DE112021001361T5 - Foam structures with a living hinge and associated methods - Google Patents

Abstract

Foam structures with living hinges and methods of making these structures are provided. The foam structures are made using a plurality of foam sheets formed from polymer foam particles and connected by living hinges. The living hinges can be conditioned to increase their density, strength and flexibility. The sheets of foam are folded together to form a foam structure suitable for use as an insulating container.

Description

Cross reference to related applications

This application claims the priority of the provisional U.S. Application No. 62/984,603 , filed March 3, 2020, which is incorporated herein by reference.

area of disclosure

This disclosure relates generally to film-hinged foam structures and methods of making such foam structures, and more particularly relates to film-hinged foam structures formed from polymeric foam particles and methods of making such foam structures.

background

Foam items are commonly used for insulation due to their light weight, thermal properties, and impact-resistant properties. For example, foam articles are useful for shipping thermally sensitive goods such as food packages, confectionery, cakes, other perishables, and medical supplies. Foam articles are also useful for protecting fragile goods such as televisions, glass based products and other fragile goods.

Previous attempts to provide foam articles have used an insulating material in combination with an additional support structure, such as corrugated cardboard. These items often wrap loose insulation in foil or paper before lining the inside of a corrugated box with these insulation "envelopes". Previous attempts to eliminate corrugated board supplemented the article with adhesive, foil, tape, glue or other means of joining separate pieces of insulating material into a single unit. In any event, previous solutions require the end user to separate insulation material from paper, foil and/or cardboard in order to recycle or compost any material.

Thus, foam articles formed from a single blank of shaped, expandable foam particles with the ability to fold into a foam structure without separating parts and without additional adhesive would be beneficial.

Short Summary

In one aspect, foam structures are provided. In some embodiments, the foam structure includes a plurality of foam sheets, each of which is formed from a plurality of polymer foam particles, wherein at least two of the plurality of foam sheets are connected by a living hinge defined by a channel between the at least two foam sheets such that the plurality of foam panels can be folded along the film hinge. In some embodiments, the living hinge has a thickness equal to one to six of the polymeric foam particles, and the polymeric foam particles are at least partially collapsed within the living hinge. In some preferred embodiments, the polymeric foam particles comprise or consist of homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, polyhydroxyalkanoate, or mixtures thereof. In this way, the foam structure can be degraded by industrial compost within a relatively short period of time, for example about 42 days.

In another aspect, methods of making foam structures are provided. In some embodiments, the method comprises (i) forming a foam sheet blank in a mold from a plurality of polymeric foam particles; and (ii) forming one or more channels in the foam sheet blank to define at least two foam sheets connected by a living hinge. The method may further include conditioning the polymeric foam particles by heating and collapsing at least a portion of the polymeric foam particles in the living hinge forming the one or more channels and thus forming the living hinge, which has been found to improve the performance of the living hinge.

character list

• 1A ist eine Querschnittsansicht einer Ausführungsform einer Schaumstruktur mit zwei Filmscharnieren gemäß der vorliegenden Offenbarung.
• 1B ist eine perspektivische Ansicht einer Ausführungsform einer Schaumstruktur mit einem Filmscharnier gemäß der vorliegenden Offenbarung.
• 1C ist eine Querschnittsansicht einer Ausführungsform einer Schaumstruktur mit einem Filmscharnier in einer offenen Konfiguration gemäß der vorliegenden Offenbarung.
• 1D ist eine Querschnittsansicht einer Ausführungsform einer Schaumstruktur mit einem Filmscharnier in einer geschlossenen Konfiguration gemäß der vorliegenden Offenbarung.
• 2 ist eine perspektivische Ansicht einer weiteren Ausführungsform einer Schaumstruktur mit einem Filmscharnier gemäß der vorliegenden Offenbarung.
• 3 ist eine Querschnittsansicht einer weiteren Ausführungsform einer Schaumstruktur mit einem Filmscharnier gemäß der vorliegenden Offenbarung.
• 4A ist eine perspektivische Ansicht einer Ausführungsform eines 3-Platten-Systems mit Filmscharnieren gemäß der vorliegenden Offenbarung.
• 4B ist eine perspektivische Ansicht der Ausführungsform des in 4A gezeigten 3-Platten-Systems, nachdem es in Übereinstimmung mit der vorliegenden Offenbarung zu einer C-förmigen Anordnung und einem 3-Platten-System gefaltet wurde.
• 5A ist eine perspektivische Ansicht einer Ausführungsform eines 5-Platten-Systems gemäß der vorliegenden Offenbarung.
• 5B ist eine perspektivische Ansicht der Ausführungsform des in 5A gezeigten 5-Platten-Systems, nachdem es in Übereinstimmung mit der vorliegenden Offenbarung zu einer 5-Platten-Schachtel gefaltet worden ist.
• 6A ist eine perspektivische Ansicht einer Ausführungsform eines 6-Platten-Systems gemäß der vorliegenden Offenbarung.
• 6B ist eine perspektivische Ansicht der Ausführungsform des in 6A gezeigten 6-Platten-Systems, nachdem es gemäß der vorliegenden Offenbarung zu einer Schaumstruktur gefaltet wurde.
• 7A ist eine perspektivische Ansicht einer Ausführungsform eines zweiteiligen Systems gemäß der vorliegenden Offenbarung.
• 7B ist eine perspektivische Ansicht der in 7A gezeigten Ausführungsform des 2-Platten-Systems, nachdem es zu einem Kantenschutz gemäß der vorliegenden Offenbarung gefaltet wurde.
• 8 ist eine perspektivische Ansicht der Innenseite einer Ausführungsform einer Schaumstruktur, die Strukturelemente für Innenwände gemäß der vorliegenden Offenbarung darstellt.
• 9A ist eine perspektivische Ansicht einer Ausführungsform einer Schaumstoffplatte mit Bruchstellen gemäß der vorliegenden Offenbarung.
• 9B ist eine perspektivische Ansicht einer Ausführungsform von Schaumplattenfragmenten gemäß der vorliegenden Offenbarung.
• 10 ist eine perspektivische Ansicht einer Ausführungsform einer Schaumstruktur, die in eine äußere Schachtel gemäß der vorliegenden Offenbarung eingesetzt ist.
• 11 ist ein Blockflussdiagramm, das eine Ausführungsform eines Verfahrens zum Herstellen einer Schaumstruktur gemäß der vorliegenden Offenbarung darstellt.
• 12A ist eine beispielhafte schematische Darstellung eines Schritts in dem Verfahren zur Herstellung einer Schaumstruktur gemäß der vorliegenden Offenbarung.
• 12B ist eine beispielhafte schematische Darstellung eines Schritts in dem Verfahren zum Herstellen einer Schaumstruktur gemäß der vorliegenden Offenbarung.
• 13 ist eine schematische Darstellung, die eine Ausführungsform eines Schritts in einem Verfahren zum Herstellen einer Schaumstruktur gemäß der vorliegenden Offenbarung darstellt.
• 14 ist eine schematische Ansicht einer Ausführungsform eines Filmscharniers gemäß der vorliegenden Offenbarung.

The detailed description is made with reference to the attached drawings. The use of the same reference numbers can designate similar or identical items. Various Embodiments may use different elements and/or components than those illustrated in the drawings, and some elements and/or components may not be present in different embodiments. Elements and/or components in the figures are not necessarily drawn to scale.

• 1A 12 is a cross-sectional view of one embodiment of a dual living hinge foam structure in accordance with the present disclosure.
• 1B 12 is a perspective view of one embodiment of a foam structure having a living hinge in accordance with the present disclosure.
• 1C 12 is a cross-sectional view of one embodiment of a foam structure with a living hinge in an open configuration, in accordance with the present disclosure.
• 1D 12 is a cross-sectional view of one embodiment of a foam structure having a living hinge in a closed configuration, in accordance with the present disclosure.
• 2 12 is a perspective view of another embodiment of a foam structure having a living hinge in accordance with the present disclosure.
• 3 12 is a cross-sectional view of another embodiment of a foam structure having a living hinge in accordance with the present disclosure.
• 4A 12 is a perspective view of an embodiment of a 3-panel living hinge system in accordance with the present disclosure.
• 4B is a perspective view of the embodiment of FIG 4A 3 panel system shown after being folded into a C-shaped configuration and 3 panel system in accordance with the present disclosure.
• 5A 14 is a perspective view of an embodiment of a 5-plate system according to the present disclosure.
• 5B is a perspective view of the embodiment of FIG 5A 5 panel system shown after being folded into a 5 panel box in accordance with the present disclosure.
• 6A 12 is a perspective view of an embodiment of a 6-plate system according to the present disclosure.
• 6B is a perspective view of the embodiment of FIG 6A 6 panel system shown after being folded into a foam structure in accordance with the present disclosure.
• 7A 12 is a perspective view of an embodiment of a two-part system according to the present disclosure.
• 7B is a perspective view of FIG 7A shown embodiment of the 2 panel system after being folded into an edge protector according to the present disclosure.
• 8th 12 is a perspective view of the inside of one embodiment of a foam structure depicting structural members for interior walls in accordance with the present disclosure.
• 9A 12 is a perspective view of one embodiment of a frangible foam panel in accordance with the present disclosure.
• 9B 12 is a perspective view of one embodiment of foam slab fragments according to the present disclosure.
• 10 12 is a perspective view of one embodiment of a foam structure inserted into an outer carton in accordance with the present disclosure.
• 11 12 is a block flow diagram depicting one embodiment of a method of making a foam structure in accordance with the present disclosure.
• 12A 1 is an exemplary schematic representation of a step in the method of making a foam structure according to the present disclosure.
• 12B 1 is an exemplary schematic representation of a step in the method of making a foam structure according to the present disclosure.
• 13 FIG. 1 is a schematic diagram depicting one embodiment of a step in a method of making a foam structure according to the present disclosure.
• 14 12 is a schematic view of an embodiment of a living hinge according to the present disclosure.

Detailed description

Foam structures with a living hinge and methods of making these structures are provided herein. Advantageously, the foam structures and methods of making the foam structures reduce the number of component parts, reduce assembly time, simplify assembly, improve thermal protection, and improve impact protection of conventional foam articles, including but not limited to insulated shipping containers. The present disclosure encompasses non-limiting embodiments of foam structures with living hinges.

Living hinge foam structures, assemblies and associated methods are provided. These foam structures consist of sheets of foam connected by living hinges that are designed to fold together and trap thermal energy when adjacent edges abut. The panels are formed from polymeric foam particles by molding, machining, or other suitable forming methods. In some embodiments, the foam structure is made up of enough sheets to form a self-contained container that can be used, for example, as an insulated shipping container for shipping heat-sensitive items, such as perishable foods or medicines. In other embodiments, the foam structure is composed of a selected number of panels and can be used, for example, as edge protection in conjunction with other foam structures and/or an outer box. In other embodiments, the foam structure can be used in conjunction with an outer box, such as a corrugated box, to provide improved heat retention, heat exclusion, and/or prevention or reduction of thermal energy transfer to or from a container that would otherwise lack such capabilities .

The embodiments are described herein in detail to enable one of ordinary skill in the art to practice the foam structures and associated methods of manufacture, although it is understood that other embodiments may be used and logical changes may be made without departing from the scope of the disclosure. Singular and plural terminology may be used interchangeably throughout the disclosure depending on the context.

In this disclosure, various aspects are presented in an area format. It should be understood that the description in domain format is for convenience and brevity only and should not be construed as an inflexible limitation on the scope of the disclosure. Accordingly, the description of a range should be considered to have expressly disclosed all possible sub-ranges as well as individual numerical values within that range. For example, a description of a range such as from 1 to 6 should be considered as having specifically disclosed sub-ranges such as from 1 to 3, from 1 to 4, from 1 to 5, from 2 to 4, from 2 to 6, from 3 to 6 etc. as well as individual numbers within this range, e.g. B. 1, 2, 3, 4, 5 and 6. This applies regardless of the width of the range.

Flat panel shipping containers are containers formed from a series of substantially flat panels that are molded or bonded together to form a three-dimensional container. For example, a flat panel shipping container can be a container blank, a partial container blank, or other semi-formed container that can be formed into a three-dimensional container or structure. Such flat panels can be easily stacked prior to assembly, so flat panel shipping containers may be preferred over pre-assembled or molded insulating boxes due to the advantageous ability to ship and store unassembled panels in a flat or semi-flat configuration, increasing efficiency in both shipping as well as in warehousing. Flat plate shipping containers are also easier to handle without breaking.

Forming the flat sheets of foam can provide better thermal properties by reducing or eliminating voids between insulating pieces through which thermal energy can enter or escape. However, the polymers must meet certain physical and chemical properties in order to be suitable for the intended application. In expandable foams, the Polymer composition can be processed into a three-dimensional form that is lightweight and provides sufficient impact and heat resistance or protection.

Film hinged foam structures have been prepared which can be made using equipment similar to that used for expandable polystyrene. Through the manufacture of foam sheets connected by living hinges, it was discovered that foam structures can be assembled without additional adhesives, films, or support structures while improving the thermal retention capabilities of traditional shipping containers and the impact protection of traditional shipping containers. In particular, it has been found that channels in a rigid, monolithic foam sheet blank can form a series of foam sheets connected by a “living hinge”, which allows the sheets to fold against one another and form a thermally effective seal, preventing thermal energy loss at the edges and a greater impact protection at the edges can be guaranteed. It has also been found that conditioning the material forming the living hinge with pressure and/or heating can strengthen the living hinge.

Foam structures with film hinges

Foam structures are disclosed herein. In some embodiments, the foam structures include a plurality of foam panels with edges. Each of the foam panels is formed from polymer foam particles. At least two of the plurality of foam sheets are juxtaposed and integrally connected along one of the edges of each of the at least two sheets by a living hinge defined by a channel between the sheets. The living hinge allows the adjacent panels to fold toward each other along the living hinge. As used herein, a "slab" refers to a substantially planar, monolithic article that is of continuous composition throughout. In some embodiments, a single panel corresponds to one side of a shipping carton, crate, or other container. The panel could be any shape such as a square, rectangle or other polygon. The plate could have a thickness of from about 0.25 inch (6.4 mm) to about 4 inches (100 mm), for example about 0.25 inch (6.4 mm), about 0.375 inch (9.52 mm) , about 0.5 inch (13 mm), about 0.75 inch (19 mm) or about 1 inch (25 mm). The thickness could be 1.25 inch (31.8 mm), 1.5 inch (38 mm), 2 inch (50 mm), 3 inch (80 mm), 4 inch (100 mm) or any thickness in between, depending of the desired thermal and mechanical properties. The panel may be from about 1 inch (25mm) to about 48 inches (1220mm) or more on a side, e.g. about 1 inch (25mm), about 2 inches (50mm), about 6 inches (150mm), about 12 inches (305 mm), about 24 inches (609 mm), about 36 inches (914 mm), about 48 inches (1220 mm), larger than 48 inches, or any side length in between depending on the size thermal desired Properties and mechanical properties of the insulating structure.

As used herein, the "thickness" of a panel refers to the depth of the panel measured from approximately the center of the panel. In other words, a panel with a beveled edge or a panel connected to another panel by a living hinge is described as having the same "thickness" as a panel with straight edges or a panel without a living hinge, although the depth of the panel changes at the edges and/or living hinge by being beveled and shaped.

The panels can be used multiple times, with two or more panels forming the foam structure and used as a self-supporting container or to improve the thermal properties of another container, box, shipping container or other structure. Thus, each plurality of panels can form the foam structure and form a self-contained container, box, or shipping container. For example, a foam structure assembled from six panels would form a standard 6-sided box and can be used without a casing or outer box.

The term "foam structure" as used herein means any structure comprising foam particles capable of retaining thermal energy, excluding thermal energy, preventing or reducing thermal energy, or a combination thereof, or contributing to, including, but not limited to an insulating shipping container with or without an attached hinged lid, edge protector, and edge protector.

As used herein, the term "shipping container" means a container for shipping articles. More specifically, an “insulated shipping container” means a container with insulation for shipping of heat-sensitive items such as perishable foods or medicines. For example, an insulated shipping container may refer to an insulated shipping container commonly used for shipping meat, fish, meals, or meal ingredients.

As used herein, the term "living hinge" means a piece of material, e.g. Polymeric foam that connects two components made of the same material, e.g. foam boards. That is, the term "living hinge" refers to a flexible, pliable area of a material that connects at least two relatively inflexible areas of the material. The flexible and inflexible areas are integrally connected, e.g. B. as part of a single, monolithic structure. The living hinge, sometimes referred to as "webbing", and the components are formed from the same material and are usually formed from the same single, continuous monolithic source of material (often referred to herein as a "blank"). In this way, the two components can be folded against each other along the living hinge without having to add a separate piece of material and without the burden of the end user having to separate or disassemble the components from the living hinge. For example, the living hinge may be defined by a channel formed between two adjacent panels. The living hinge may be formed after the blank has been formed, such as by removing material or by a secondary forming process. The living hinge can be formed simultaneously with the blank, for example by a modified molding process.

As used herein, the term "seal" means a joint formed by two or more surfaces of one or more objects that come into substantial contact with one another in a manner that permits the transfer of thermal energy through, around, or in connection with the Seal reduced or prevented.

In some embodiments, the foam panels are rigid. As used herein, the term "rigid" means having a bulk modulus greater than 1 MPa. A rigid object is therefore more likely to break than deform. More specifically, a "rigid foam board" means a single, monolithic foam board with a Young's modulus greater than 1 GPa such that the board will fracture under sufficient stress rather than deform. It should be noted that a rigid object may have a high flexural strength, which is the stress at failure in a flexural test.

In some embodiments, the polymeric foam particles are compostable and/or biodegradable. Biodegradable polymeric foam particles include homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, or polyhydroxyalkanoate. Foam structures comprising biodegradable polymeric foam particles can be degraded by an industrial composting facility in about 7 to about 42 days, such as within about 7 to about 21 days.

The term "compostable" is used to refer to materials that meet or exceed relevant degradation standards in commercial composting facilities, such as the standards listed in ASTM D5338, ASTM D6400, and/or ISO 20200. For example, the compostable articles described herein degrade according to the criteria set forth in ASTM D5338, ASTM D6400, and/or ISO 20200. That is, the compostable articles described herein will break down or be digested by microbes in 180 days, 90 days, or less in a controlled compost study. In certain embodiments, the compostable articles described herein are compostable in an industrial compost site in about 42 days or less.

In other embodiments, the polymer foam particles are formed from materials that are not biodegradable, such as polystyrene, polyethylene terephthalate, thermoplastic polyurethane, polyvinyl chloride, starch, poly(ethylene vinyl acetate), polyethylene, polypropylene, polyacrylic acid, or mixtures thereof.

In some embodiments, the living hinge comprises polymeric foam particles formed by standard molding without any post-processing. As used herein, "standard molding" refers to a molding process in which polymer foam particles are injected into a mold where they are compressed in the presence of steam to collapse the polymer foam particles and form a monolithic foam article. The formation of a living hinge using standard molds has limitations on the thickness of the living hinge, i.e. the hinge must have a thickness between about 2 to 4 polymeric foam particles.

In other embodiments, the living hinge comprises polymeric foam particles that have been conditioned through the application of localized pressure and/or localized heat. By conditioning the polymer foam particles that form the living hinge, the density, flexibility and strength of the living hinge can be increased compared to the standard molding process. By conditioning the polymeric foam particles that form the living hinge, the living hinge can be thicker (ie, 4 polymeric foam particles or more) or thinner (ie, 1 to 2 polymeric foam particles) than a living hinge formed by a standard molding process.

In some embodiments, the connecting edges of the at least two foam panels are beveled. As used herein, the term "beveled" means inclined or angled relative to a right angle. More specifically, a “beveled edge” means an edge that is inclined or angled relative to a right-angled edge.

In some embodiments, the abutting edges of the at least two foam sheets include edge features such as mechanical locking tabs and mechanical locking slots, wherein the tabs and the slots are configured to interlock to secure two or more foam sheets together and/or two or more To guide or align foam panels connected by a living hinge when folded together. In some embodiments, the facing edges of at least two foam sheets have mechanical locking tabs and mechanical locking slots to facilitate friction fit or compression fit locking. Such locking or interlocking features may facilitate securing the living hinge in a closed configuration, which may be useful, for example, in the process of assembling panels or panel systems into a container.

In embodiments, the at least two foam panels, which are connected by a film hinge, share a common surface. A first face of one panel abuts a living hinge face and the living hinge face adjoins a second face of the adjacent panel. The common surface is thus continuous across the first panel, the hinge and the second panel.

In some embodiments, the living hinge is reinforced. For example, the living hinge can be reinforced with a reinforcing material such as tape, laminate, rubber backing, filament, or a mechanical support. As used herein, the term "adhesive tape" means any strip of adhesive material suitable for joining two or more objects together. The adhesive material may include a backing layer and an adhesive coating layer. Non-limiting examples of adhesive tapes include gummed kraft paper tape or rubber paper tape. The term "filament" as used herein means a thin, flexible piece of material that usually takes the form of a cord or cord. In some embodiments, the adhesive tape is printed with identifying markings, such as a brand indicator, label, package shipping/tracking, or other information.

Plate systems for the formation of foam structures

Panel systems for forming foam structures are also disclosed herein. In some embodiments, a panel system for forming a foam structure includes a plurality of foam panels formed from polymeric foam particles, wherein at least two of the foam panels are connected by at least one living hinge. In some embodiments, the at least two foam panels are connected along one of the edges of each of the at least two panels by a living hinge, the living hinge being defined by a channel between the panels.

In some embodiments, the plurality of foam panels that make up the panel system are arranged in a flat configuration and connected by living hinges. In some embodiments, when the system is folded at the living hinges, edges of at least two of the plurality of foam panels are configured to bond and form a seal at the bond edges. That is, the seal can be formed when the living hinges are in a closed configuration.

In some embodiments, the plurality of foam panels forming the panel system comprises three foam panels arranged in series with adjacent panels connected by living hinges to form a panel system configured to fold into a C-shape arrangement folds. In some embodiments, two of the C-shaped assemblies are configured to be joined together to form the foam structure.

In some embodiments, the plurality of foam panels forming the panel system comprises five foam panels, with adjacent panels connected by living hinges to form a panel system configured to fold into a five panel box. In some embodiments, the 5 panel box is configured to be bonded to a foam panel lid of the foam structure.

In some embodiments, the plurality of foam panels forming the panel system comprises six foam panels, with adjacent panels connected by living hinges to form a panel system configured to fold into a 6 panel box. For example, the 6-panel box is a folded foam structure that can be used as shipping packaging, with or without the addition of a corrugated box.

In some embodiments, the plurality of foam panels that form the panel system include two foam panels joined together by a living hinge to form a panel system that is configured to fold into an edge protector that can be used alone or in combination can be used with other edge protectors as a foam structure.

While reference has been made to configurations wherein the plurality of foam panels making up the panel system comprises 2, 3, 5 or 6 foam panels configured to be folded into a panel subassembly and in some embodiments with one or more other panel subassemblies or foam to be joined to form the foam structure, it is understood that the foam structure of the present disclosure may have more than 6 foam slabs, such as 7 foam slabs, 8 foam slabs or more, and less than 6 foam slabs, such as 1 foam slab or 4 foam sheets may include.

In some embodiments, the foam panels include structural members configured to attach one or more interior walls. For example, the one or more interior walls can divide the foam structure into two or more separate chambers. As used herein, "structural elements" means lips, notches, ridges, grooves, or other physical features that form, align, and/or secure one or more interior walls in the foam structure.

In some embodiments, one or more of the foam sheets contain one or more points of fracture. As used and described herein, the living hinges are not breakable. For example, the fracture sites may allow the foam slab to be broken into one or more foam slab fragments at a given point, thereby reducing the size of the foam slab to facilitate disposal and composting. As used herein, "fracture point" means an engineered, machined, or molded feature at which the foam sheet preferentially fractures when a force is applied. For example, the breakpoints can be in the form of a line or a series of indentations.

In some embodiments, the plurality of foam slabs are formed, such as by any suitable forming methods known for such materials. An example of a suitable molding process includes forming polymeric particles from a melt-processible extrudate, introducing air into the polymeric particles, and introducing the particles into a mold. The particles can then be subjected to a series of cross-steaming and rinsing steps, resulting in a single, monolithic shaped body.

In some embodiments, the plurality of foam panels are machined from a block of foam. As used herein, "machined" means scraping, carving, or cutting a block of foam to reduce its size and shape to the desired shape. In some embodiments, the block of biodegradable foam is initially formed by a molding process.

In some embodiments, the foam structure is in the form of an insulated shipping container that does not contain corrugated cardboard. In some embodiments, the foam structure is surrounded by an outer box. For example, the outer box could be corrugated cardboard and the foam structure lines the inner walls of the outer box, creating an interior space. This interior space can be surrounded on all sides by the foam structure on the one hand and by the corrugated cardboard box on the other.

1A 10 shows a foam structure 100 including a plurality of foam panels 102 having edges 104. FIG. The panels are connected by living hinges 106 defined by channels 108 . A common surface 110 connects a surface 112 of one panel 102, a surface 114 of an adjacent panel 102, and a living hinge surface 116 of living hinge 106. In this manner, the common surface 110 is continuous across the adjacent panels 102 and living hinge 106. In some cases, the foam structure comprises two panels connected at adjacent edges by a living hinge. In other cases, the foam structure has more than two panels, such as three panels, four panels, five panels, or more panels, with each pair of interface edges connected by a living hinge. The panels may have a square shape with four edges of equal length, a rectangular shape with two pairs of edges of different lengths, or some other shape with a corresponding number of edges of suitable lengths. In some cases, the canal has a “V” shape in cross section. In other cases, the channel has a rectilinear or other suitable shape. In other cases, the edges of the channel have curved or wavy surfaces.

As used herein, a channel having a “V” shape generally refers to two panels, each having beveled or angled edges, joined by a living hinge. The "V" shape can resemble a "V" where the beveled edges of connected panels meet at a sharp, angled corner. Alternatively, the "V" shape may have a curved profile resembling a "V" with a rounded tip rather than a sharp corner (e.g., a "U" shape) at the point where the joined panels meet. Therefore, the use of "V" throughout is for brevity, and any suitable geometry of the two plates connected by a living hinge may be used. In addition, as discussed above, the channel may have a rectilinear or other suitable shape.

The joining edges of at least two panels may be configured to be brought into contact to form a thermal seal between those panels, i.e., thermal energy transfer between an interior volume defined by the panels and an exterior volume outside the volume enclosed by the panels 102 to prevent or reduce. The length of an edge may or may not be the same length as a joining edge so that a seal is formed between adjacent edges. The shape of an edge may correspond to the shape of a boundary edge such that a seal is formed between adjacent edges. Various configurations of such corresponding edges are described below; however, any suitable mechanical edge joint that achieves the desired thermal seal between adjacent panels may be used. The shape of all edges of a panel can be the same, or some edges can have one shape, e.g. bevelled, while other edges have a different shape, e.g. straight.

1B Figure 1 shows a foam structure 100 having two foam panels 102 having edges 104 and connected by a living hinge 106 defined by channel 108, such as can be used to form an insulating liner or partially insulating container, or which can be used with additional panels can be combined to form a container as described herein.

1C 12 shows a foam structure 100 having two foam sheets 102 having edges 104 and connected by a living hinge 106 defined by channel 108. FIG. 1C Figure 12 shows the foam structure 100 in an unfolded state or an open configuration. 1D shows the foam structure 100 of FIG 1C in a folded state or a closed configuration. In some cases, the edges of the panel are formed at an angle, such as by beveling, chamfering, rubbing, or other methods, to increase the available surface area for the edges of adjacent panels to contact one another. Although the thickness of a panel can be a measure, the process of forming the edge, e.g. B. chamfering, to a chamfered surface of length greater than the thickness of the slab, thereby improving heat storage properties without significantly changing the slab dimensions or the dimensions of the foam structure.

While reference has been made in some embodiments to "beveled" edges, it should be understood that any suitably shaped edge that allows interface panels to form a thermally adequate seal is contemplated. For example, in other embodiments, panel edges may have other suitable shapes that may be used in place of or in addition to a beveled edge.

In some embodiments, the plate edges may be formed and shaped by a channeling process, ie, the creation of channels results in beveled edges or straight edges ten or other shaped edge. In some other embodiments, the panel edges may be formed by a process after the channels are formed, ie, panel edges are subsequently formed into beveled edges or straight edges or any other shaped edge.

2 12 shows a foam structure 100 having two foam sheets 102 having edges 104 and connected by a living hinge 106 defined by a channel 108. FIG. Edges 104 have mechanical locking tabs 202 and corresponding mechanical locking slots 204 . In some cases there may be a set of mechanical locking tabs and corresponding slots running the length of the edge of a panel. In other cases, there are multiple sets of discrete tabs and corresponding slots at specific locations along the edge of a panel. The edge of a panel may have a portion with mechanical locking tabs or slots and a portion without tabs or slots. The edge of one panel may have both tabs and slots that correspond to mating slots and tabs on the edge of an adjacent panel. The edges of a panel can vary in shape, with some edges being beveled and others straight, but both types of edges can have mechanical locking tabs and slots that correspond to mechanical locking slots and tabs of edges of adjacent panels. In some embodiments, edge features such as the mechanical locking tabs and corresponding slots are formed when the channels are formed, ie, the same process that forms the channel also forms the mechanical locking tabs and slots. In other embodiments, the edge features are formed by a process after the channels are formed, ie, plate edges are subsequently machined to form edge features.

3 12 shows a foam structure 100 having two foam sheets 102 having edges 104 and connected by a living hinge 106 defined by a channel 108. FIG. The living hinge 106 is reinforced by reinforcement material 302 . The reinforcement material 302 can be any suitable reinforcement material, such as tape, laminate, rubber backing, filament, or mechanical support. The reinforcing material may run the entire length of the living hinge, or there may be multiple separate pieces of reinforcing material at separate locations along the living hinge. In foam structures with multiple living hinges, all living hinges may contain reinforcing material, or only certain living hinges may contain reinforcing material.

Reinforcement material may be used to increase the thermal or impact properties of the living hinge. Reinforcing material may be used to reinforce the hinge properties of the living hinge, i.e. the reinforcing material may extend from one panel to an adjacent connected panel and act as a hinge in addition to or as an alternative to the living hinge or if the living hinge fails for any reason. In some cases, the reinforcing material runs the length of the living hinge with minimal interference with panels connected by the living hinge. In other cases, discrete pieces of reinforcing material may connect adjacent panels that are connected by living hinges. In other cases, lengths of reinforcing material may run from one edge of the foam structure to the other, i.e. from the edge of one panel across the entirety of a central panel to the edge of a third panel where the panels are connected in series by hinges.

4A Figure 13 shows three foam panels 102 joined by living hinges 106 to form a 3 panel system 402 configured to be folded into a C-shaped configuration. The three foam panels are connected in series, with a first panel connected to a second panel by a living hinge and the second panel connected to a third panel by a living hinge, resulting in a panel-panel-panel system. 4B 4 is a perspective view of a 3 panel system 402 that has been folded to form a C-shaped assembly 404 positioned proximal to another 3 panel system 402 to form the foam structure 100. FIG. In some cases, two C-shaped assemblies are configured to be joined together to form the foam structure. In other cases, depending on the circumstances, a C-shaped arrangement forms the foam structure. In other cases, a C-shaped assembly is used in conjunction with one or more foam panels, which may or may not be connected by living hinges, to form the foam structure. For example, a C-shaped assembly can be used in conjunction with two panels connected by a living hinge to form a five-sided open box. The edges of the panels may be beveled so that the gap between joined panels is minimal, but the beveled surface allows the panels to be folded against one another. The edges of the panels may have edge modifications such as mechanical locking tabs and/or slots, and these modifications can make it easier to connect one C-shaped assembly to another C-shaped assembly.

5A Figure 12 shows five foam panels 102 joined by living hinges 106 to form a 5 panel system 502 configured to be folded into a 5 panel box. 5B FIG. 5 is a perspective view of a 5 panel system 502 that has been folded to form a 5 panel box 504. FIG. Foam lid 506 positioned against 5 panel box 504 to form foam structure 100. FIG. In some cases, the five panels can be joined to form a "T" shaped panel system when positioned in a flat configuration, or blank, with three panels connected in series by living hinges and the middle panel also by a living hinge connected on a third side to a fourth panel, and the fourth panel is connected by a film hinge to a fifth panel on the opposite side, as in 5A shown. In other cases, the five panels can be joined to form a "+" shaped or cross-shaped panel system when positioned in a flat configuration, or blank, with three panels connected in series by living hinges and the middle panel also by Film hinges is connected on a third side to a fourth plate and on a fourth side to a fifth plate. In other cases, the five panels may be joined to form an "S" shaped panel system when positioned in a flat configuration, or blank, with a first panel connected by a living hinge to a second panel, the second panel on a side perpendicular to the first panel by a living hinge to a third panel, the third panel on the opposite side of the second panel is hinged to a fourth panel and the fourth panel on a side perpendicular to the third panel by a living hinge connected to a fifth disk. Any suitable positioning of the five panels can be used to form the panel system configured to fold into a 5 panel box. The five panels can be connected with film hinges. The panels may have beveled edges. A foam topper may have beveled edges, straight edges, a combination of beveled edges and straight edges, or any suitable shaped edge.

6A Figure 12 shows six foam panels 102 joined by living hinges 106 to form a 6 panel system 602 configured to be folded into a 6 panel box. 6B 12 is a perspective view of a 6 panel system 602 that has been folded to form a foam structure 100. FIG. In some cases, the six panels can be joined to form a "T" shaped panel system when positioned in a flat configuration, or blank, with three panels connected in series by living hinges and the middle panel also by a living hinge connected on a third side to a fourth panel, the fourth panel is connected by a living hinge to a fifth panel on the opposite side, and the fifth panel is connected to a sixth panel by a living hinge on the opposite side. In other cases, the six panels can be joined to form a "+" shaped or cross-shaped panel system when positioned in a flat configuration, or blank, with three panels connected in series by living hinges, the middle panel also through Film hinges connected to a fourth panel on a third side and to a fifth panel on a fourth side, and either the fourth panel or the fifth panel is connected to a sixth panel. In other cases, the six panels may be connected to form an “S” shaped panel system, in which a first panel is connected by a living hinge to a second panel, the second panel on a side perpendicular to the first panel being connected by a living hinge a third panel, the third panel is hinged to a fourth panel on the opposite side of the second panel, the fourth panel is hinged to a fifth panel on the opposite side of the third panel, and the fifth panel is connected to a sixth plate by a film hinge on one side perpendicular to the fourth plate. Any suitable positioning of the six panels can be used to form the panel system configured to be folded into a 6 panel box. When folded, the resulting foam structure may have a "lid" formed by one of the six panels so that the structure can be "opened" by unfolding the panel.

7A Figure 12 shows two foam panels 102 joined by living hinges 106 to form a 2-panel system 702 configured to be folded into an edge protector. 7B FIG. 7 is a perspective view of a two panel system 702 that has been folded to form an edge protector 704. FIG. In some cases, the two panels have an oblong-rectangular shape and are joined at the long edge. In other cases, the panels are joined at the short edge. In other cases, the panels are the same size and are joined at each edge. In other cases, the plates are of different sizes. Any suitable size and shape of the two plates can be used to achieve this to form a 2-panel system. When folded, the resulting edge protector can be isolated or used in conjunction with another edge protector or in conjunction with another foam structure.

8th 12 shows the interior of a foam structure 100 that includes a plurality of foam panels 102. FIG. The foam panels 102 include structural members 802 that align and secure interior walls 804 . The structural elements can be lips, notches, ridges, grooves, or other physical features that form, align, and/or secure one or more interior walls in the foam structure. The structural elements may extend the length of the panel, or there may be multiple discrete structural elements. There may be multiple sets of structural elements designed to divide the foam structure into two, three, four or more separate chambers. The inner wall may be formed of foam, corrugated cardboard, or any other material suitable for dividing the foam structure into multiple compartments. The inner wall can be positioned vertically, horizontally, or in any orientation suitable for dividing the foam structure into multiple chambers. The inner wall can be positioned perpendicular to the structural panel, or it can be positioned at any angle to the perpendicular.

9A shows a foam sheet 102 with break points 902. 9B 12 shows foam sheet 102 after fracture along fracture point 902, creating two foam sheet fragments 904. FIG. In some cases there is a breakpoint. In other cases there are two, three, four or more breakpoints. The point of fracture may result in two foam board fragments of the same size, or the fragments may be of different sizes. The point of breakage can be designed to result in fragments of a size and shape suitable for composting or other post-consumer processing.

10 10 shows a foam structure 100 having a plurality of foam panels 102 surrounded by an outer box 1002. FIG. The outer box can be made of corrugated cardboard or other material suitable as a container. For example, the outer box can provide structural support and mechanical properties suitable for use as a shipping container. The outer box may have a lid that folds over to cover the foam structure. The outer box may enclose only part of the foam structure, leaving one or more sides uncovered.

Process for the manufacture of foam structures

Methods of making a foam structure are also disclosed herein. As described herein, the foam structure can be any structure formed from foam particles and having a hinge or connection between adjacent components. In one aspect, a method includes providing a foam sheet blank formed from a plurality of polymeric foam particles. In some embodiments, the method further comprises forming one or more channels in the blank foam sheet to define a plurality of foam sheets, the foam sheets having a living hinge defined by the one or more channels between the sheets. In some embodiments, at least two of the plurality of foam panels are arranged side-by-side and abutted at at least one of the edges of each of the at least two panels, with the abutting edges forming a living hinge. Any suitable method and equipment known for forming a foam board blank can be used to make the boards described herein. For example, methods and equipment known for the manufacture of EPS board can be used. The panels made by these methods can be the panels described herein, including any combination of features thereof.

In some embodiments, known methods are used to prepare the foam blanks used in the methods disclosed herein. For example, US Pat. No. 10,518,444 to Pawloski et al. discloses processes for making compostable or bio-based foams useful for making foamed articles. In the disclosed method, foamed beads formed from a bio-based polyester and a blowing agent are molded to form a molded article. These methods can be used to make the foamboard blanks used to make the foamboards of the present disclosure. In another example, US Pat. No. 10,688,698 to Bhargava et al. discloses methods of making molded foam articles that can be used to make the foam sheet blanks used to make the foam sheets of the present disclosure.

In some embodiments, forming the foam sheet blank involves forming foam particles using standard molds without post-processing. Forming foam sheet blanks using standard molds involves using a mold with the shape of the final product, including a space for the living hinge, so that the foam sheet blank has a uniform density and composition across the living hinge. In other embodiments, forming the blank foam panel includes post-conditioning the foam particles to form the living hinge. Forming the cured foam sheet blank involves using a mold with a gap or gap at the location where the living hinge is desired and then forming the living hinge using a secondary, e.g., separate, molding process. As used herein, "post-conditioning" refers to the application of localized heat and/or pressure to change the density, strength, and flexibility of the polymeric foam particles, eg, in an area of the material that forms the living hinge.

In some embodiments, the post-conditioning includes the use of a core puller. As used herein, a “core pull” refers to a moveable element that is inserted into and withdrawn from a standard mold cavity to change the pressure and/or temperature at a specific location within the mold. The core pull can be controlled by a linear actuator that controls the distance and force of the core pull as it enters the mold cavity and contacts the material within the mold. The core train may include a heating source such as an electrically heated platen or a showerhead to disperse steam. The core train may include a source of cooling, such as a showerhead, for distributing fluid, such as cooling air.

In some embodiments, the post-conditioning includes the use of an improved core puller equipped with an inflating injector. The fill injector may allow for the injection of polymeric foam particles at a concentration point within the mold cavity.

In some embodiments, the improved core puller includes one or more guide rods that are bushed and sealed so that they can retract into and retract from the mold cavity without changing the pressure in the mold cavity and without allowing vapor to escape from the mold cavity escapes.

In some embodiments, forming the foam sheet blank includes molding polymeric foam particles in a mold cavity with a gap or gap at the location where the living hinge is desired. A core pull can be designed to actuate and contact the polymeric foam particles in the gap or gap, thereby packing and compacting the polymeric foam particles at a specific location. After compacting the polymeric foam particles using the core puller, steam can be applied to the mold cavity, causing the polymeric foam particles to expand and melt. During or after the steaming process, the core pull can be heated and/or used to condition the living hinge section. In some embodiments, the core pull is cooled to stabilize the living hinge portion prior to ejection from the mold.

In some embodiments, the method further includes assembling the foam structure from the foam slabs. In some embodiments, the assembling step includes folding the foam sheets at the living hinge, thereby forming a seal between at least a pair of adjacent edges of the foam sheets to contain thermal energy at the edges.

In some embodiments, the foam panels are rigid. In some embodiments, the foam panels include beveled edges on each of the panels. In certain embodiments, the edges of the foam sheets are shaped or machined to form the desired edge geometry.

In some embodiments, the channels that define the living hinge in the foam sheet blank have a "V" cross-sectional shape in the open configuration. In other embodiments, the channels may have a different shape, such as a rectilinear shape or curved surfaces, as described herein.

Any suitable method of forming the one or more channels can be used. For example, the channel can be formed simultaneously with the molding of the foam sheets using a mold cavity having the shape of a living hinge. Alternatively, the channel can be formed immediately after molding the foam sheets using a core puller that configured to provide localized pressure and/or heat to compress and condition the living hinge. In another embodiment, forming the one or more channels can be performed by mechanical milling. In another embodiment, forming the channels is performed by wire cutting. In another embodiment, forming the channels is performed by laser cutting. In another embodiment, the channels are formed by water jet cutting. In another embodiment, the channel can be shaped.

In some embodiments, forming the living hinge includes compressing the beads in the channel to allow the hinge to flex. In some embodiments, bead collapse is performed by a heated scribe wheel. In another embodiment, the collapse of the beads is performed by a core puller that is inserted into a mold after the foam board blank and channels have been formed. In another embodiment, the collapse of the beads is performed by a core puller equipped with guide rods that are bushed and sealed so that they can extend into and retract from the mold cavity without opening the mold cavity. In another embodiment, bead collapse is accomplished by moving the foam sheet blank over a conveyor belt, aligning heated die heads over the blank, and lowering the heated die heads onto the blank to collapse the polymeric foam particles and form the channels.

In embodiments where the channels are formed in a molding machine, the beads are collapsed by subsequently conditioning the beads within the mold by a core pull. Conditioning using a core pull can increase the total cycle time by less than about 3 seconds, such as less than 1 second or less than 10% of the total cycle time. In some embodiments, conditioning using a core pull does not increase the overall cycle time.

In some embodiments, the foam panels include mechanical interlocking tabs and corresponding mechanical interlocking slots on the edges of each of the panels to facilitate a compression fit interlock with adjacent edges of the panels. In some embodiments, the mechanical locking tabs and slots may be on or in beveled edge surfaces of panels, which surfaces are interfaces when a living hinge between the panels is in the closed configuration.

In some embodiments, the foam structure, e.g., the foam panels, includes a reinforcing material attached to a surface of the living hinge. In some embodiments, the reinforcing material is tape, laminate, rubber, filament, or a mechanical support. In some embodiments, the reinforcing material can reinforce the living hinges without penetrating the surface of the panels connected by the living hinge. In other embodiments, discrete pieces of reinforcing material may extend onto the panels to act as a hinge in addition to or as an alternative to the living hinge, or if the living hinge fails for any reason. In other embodiments, the reinforcing material may span the length of the foam structure from the edge of one panel through the entire length of a middle panel to the edge of a third panel, in the example of three panels connected in series.

In some embodiments, the plurality of foam panels connected by living hinges are provided as a 3 panel system configured to form a C-shaped array. In some embodiments, assembly includes folding any two of the 3-panel systems into a C-shaped configuration and attaching the two C-shaped configurations together to form the foam structure.

In some embodiments, the plurality of foam panels are provided in a 5 panel system, and assembling comprises folding the 5 panel system and attaching edges of the panels to form a 5 panel box. In some embodiments, assembling the foam structure includes positioning a foam panel lid on an open side of the 5 panel box to form the foam structure.

In some embodiments, the plurality of foam panels are provided in a 6 panel system, and assembling includes folding the 6 panel system and attaching edges of the panels to form the foam structure.

In some embodiments, the plurality of foam panels are provided in a 2-panel system, and assembling includes folding the 2-panel system and attaching edges of the panels to form an edge protector.

In some embodiments, the plurality of foam panels includes structural members on one or more of the panels configured to attach one or more interior walls. In some embodiments, assembling includes installing one or more interior walls to separate the foam structure into two or more separate chambers.

In some embodiments, one or more of the multiple foam sheets includes one or more fracture points to facilitate breaking one or more of the foam sheets into fragments for disposal and composting. For example, the fracture sites can be formed by scribing, scoring, perforating, or other suitable methods.

In some embodiments, assembling includes surrounding the foam panels with an outer box. For example, the plurality of foam sheets may be surrounded by a corrugated paperboard outer box. In particular, an outer box is useful when the foam structure is composed of fewer sheets of foam than are required to form a self-contained container. For example, a foam structure formed from three panels may be insufficient to be used as a stand-alone container, so an outer box would enclose the foam structure. In some embodiments, the outer box can provide further structural support for the foam structure.

In some embodiments, the foam panel blank is formed from a plurality of biodegradable foam particles. Biodegradable foam particles include homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, or polyhydroxyalkanoate. A foam panel blank and foam structure formed from biodegradable foam particles are degraded by industrial compost within a period of from about 7 days to about 41 days, such as from about 7 to about 21 days.

In other embodiments, the foam sheet blank is formed from a plurality of foam particles that are not biodegradable, such as particles containing polystyrene, polyethylene terephthalate, thermoplastic polyurethane, polyvinyl chloride, starch, poly(ethylene vinyl acetate), polyethylene, polypropylene, polyacrylic acid, or mixtures thereof.

11 FIG. 11 is a flow chart depicting a method 1100 for fabricating a foam structure. Step 1102 includes forming a foam sheet blank in a mold from a plurality of polymer foam particles. Step 1104 includes forming one or more channels in the foam sheet blank to define a plurality of edged foam sheets. Optional step 1106 includes assembling the foam structure by folding the plurality of foam sheets at the living hinge. Optional step 1108 includes burning identification markings into the plurality of foam sheets to identify content, destination, source, expiration date, and/or other identifier. In some cases, the method may include steps 1102 and 1104 but omit steps 1106 and 1108. For example, steps 1102 and 1104 may be performed on a single assembly line or within a single manufacturing facility, while steps 1106 and/or 1108 may be performed off-line or off-site, such as by a goods packer or shipping container. In other cases, the method may include step 1106 but omit step 1108. In other cases, all steps 1102, 1104, 1106, and 1108 are included.

12A 12 is an illustration of step 1104 in which a foam sheet blank containing foam sheets 102 is formed in mold 1202. FIG. 12B 12 shows core trains 1204 post-conditioning the foam sheets 102 by being pressed and formed into the channel 108 and the beads collapsing to form living hinges 106. FIG. In some embodiments, the core pulls are actuated while the foam sheet blank is being formed. In other embodiments, the core pulls are actuated after the molding process is complete but while the foam sheet blank is still hot. In some embodiments, the core features are "V" shaped such that the beads collapse into a "V" shape when the "V" shaped channel is formed. In other embodiments, the core features are straight so that the beads collapse into a straight shape when a straight channel is formed. In other embodiments, the core features are straight but the beads collapse, after the beads have started to melt, resulting in a sloped shape as the channel is formed. In some embodiments, the mold is configured to form a channel and living hinge. In other embodiments, the mold is configured to form two channels and two living hinges. In other embodiments, the mold is configured to form more than two channels and more than two living hinges, such as three channels and living hinges, four channels and living hinges, five channels and living hinges, or more channels and living hinges. In some embodiments, the channels and living hinges are parallel to each other. In other embodiments, the channels and living hinges vary in their relative positioning, such as some channels being perpendicular to other channels.

13 13 is an alternative illustration of step 1104 in which the foam sheet blank including foam sheets 102 moves over a conveyor 1302. FIG. An array 1304 of heated forming heads 1306 is aligned over the foam sheet blank. The assembly 1304 is lowered onto the foam board blank and the heated forming heads collapse the polymeric foam particles to form the channels and living hinges. The separating head 1308 is then lowered through one of the one or more channels to completely separate one foam slab from the next foam slab (eg, to separate one foam structure from the next foam structure), resulting in a foam structure 100 .

Example 1: Cycle and strength tests of film hinges with and without post-conditioning

Polymer foam panels connected by hinges were load tested to determine hinge durability. Each set of plates tested had a thickness of 1.5 inches (38.1 mm) and a living hinge formed at a 45° angle. The panels had thicknesses and widths for living hinges as described below. Each plate was formed from polylactic acid as in U.S. Patent No. 10,688,698 described. Three tests were conducted. The first test was a cycle test in which the living hinge was rotated between an open configuration in which the panels were substantially parallel to each other at a 180° angle and a closed position in which the panels were substantially perpendicular at a 90° angle were to each other. The living hinge was cycled between the open and closed configurations until failure occurred in the form of cracks in the polymer foam. The number of cycles before failure was recorded and compared.

The second test was an open strength test. It was found that the living hinges of the present disclosure could withstand hundreds of cycles after post conditioning. To more quickly examine the strength of the conditioned living hinges, the living hinge was opened through 180°, i.e. the living hinge was flexed in the opposite direction from the closed position. The angle at which failure occurs was found to correlate with the number of cycles the living hinge was able to endure before failure.

The third test was a closed strength test. In this test, the living hinge was folded to the closed position, ie 90°, and then a force was applied as if to close the living hinge further than 90° until the hinge failed. The breaking force was recorded and compared. The results of the cycle, open strength and closed strength tests are shown in Table 1. Table 1 hinge type Film hinge thickness width of the living hinge Cycle Test: Average number of cycles to failure Open strength test: angle at failure Closed Strength Test: Force applied at failure standard shaped 0.0625 inches (1.59mm) 0.125 inches (3.17mm) 3 190° 85g standard shaped 0.16 inches (4.06mm) 0.31 inches (7.87mm) 25 210-215 degrees 450-650g Postconditioned 0.0625 inches (1.59mm) 0.125 inches (3.17mm) 75-110 215-225 degrees 850-1500g

As shown in Table 1, a 0.16 inch (4.06 mm) thick living hinge made using a standard molding process survived more cycles than a 0.0625 inch (1.59 mm). However, using the post-conditioning described herein significantly improved both the cycle count and the strength of the living hinge while maintaining the thinner 0.0625 inch (1.59 mm).

Example 2: Exemplary dimensions of the film hinge

Two foam sheets connected by a living hinge were prepared and conditioned as described herein. A single station Ving 31" x 39" pneumatic flat bed heat press machine with a heated ram rod was used. The heated ram rod had a 0.375 inch (9.52 mm) cross section with chamfered edges at 45°. The flat pressing surface of the ram rod had a width of 0.0625 inch (1.59 mm). The ram beam was heated to 300°C and pressed against the foam panels for 5 seconds with a pressure of 0.5 MPa. The dimensions of the resulting living hinge are in 14 shown.

While the disclosure has been described with reference to a number of embodiments, those skilled in the art will appreciate that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure may be modified to incorporate any number of variations, changes, substitutions, or equivalent arrangements not described herein but which are within the spirit and scope of the disclosure. Conditional expressions such as “may” or “could” used herein, unless expressly stated otherwise or otherwise understood in the context as used, are generally intended to convey that certain embodiments include other embodiments that do not include certain features, elements, or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it should be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be considered limited by the foregoing description, but only by the scope of the appended claims.

QUOTES INCLUDED IN DESCRIPTION

This list of the documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• US62984603 [0001]
• US10688698 [0089]

Claims (44)

Foam structure comprising: - a plurality of foam slabs, each of the plurality of foam slabs being formed from a plurality of polymeric foam particles; - wherein at least two of the plurality of foam sheets are connected by a living hinge defined by a channel between the at least two foam sheets such that the plurality of foam sheets are foldable along the living hinge. foam structure claim 1 wherein: - the living hinge has a thickness equal to one to six of the polymeric foam particles, and - the polymeric foam particles in the living hinge are at least partially collapsed. foam structure claim 1 wherein the channel is defined between adjacent edges of the at least two foam sheets and the adjacent edges are bevelled. foam structure claim 1 wherein the at least two foam sheets of the plurality of foam sheets further comprise one or more edge features for facilitating interlocking and aligning the at least two foam sheets when the living hinge is in the closed configuration. foam structure claim 1 wherein: - a common surface of the plurality of foam sheets comprises a first surface of a first foam sheet, a second surface of a second foam sheet, and a living hinge surface of the living hinge connecting the first and second foam sheets, and - the common surface continuous across the first and second foam sheets foam board and the film hinge is. foam structure claim 1 , and a reinforcing material attached to a surface of the living hinge. foam structure claim 1 wherein: the plurality of foam panels comprises three foam panels positioned in series, - each foam panel in the plurality of foam panels is connected to adjacent foam panels by hinges forming a 3 panel system, and - the 3 panel system is foldable, to form a C-shaped arrangement. foam structure claim 7 wherein the C-shaped assembly is configured to be connected to an identical C-shaped assembly to form a box structure. foam structure claim 1 wherein: - the plurality of foam panels comprises five foam panels, - each foam panel in the plurality of foam panels is connected to adjacent foam panels by hinges forming a 5 panel system, and - the 5 panel system into a 5 panel - Box is foldable. foam structure claim 1 wherein: - the plurality of foam panels comprises six foam panels, - each foam panel in the plurality of foam panels is connected to adjacent foam panels by hinges forming a 6 panel system, and - the 6 panel system is foldable to form a to form a box structure. foam structure claim 1 , wherein: - the plurality of foam panels comprises two foam panels which are connected to one another by a film hinge and form a 2-panel system, and - the 2-panel system can be folded to form an edge protector. foam structure claim 1 wherein the plurality of foam panels further comprises structural members for attaching one or more interior walls to separate the foam structure into two or more separate chambers. foam structure claim 1 wherein at least one sheet of the plurality of foam sheets further comprises one or more fracture points to facilitate breaking into one or more fragments to facilitate disposal and composting. foam structure claim 1 , wherein the plurality of foam sheets are shaped. foam structure Claim 14 wherein the living hinge is formed simultaneously with the forming of the plurality of foam sheets. foam structure Claim 14 wherein the living hinge is formed using a core puller immediately after forming the plurality of foam sheets. foam structure claim 1 wherein the plurality of foam slabs are machined from a block of foam. foam structure claim 1 wherein: - the foam structure forms an insulated shipping container for shipping heat sensitive articles, and - no corrugated paperboard is used in forming the insulated shipping container. foam structure claim 1 , further comprising an outer box surrounding the plurality of foam sheets. foam structure claim 19 , wherein the outer box comprises corrugated cardboard. foam structure claim 1 wherein the foam structure is in the form of an insulated shipping container suitable for shipping fragile articles. Foam structure according to one of Claims 1 until 21 wherein the polymeric foam particles comprise homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, polyhydroxyalkanoate, or mixtures thereof. foam structure Claim 22 , the foam structure being degraded by industrial compost over a period of about 42 days. A method of making a foam structure comprising: - forming a foam sheet blank in a mold from a plurality of polymer foam particles; and - Forming one or more channels in the foam sheet blank to define at least two foam sheets connected by a living hinge. procedure after Claim 24 , further comprising conditioning the polymeric foam particles forming the one or more channels by heating and collapsing at least a portion of the polymeric foam particles in the living hinge. procedure after Claim 24 , further comprising folding the at least two of the plurality of foam sheets at the living hinge. procedure after Claim 24 , where the foam sheet blank is rigid. procedure after Claim 24 , wherein the one or more channels have a V-shaped cross-sectional shape. procedure after Claim 24 , wherein forming the one or more channels comprises milling. procedure after Claim 24 , wherein forming the one or more channels comprises wire cutting. procedure after Claim 24 , wherein forming the one or more channels comprises laser cutting. procedure after Claim 24 , wherein forming the one or more channels comprises water jet cutting. procedure after Claim 24 , wherein forming the one or more channels comprises applying a heated scribe wheel. procedure after Claim 25 wherein the conditioning comprises molding the one or more channels concurrently with molding the foam sheet blank. procedure after Claim 37 wherein the conditioning comprises driving a core puller into the polymeric foam particles in a mold. procedure after Claim 35 , inserting the core puller into the mold increases an overall cycle time by less than 3 seconds. procedure after Claim 36 wherein inserting the core puller into the mold increases an overall cycle time by less than 10% of an overall cycle time for the mold. procedure after Claim 35 , wherein the insertion of the core puller into the mold does not increase an overall cycle time for the mold. procedure after Claim 24 wherein forming the one or more channels comprises: - moving the foam sheet blank over a conveyor belt; - aligning an array of heated forming heads over the foam board blank; - lowering the heated forming heads onto the blank foam sheet, the heated forming heads forming the one or more channels and collapsing at least a portion of the polymeric foam particles defining the living hinge. procedure after Claim 39 , further comprising lowering a cutting head through one of the one or more channels to yield the plurality of foam structures. procedure after Claim 24 , further comprising forming one or more mechanical locking tabs and mechanical locking slots configured to lock edges of the plurality of foam panels when the living hinge is in a closed configuration. procedure after Claim 24 , further comprising forming beveled edges on at least one of the plurality of foam panels. procedure after Claim 24 , further comprising forming one or more fracture sites in one or more of the plurality of foam panels. Procedure according to one of claims 24 until 43 wherein the polymeric foam particles comprise homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, polyhydroxyalkanoate, or mixtures thereof.

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