the surface facing away from the second layer . Such a paper layer increases the stability of the first layer and / or the third layer against external influences , both mechanical and chemical . Again, the term "paper" is to be understood in a broad sense , as explained above .

[0018] In a further embodiment , an edge of a wall of a honeycomb of the second layer, which faces the first layer or the third layer, comprises at least one recess . As a result , the wall of the honeycomb is additionally hooked into the respective first layer or third layer, whereby the connection between the layers is further improved .

[0019] The invention also relates to a protective packaging product comprising a stack of a plurality of main layers , each main layer made of a protective packaging product of the above-mentioned type . The main layers are firmly bonded to each other - directly or indirectly . In this way, a comparatively thick and stable protective packaging product can be created .

[0020] In a further embodiment , the protective packaging product comprises an intermediate layer made of corrugated cardboard, which is arranged between two main layers and firmly bonded to them . This further improves the stability of the overall packaging product .

[0021] The invention also relates to a method for producing a protective packaging product of the type described above . The method comprises the following steps : a ) providing a first layer of a foamed polysaccharide material ; b ) providing a second layer of a paper honeycomb material ; c ) spraying a liquid (preferably a water based liquid or still more preferred water ) onto a surface of the first layer facing the second layer ; d) pressing the first layer with its water-sprayed surface in direct contact against the second layer . This method can be reali zed automatically as a continuous process , which enables a very inexpensive production of the protective packaging product according to the invention . The liquid may " activate" or " create" the bonding means by reacting with material or dissolving material of the first layer, or may comprise the bonding means .

[0022] In a further development thereof , the method also comprises the following steps : e ) providing a third layer of a foamed polysaccharide material relative to the first layer on an opposite side of the second layer ; f ) spraying a liquid (preferably a water based liquid or still more preferred water ) onto a surface of the third layer facing the second layer ; g) pressing the third layer with its water-sprayed surface in direct contact against the second layer . In this way, a classic sandwich material with a core ( second layer ) and two cover layers ( first layer and third layer ) is produced simply and in a possible continuous process , which is very stable . Again, the liquid may " activate" or "create" the bonding means by reacting with material or dissolving material of the third layer, or may comprise the bonding means .

[0023] In a further embodiment , steps a and e are carried out simultaneously, steps c and f are carried out simultaneously, and steps d and g are carried out simultaneously . In this way, the first layer and the third layer are bonded to the second layer at the same time , which speeds up and simpli fies manufacture .

[0024] In the following, embodiments of the invention are explained with reference to the accompanying drawing . The drawing shows :

[0025] Figure 1 an exploded perspective view of a region of a protective packaging product comprising a first layer, a second layer and a third layer ;

[0026] Figure 2 a sectional view of the protective packaging product of Figure 1 ;

[0027] Figure 3 a detail of the protective packaging product of Figure 2 ;

[0028] Figure 4 the detail of Figure 3 under the action of an external force ; Figure 5 a sectional view of a protective packaging product formed from two protective packaging products as shown in Figure 2 ;

[0029] Figure 6 a top view of a packaging container with several protective packaging products according to Figure 5 and an obj ect to be protected;

[0030] Figure 7 an illustration similar to Figure 2 of an alternative embodiment of a protective packaging product ;

[0031] Figure 8 an illustration similar to Figure 2 of a further alternative embodiment of a protective packaging product ;

[0032] Figure 9 a representation similar to Figure 5 of an alternative embodiment of a protective packaging product ;

[0033] Figure 10 a representation similar to Figure 2 of an alternative embodiment of a protective packaging product ;

[0034] Figure 11 a perspective view of an alternative embodiment of a honeycomb of the second layer of Figure 1 ;

[0035] Figure 12 a representation similar to Figure 9 with an obj ect to be protected; Figure 13 a sectional view similar to Figure 2 of a further alternative embodiment of a protective packaging product ; and

[0036] Figure 14 a schematic representation of a device for carrying out a method for producing the protective packaging product of Figure 2 .

[0037] In the following, functionally equivalent elements and areas in di f ferent figures and in di f ferent embodiments have the same reference signs . They are normally only described in detail when first mentioned . Furthermore , for reasons of simpli fication, not all reference signs are shown in all figures .

[0038] A protective packaging product bears the reference sign 10 in the figures generally . It comprises a first layer 12 , a second layer 14 and a third layer 16 . The first layer 12 and the third layer 16 are identical in the present example . They comprise a foamed polysaccharide material , in the present case foamed starch . In the present exemplary embodiment , the two layers 12 and 16 substantially (by at least 75 percent by weight ) consist of the foamed starch, optionally with an addition of polyvinyl alcohol . It can be seen that a thickness extension D of the layers 14 and 16 , which extends orthogonally to a respective plane of the two layers 12 and 16 , is signi ficantly smaller than a length extension L and a width extension B of the layers 14 and 16 , which span the said plane . The second layer 14 is a honeycomb layer made of a paper material . The preferred paper material is kraft paper, but cardboard, high-yield paper, recycled paper and combinations of such papers or the like is also possible , for example . In the present case , the second layer 14 comprises a plurality of essentially hexagonal honeycombs 18 having a first and, in the figures , upper edge 20 facing the first layer 12 and a second and, in the figures , lower edge 22 facing the third layer 16 . A longitudinal axis 24 of a honeycomb 18 of the second layer 14 is substantially orthogonal to the planes spanned by the lengthwise extension L and the widthwise extension B of the layers 12 and 16 .

[0039] As can be seen from Figures 2 and 3 , the two layers 12 and 16 are arranged directly adj acent to the second layer 14 and are connected thereto by an adhesive bond or adhesive means 26 . This is indicated by dashed lines in Figures 2 and 3 . The adhesive means 26 is produced, as will be explained below, by spraying the surfaces 28 and 30 of the layers 12 and 16 facing the second layer 14 in the present exemplay and preferred embodiment with water or a water based liquid ( other liquids also being possible ) prior to j oining them to the second layer 14 . In this way, the starch ( and / or the PVA) from which the layers 12 and 16 are made becomes moist on the surfaces 28 and 30 and thereby sticky, thus forming said starch adhesive 26 . After the starch adhesive 26 has dried, the two layers 12 and 14 are firmly bonded to the respective edges 20 and 22 of the honeycombs 18 . Figure 3 also shows that the upper edge 20 of a wall 32 of the honeycomb 18 penetrates into the first layer 12 by a distance S . Identical to this , the lower edge 22 of the wall 32 of the honeycombs 18 penetrates into the third layer 16 by such a distance , wherein this is not drawn . This increases the contact area between the first layer 12 and the second layer 14 or between the third layer 16 and the second layer 14 , which is available for the bonding 26 , and this improves the stability of the overall sandwich composite comprising the first layer 12 , the second layer 14 and the third layer 16 .

[0040] Figure 4 shows the area of the protective packaging product 10 shown in Figure 3 under the action of an external load F . It can be seen that , in particular due to the high stretchability of the first layer 12 , the second layer 14 is only pressed in very locally in the area of a wall 32 .

[0041] In order to obtain an overall thicker protective packaging product , it can be designed as a stack 34 comprising a plurality of main layers 36 , each main layer 36 formed by a protective packaging product 10 according to Figure 2 . The two packaging products 10 are bonded together in the region of a lower surface 38 of the third layer 16 of the upper packaging product 10 shown in Figure 5 and an upper surface 40 of the first layer 12 of the lower packaging product 10 , also by an adhesive 26 at least essentially of starch produced by moistening the respective surfaces 38 and 40 . Figure 6 shows an example of a possible use of the protective packaging product 34 of Figure 5 . The top view shows a rectangular container 42 , for example a packaging carton . An obj ect 44 , which is to be transported in the container 42 , is arranged inside the container 42 . A plurality of protective packaging products 34 is arranged between the obj ect 44 and the container 42 as shown in Figure 5 , in such a way that the longitudinal axis 24 of the honeycombs 18 extend orthogonally to the respective wall of the container 42 or the obj ect 44 , between which the stacks 34 of packaging products 10 are arranged . In this way, the article 44 is very reliably protected from impact loads that can act on the container 42 .

[0042] In an alternative embodiment of a protective packaging product 10 shown in Figure 7 , an outer surface 46 of the first layer 12 facing away from the second layer 14 is covered by a thin paper layer 48 . A bond 26 can also be used for this purpose , which is created by moistening the outer surface 46 . The third layer 16 can also comprise such a paper layer 48 on its outer surface .

[0043] In yet another alternative embodiment , the protective packaging product 10 is bonded to a standard honeycomb sandwich panel 49 with an outer surface 50 of the third layer 16 facing away from the second layer 14 , again using an adhesive 26 produced by moistening the surface 50 .

[0044] In another alternative embodiment of a stack 34 , an intermediate layer 52 of corrugated cardboard is arranged between the two main layers 36 formed by a packaging product 10 . This intermediate layer 52 is also bonded to the present exemplary lower surface 38 of the upper packaging product 10 and to the present exemplary upper surface 40 of the lower packaging product 10 by a starch adhesive 26 , as already described above in another context .

[0045] As can be seen from Figure 10 , a curved packaging product 10 can also be produced due to the elasticity and stretchability of the first layer 12 and the second layer 14 . As can be seen from Figure 10 , such a packaging product 10 can be curved in one direction, but in an embodiment not shown it can also be curved in di f ferent directions , for example in a wave-like manner .

[0046] As can be seen from Figure 11 , the edge 20 of the walls 32 of the honeycombs 18 facing the first layer 12 can comprise one or more recesses 54 , which preferably widen away from the first layer 12 as shown in Figure 11 . This further improves the connection between the first layer 12 and the second layer 14 . It will be understood that the lower edge 22 of the walls 32 of the honeycombs 18 shown in Figure 11 can also comprise such recesses 54 , although this is not shown in Figure 11 for the sake of simplicity .

[0047] Figure 12 shows a use of the stack 34 shown in Figure 9 for holding an obj ect 44 , for example a very heavy obj ect such as a washing machine or the like . It can be seen that the upper main layer 36 in Figure 12 deforms to accommodate the obj ect 44 , but that this deformation is only of a limited extent . This is achieved in particular by the intermediate layer 52 of corrugated cardboard .

[0048] As can be seen from Figure 13 , the technology described above can also be used to produce a very simple composite of two protective packaging products 10 arranged at right angles to each other . For this purpose , a first protective packaging product 10A is used, the first layer 12 and the third layer 16 of which protrude beyond the middle layer 14 at the right-hand end shown in Figure 13 with a respective portion 12A and 16A. The lower portion 16A in Figure 13 is folded down by 90 ° .

[0049] Now a second protective packaging product 10B is placed at an angle of 90 ° . Its upper end surface 56 in Figure 13 is bonded to the upper portion 12A of the first layer 12 in Figure 13 , and the outer surface 50 of the third layer 16 of the second protective packaging product 10B pointing to the left in Figure 13 is bonded to the folded down portion 16A. The bonding is reali zed by moistening creating an adhesive 26 as described above .

[0050] Referring now to Figure 14 , a device 58 and a method operating on the device 58 by which a protective packaging product 10 as shown in Figure 2 can be produced will be explained .

[0051] A functional block 60 symboli zes the provision of the first layer 12 of foamed polysaccharide material ( starch) , and a functional block 62 symboli zes the provision of the third layer 16 also of foamed polysaccharide material ( starch) . A function block 64 symboli zes the provision of the second layer 14 made of a paper honeycomb material , which has not yet been expanded . The expansion takes place in a function block 66 .

[0052] The three layers 12 , 14 and 16 are introduced into an intermediate space 67 between two belt conveyors 68 and 70 . Beforehand, the surfaces 28 and 30 of the layers 12 and 14 facing the second layer 14 are sprayed in the present exemplay and preferred embodiment with water or a water based liquid ( other liquids also being possible ) and thereby moistened to produce the starch adhesive 26 , which is indicated by arrows 72 . A width 74 of the gap 67 corresponds to a height H of the packaging product 10 of Figure 2 .

[0053] As the product passes through the two belt conveyors 68 and 70 , the two layers 12 and 16 are simultaneously pressed into direct contact with the second layer 14 and thereby bonded or adhered thereto . Heat can also be applied to accelerate the drying process . The packaging product 10 is thus laminated as it passes through the two belt conveyors 68 and 70 .

[0054] This produces a laminated continuous product 76 , from which individual protective packaging products 10 are punched out by a punching tool 78 . A robot 80 takes the punched-out packaging products 10 and places them on a further conveyor 82 , which conveys them to a robot 84 and a spraying system 86 . This activates a lower outer surface 50 of the third layer 16 so that it can be bonded to an intermediate layer

[0055] 52 of corrugated cardboard .

Claims

Claims1. A protective packaging product (10) having a first layer (12) and a second layer (14) , the first layer (12) comprising a foamed Polysaccharide material being adjacent and connected to the second layer (14) , characterized in that the second layer (14) comprises a honeycomb layer made of a paper material, wherein a longitudinal axis (24) of the honeycombs (18) of the second layer (14) is essentially orthogonal to a plane of the first layer (12) .

2. The protective packaging (10) product of claim 1, wherein the foamed Polysaccharide material of the first layer (12) comprises foamed starch or is substantially foamed starch.

3. The protective packaging product (10) of at least one of the preceding claims, wherein it comprises a third layer (16) of a material similar or identical to that of the first layer (12) , which is arranged relative to the first layer (12) on an opposite side of the second layer (14) and which is also adjacent and connected to the second layer (14) , wherein a longitudinal axis (24) of the honeycombs (18) of the second layer (14) is essentially orthogonal to a plane of the third layer (1 ) .The protective packaging product (10) of at least one of the preceding claims, wherein the first layer (12)and / or the third layer (16) are connected to the second layer (14) by a bonding means (26) , which preferably comprises at least one of following materials: dispersion and / or emulsion of synthetic or natural polymers; synthetic or natural polymers applied in hot melt; natural polymers, such as starch, dextrin, casein, Arabic gum; synthetic polymers, such as ethylene-vinylacetat-copolymers , polyurethane, polyethylene, styrenic basis, epoxy, latex, polyvinyl alcohol; the foregoing materials, at least one of which being biobased.

5. The protective packaging product (10) of at least one of the preceding claims, wherein at least some of the walls (32) of the honeycombs (18) of the second layer (14) penetrate a distance (S) into the first layer (12) and / or the third layer (16) .

6. The protective packaging product (10) of at least one of the preceding claims, wherein an outside surface (46) of the first layer (12) and / or the third layer (16) is covered by a paper layer (48) .

7. The protective packaging product (10) of at least one of the preceding claims, wherein an edge (20) of a honeycomb wall (32) of the second layer (14) facing the first layer (12) or third layer (16) comprises at least one recess (54) .

8. A protective packaging product, characterized in that it comprises a stack (34) of a plurality of mainlayers (36) each made of a protective packaging product (10) of at least one of the preceding claims, the main layers (36) being connected to each other.

9. The protective packaging product of claim 8, wherein it comprises at least one intermediate layer (52) made of corrugated paper, the intermediate layer (52) being arranged between two main layers (36) .

10. A method for manufacturing the protective packaging product (10) of at least one of the preceding claims 1-7, characterized in that it comprises the following steps : a. providing a first layer (12) of a foamed Polysaccharide material; b. providing a second layer (14) of a paper honeycomb material; c. spraying a liquid onto a surface of the first layer (12) facing to the second layer (14) ; d. pressing the first layer (12) with its liquid sprayed surface in direct contact against the second layer (14) .

11. The method of claim 10, wherein it comprises the following steps: e. providing a third layer (16) of a foamed Polysaccharide material relative to the firstlayer (12) on an opposite side of the second layer ( 14 ) , f. spraying a liquid onto a surface of the third layer (16) facing to the second layer (14) , and g. pressing the third layer (16) with its liquid sprayed surface in direct contact against the second layer. (14)12. The method of claim 11, wherein steps a and e are executed simultaneously, steps c and f are executed simultaneously, and steps d and g are executed simultaneously .

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