Publication NumberUS 20160052692
Assignees
    Filing StatusPatent Application
    US PAIR StatusAbandoned -- Failure to Respond to an Office Action
    US PAIR Status Date2019-09-02
    Application Number14/464281
    AvailabilityUnknown
    Filing Date2014-08-20
    Publication Date2016-02-25

    Abstract

    A biodegradable, thermally insulated mailer and cooler, and method of making them, are disclosed. The thermally insulated packaging material are made from laminated starch foam and bio-plastic film. The lamination can be performed by heat bonding, without the use of an adhesive bonding agent, to produce biodegradable packaging materials that can pass ASTM and other certifications for home compostability and marine environment safety.

    Claims

    • 1. A biodegradable mailer, made from a composite consisting essentially of: a corn starch foam paper; a bio-plastic film that is heat-bonded to the corn starch foam paper; compostable ink; wherein the compostable ink is used to present information about biodegradability of the mailer.
    • 2. The biodegradable mailer of claim 1, wherein the petroleum based bio-plastic film is Danimer 12291.
    • 3. The biodegradable mailer of claim 1, wherein the corn starch foam paper is made from Green Cell Foam™ by compressing it into a thin, flexible sheet.
    • 4. The biodegradable mailer of claim 3, wherein the petroleum based bio-plastic film is Danimer 12291.
    • 5. The biodegradable mailer of claim 1, wherein the film is heat-bonded to the corn starch paper at a temperature between about 248° F. and about 255° F., at a speed between about 22 ft/s and about 40 ft/s.
    • 6. The biodegradable mailer of claim 5, wherein the temperature is between about 253° F. and about 258° F., and the speed is about 31 ft/s and about 36 ft/s.
    • 7. A composite paper comprising: a compressed, flexible corn starch foam sheet; a bio-plastic film that is heat bonded to the corn starch paper, wherein no adhesive is used to bond the corn starch film and the bio-plastic film.
    • 8. A method of making a biodegradable composite paper comprising: providing a compressed, flexible corn starch foam sheet; providing a bio-plastic film; adhering the corn starch foam sheet and the bio-plastic film by running them through a laminator, without an adhesive.
    • 9. The method of claim 8, wherein a fine water mist is applied in place of an adhesive to assist in achieving a consistent lamination between the foam and the film.
    • 10. The method of claim 8, wherein the foam is Green Cell Foam™.
    • 11. The method of claim 8, wherein the film is Danimer 12291.
    • 12. A biodegradable cooler, comprising: corn starch foam panels; a bio-plastic film that is heat-bonded to the corn starch foam panels; wherein the bio-plastic film encloses the corn starch foam panels, and wherein no adhesive is used to bond the bio-plastic film.
    • 13. The biodegradable cooler of claim 12, wherein the corn starch film is Green Cell Foam™.
    • 14. The biodegradable cooler of claim 12, wherein the bio-plastic film is Danimer 12291.
    • 15. The biodegradable cooler of claim 12, wherein the bioplastic film flexibly connects at least two of the corn starch panels to one another to form a hinge.
    • 16. The biodegradable cooler of claim 15, wherein the bioplastic film flexibly connects exactly three of the corn starch panels, whereby the cooler can be assembled for use by inserting two 3-panel pieces into a standard box to form two interlocking “C” forms.
    • 17. The biodegradable cooler of claim 13, wherein the corn start foam panels are formed by laminating multiple layers of Green Cell Foam™ to one another to form at least 2″ thick sheets.
    • 18. A method of making biodegradable packaging comprising heat bonding corn starch foam and bio-plastic film without an adhesive bonding agent.
    • 19. The method of claim 18, wherein at least some of the corn starch foam has been made into corn starch paper.
    • 20. The method of claim 19, wherein the heat bonding is performed by a lamination at a temperature between about 253° F. and about 258° F. and a speed of about 31 ft/s and about 36 ft/s.