WO2021178523A1

WO2021178523A1 - Foam structures having a living hinge and associated methods

Info

Publication number: WO2021178523A1
Application number: PCT/US2021/020651
Authority: WO
Inventors: Saumitra BHARGAVA; Tim Pritchett; Walter Mercy
Original assignee: Lifoam Industries, Llc
Priority date: 2020-03-03
Filing date: 2021-03-03
Publication date: 2021-09-10
Also published as: PL442175A1; KR20220146508A; DE112021001361T5

Abstract

Foam structures having living hinges and methods of making those structures are provided. The foam structures are produced using a plurality of foam panels formed from polymer foam particles and connected by living hinges. The living hinges may be conditioned to increase their density, strength, and flexibility. The foam panels are folded together to form a foam structure suitable as an insulating container.

Description

FOAM STRUCTURES HAVING A LIVING HINGE AND ASSOCIATED

METHODS

CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims priority to U.S. Provisional Application No. 62/984,603, filed March 3, 2020, which is incorporated herein by reference.

FIELD OF THE DISCLOSURE

[0002] This disclosure relates generally to foam structures having living hinges and to methods for producing such foam structures and, in particular, relates to foam structures having living hinges formed from polymer foam particles and methods for producing such foam structures.

BACKGROUND [0003] Foam articles are commonly used for insulation because of their light weight, thermal properties, and impact resistant properties. For example, foam articles are useful for shipping thermally sensitive commodities, such as meal kits, confectionary products, cakes, other perishable goods, and medical items. Foam articles are also useful for protecting fragile goods, such as televisions, glass-based products, and other breakable goods.

[0004] Prior attempts to provide foam articles utilize an insulating material in combination with an additional supporting structure, such as corrugated cardboard. These articles often pack loose insulation into film or paper before lining the inside of a corrugated cardboard box with these “envelopes” of insulation. Prior attempts to omit corrugated cardboard supplement the article with adhesive, film, tape, glue, or some other means of joining separate pieces of insulating material into a single unit. In any event, prior solutions require the end-user to separate insulating material from paper, film, and/or cardboard in order to recycle or compost any material.

[0005] Thus, foam articles formed from a single blank of molded expandable foam particles with the ability to fold into a foam structure without separating pieces and without additional adhesive would be beneficial.

BRIEF SUMMARY

[0006] In one aspect, foam structures are provided. In some embodiments, the foam structure includes a plurality of foam panels, each of one which is formed of a plurality of polymer foam particles, wherein at least two of the plurality of foam panels are connected by a living hinge defined by a channel between the at least two foam panels, such that the plurality of foam panels is foldable along the living hinge. In some embodiments, the living hinge has a thickness equal to from one to six of the polymer foam particles, and the polymer foam particles in the living hinge are at least partially collapsed. In some preferred embodiments, the polymer 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 may degrades by industrial compost within a relatively short period, for example, about 42 days.

[0007] In another aspect, methods of making foam structures are provided. In some embodiments, the method includes (i) molding a foam panel blank in a mold from a plurality of polymer foam particles; and (ii) forming one or more channels in the foam panel blank to define at least two foam panels connected by a living hinge. The method may further include conditioning the polymer foam particles that form the one or more channels, and thus form the living hinge, by heating and collapsing at least a portion of the polymer foam particles in the living hinge, which has been found to enhance the performance of the living hinge.

BRIEF DESCRIPTION OF THE DRAWINGS [0008] The detailed description is set forth with reference to the accompanying drawings. The use of the same reference numerals may indicate similar to identical items. Various embodiments may utilize elements and/or components other than those illustrated in the drawings, and some elements and/or components may not be present in various embodiments. Elements and/or components in the figures are not necessarily drawn to scale.

[0009] FIG. 1A is a cross-sectional view of one embodiment of a foam structure having two living hinges in accordance with the present disclosure.

[0010] FIG. IB is a perspective view of one embodiment of a foam structure having a living hinge in accordance with the present disclosure.

[0011] FIG. 1C is a cross-sectional view of one embodiment of a foam structure having a living hinge in an open configuration in accordance with the present disclosure.

[0012] FIG. ID 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. [0013] FIG. 2 is a perspective view of another embodiment of a foam structure in having a living hinge accordance with the present disclosure.

[0014] FIG. 3 is a cross-sectional view of another embodiment of a foam structure having a living hinge in accordance with the present disclosure.

[0015] FIG. 4A is a perspective view of one embodiment of a 3-panel system having living hinges in accordance with the present disclosure.

[0016] FIG. 4B is a perspective view of the embodiment of the 3-panel system shown in FIG. 4A after it has been folded into a C-shaped assembly and 3-panel system in accordance with the present disclosure.

[0017] FIG. 5A is a perspective view of one embodiment of a 5-panel system in accordance with the present disclosure.

[0018] FIG. 5B is a perspective view of the embodiment of the 5-panel system shown in FIG. 5A after it has been folded into a 5-panel box in accordance with the present disclosure.

[0019] FIG. 6A is a perspective view of one embodiment of a 6-panel system in accordance with the present disclosure.

[0020] FIG. 6B is a perspective view of the embodiment of the 6-panel system shown in FIG. 6A after it has been folded into a foam structure in accordance with the present disclosure.

[0021] FIG. 7A is a perspective view of one embodiment of a 2-panel system in accordance with the present disclosure.

[0022] FIG. 7B is a perspective view of the embodiment of the 2-panel system shown in FIG. 7A after it has been folded into an edge protector in accordance with the present disclosure.

[0023] FIG. 8 is a perspective view of the inside of one embodiment of a foam structure depicting structural elements for internal walls in accordance with the present disclosure. [0024] FIG. 9A is a perspective view of one embodiment of a foam panel having break points in accordance with the present disclosure.

[0025] FIG. 9B is a perspective view of one embodiment of foam panel fragments in accordance with the present disclosure.

[0026] FIG. 10 is a perspective view of one embodiment of a foam structure inserted into an outer box in accordance with the present disclosure. [0027] FIG. 11 is a block flow diagram depicting one embodiment of a method for making a foam structure in accordance with the present disclosure.

[0028] FIG. 12A is an exemplary schematic of a step in the method for making a foam structure in accordance with the present disclosure.

[0029] FIG. 12B is an exemplary schematic of a step in the method for making a foam structure in accordance with the present disclosure.

[0030] FIG. 13 is a schematic illustrating one embodiment of a step in a method for making a foam structure in accordance with the present disclosure.

[0031] FIG. 14 is a schematic view of one embodiment of a living hinge in accordance with the present disclosure.

DETAILED DESCRIPTION

[0032] Foam structures having a living hinge and methods of making those structures are provided herein. The foam structures, and methods of making the foam structures, advantageously 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 shippers. The present disclosure includes non-limiting embodiments of foam structures having living hinges.

[0033] Foam structures having living hinges, assemblies, and associated methods are provided. These foam structures are formed out of foam panels connected by living hinges designed to fold together and seal in thermal energy when neighboring edges interface with each other. The panels are formed out of polymer foam particles by molding, machining, or other suitable forming process. In some embodiments, the foam structure is composed of enough panels to form a stand-alone container that may be used as, for example, an insulated shipper for shipping thermally sensitive articles, such as perishable food or medicine. In other embodiments, the foam structure is composed out of a select number of panels and may be used as, for example, an edge protector in conjunction with other foam structures and/or an outer box. In other embodiments, the foam structure may be used in conjunction with an outer box, such as a corrugated cardboard box, to provide improved thermal retention, thermal exclusion, and/or prevention or reduction of thermal energy transfer to or from a container that would otherwise lack such capabilities. [0034] The embodiments are described in detail herein to enable one of ordinary skill in the art to practice the foam structures and associated methods of making, although it is to be understood that other embodiments may be utilized and that logical changes may be made without departing from the scope of the disclosure. Throughout the disclosure, depending on the context, singular and plural terminology may be used interchangeably. [0035] Throughout this disclosure, various aspects are presented in a range format. It should be understood that the description in range format is merely for convenience and brevity 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 specifically disclosed all the possible sub-ranges as well as individual numerical values within that range. For example, description of a range such as from 1 to 6 should be considered to have 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 that range, for example, 1, 2, 3, 4, 5, and 6. This applies regardless of the breadth of the range. [0036] Flat panel shippers are containers formed out of a series of substantially flat panels that are formed or connected together to form a three-dimensional container. For example, a flat panel shipper may be a container blank, partial container blank, or other semi-formed container that may be formed into a three-dimensional container or structure. Such flat panels, before assembly, may be easily stacked, so that flat panel shippers may be preferred over pre-assembled or molded insulated boxes due to the beneficial ability to ship and store unassembled panels in a flat or semi-flat configuration, increasing efficiency in both shipping and warehouse storage. Flat panel shippers are also easier to handle without breakage.

[0037] Forming the flat panels out of foam may provide greater thermal properties by reducing or removing voids between pieces of insulation through which thermal energy can enter or escape. However, the polymers must meet certain physical and chemical characteristics in order for them to be suitable for the intended application. In expandable foams, the polymer composition must be able to be fabricated into a three dimensional shape that is lightweight and provides sufficient impact and thermal resistance or protection.

[0038] Foam structures have been produced having living hinges that can be fabricated using equipment similar to that used for expandable polystyrene. By producing foam panels joined by living hinges, it has been discovered that foam structures can be assembled without any additional adhesive, film, or supporting structures, while improving on the thermal retention capabilities of conventional shippers and the impact protection of conventional shippers. In particular, it has been found that channels in a rigid, monolithic foam panel blank can form a series of foam panels connected by a “living hinge” that allows the panels to fold against each other and form a thermally effective seal, preventing thermal energy loss at the edges and providing greater impact protection at the edges. It has been further found that conditioning the material that forms the living hinge, through pressure and/or heating, can strengthen the living hinge.

Foam Structures Having Living Hinges

[0039] Foam structures are disclosed herein. In some embodiments, the foam structures include a plurality of foam panels having edges. Each of the foam panels is formed out of polymer foam particles. At least two of the plurality of foam panels are disposed next to one another and are integrally connected along one of the edges of each of the at least two panels by a living hinge defined by a channel between the panels. The living hinge allows the adjacent panels to fold towards one another along the living hinge. As used herein, a “panel” refers to a substantially planar, monolithic article, having a continuous composition throughout. In some embodiments, a single panel corresponds to one side of a shipper, box, or other container. The panel could be any shape, such as a square, rectangle, or other polygon. The panel could have a thickness of from about 0.25 inches (6.4 mm) to about 4 inches (100 mm), for example about 0.25 inches (6.4 mm), about 0.375 inches (9.52 mm), about 0.5 inches (13 mm), about 0.75 inches (19 mm), or about 1 inch (25 mm). The thickness could be 1.25 inches (31.8 mm), 1.5 inches (38 mm), 2 inches (50 mm), 3 inches (80 mm), 4 inches (100 mm), or any thickness in between depending on the desired thermal and mechanical properties. The panel may have a side- length of from about 1 inch (25 mm) to about 48 inches (1220 mm) or greater, for example about 1 inch (25 mm), about 2 inches (50 mm), about 6 inches (150 mm), about 12 inches (305 mm), about 24 inches (609 mm), about 36 inches (914 mm), about 48 inches (1220 mm), greater than 48 inches, or any side-length in between depending on the desired size, thermal properties, and mechanical properties of the insulating structure.

[0040] 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 having a beveled edge or a panel connected to another panel by a living hinge is described has having the same “thickness” as a panel with rectilinear edges or a panel without a living hinge, although the depth of the panel changes at the edges and/or at the living hinge by virtue of being beveled and shaped.

[0041] The panels may be used in plurality, where two or more panels constitute the foam structure and are used as a self-supporting container or to enhance the thermal properties of another container, box, shipper, or other structure. Thus, any plurality of panels may form the foam structure and constitute a stand-alone container, box, or shipper. For example, a foam structure composed of six panels would form a standard 6-sided box and may be used without a housing or outer box.

[0042] As used herein, the term “foam structure” means any structure comprising foam particles capable of or contributing to the retention of thermal energy, exclusion of thermal energy, prevention or reduction of thermal energy transfer, or a combination thereof, including but not limited to an insulating shipper, with or without an attached hinged lid, a comer protector, and an edge protector.

[0043] As used herein, the term “shipper” means a container for shipping articles. More specifically, an “insulated shipper” means a container having insulation for shipping thermally-sensitive articles, such as perishable food or medicine. For example, an insulated shipper may refer to an insulated shipper conventionally used for shipping meats, fish, meals, or ingredients for meals.

[0044] As used herein, the term “living hinge” means a piece of material, e.g. polymer foam, joining two components that are formed of the same material, together, e.g. foam panels. That is, the term “living hinge” refers to a flexible, bendable region of a material connecting at least two relatively inflexible regions of the material. The flexible and inflexible regions are integrally connected, e.g., as a part a single, monolithic structure.

The living hinge, sometimes called “webbing,” and components are formed from the same material, and are usually formed from the same single, continuous monolithic source of material (often described herein as a “blank”). In this way, the two components may be folded against each other along the living hinge, without requiring the addition of a separate piece of material and without charging the end-user with separation or disassembly of the components from the living hinge. For example, the living hinge may be defined by a channel that is formed between two adjacent panels. The living hinge may be formed after the blank has been formed, such as through the removal of material or through a secondary molding process. The living hinge may be formed simultaneously as the blank, such as through a modified molding process. [0045] As used herein, the term “seal” means a juncture formed by two or more surfaces of one or more objects substantially coming into contact with each other in a manner that reduces or prevents the transfer of thermal energy through, around, or in connection with the seal.

[0046] In some embodiments, the foam panels are rigid. As used herein, the term “rigid” means having a compressive modulus greater than 1 MPa. A rigid object therefore tends to break rather than deform. More specifically, a “rigid foam panel” means a single, monolithic foam panel having an elastic modulus greater than 1 GPa such that the panel breaks under sufficient stress rather than deforming. Note that a rigid object can have a high flex strength, which is the stress at failure in a bending test.

[0047] In some embodiments, the polymer foam particles are compostable and/or biodegradable. Biodegradable polymer foam particles include homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, or polyhydroxyalkanoate. Foam structures comprising biodegradable polymer foam particles may degrade by industrial compost facility in about 7 to about 42 days, such as within about 7 to about 21 days.

[0048] The term “compostable” is used to refer to materials that meet or exceed the relevant degradation standards in commercial composting facilities, such as the standards enumerated in ASTM D5338, ASTM D6400, and/or ISO 20200. For example, the compostable articles described herein degrade per the criteria set forth in ASTM D5338, ASTM D6400, and/or ISO 20200. That is, the compostable articles described herein degrade or be digested by microbes in a controlled compost study within 180 days, 90 days, or shorter. In certain embodiments, the compostable articles described herein are compostable in an industrial compost in about 42 days or shorter.

[0049] 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.

[0050] In some embodiments, the living hinge includes polymer foam particles formed by standard molding, without any post-conditioning process. 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 molding has limitations on the thickness of the living hinge, i.e., the hinge must have a thickness of between approximately 2 to 4 polymer foam particles.

[0051] In other embodiments, the living hinge includes polymer 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 augmented relative to the standard molding process. By conditioning the polymer foam particles that form the living hinge, the living hinge can be thicker (i.e., 4 polymer foam particles or greater) or thinner (i.e. 1 to 2 polymer foam particles) than a living hinge formed by a standard molding process.

[0052] In some embodiments, the interfacing edges of the at least two foam panels are beveled. As used herein, the term “beveled” means sloped or angled relative to a right- angle. More specifically, a “beveled edge” means an edge that is sloped or angled relative to an edge consisting of right-angles.

[0053] In some embodiments, the interfacing edges of the at least two foam panels 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 panels to one another and/or guide or align two or more foam panels joined by a living hinge when they are folded together. In some embodiments, the interfacing edges of at least two foam panels have mechanical locking tabs and mechanical locking slots to facilitate a friction fit or compression fit interlock. Such locking, or interlocking, features can facilitate securing the living hinge in a closed configuration, which, for example, may be useful in the process of assembling panels or panel systems into a container.

[0054] In embodiments, the at least two foam panels connected by a living hinge share a common surface. A first surface of one panel joins a living hinge surface and the living hinge surface subsequently joins a second surface of the adjacent panel. The common surface is thus continuous across the first panel, living hinge, and second panel.

[0055] In some embodiments, the living hinge is reinforced. For example, the living hinge may be reinforced with a reinforcing material such as tape, laminate, gumback, filament, or a mechanical support. As used herein, the term “tape” means any strip of adhesive material suitable for connecting two or more items together. The adhesive material may include a backing layer and an adhesive coating layer. Non-limiting examples of tape include gummed kraft paper tape or gumback paper tape. As used herein, the term “filament” means a thin, flexible piece of material, usually taking the shape of a string or line. In some embodiments, the tape is printed with identifying marks, such as a brand indicator, label, package shipping/tracking, or other information.

Panel Systems for Forming Foam Structures [0056] 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 out of polymer 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, wherein the living hinge is defined by a channel between the panels.

[0057] In some embodiments, the plurality of foam panels that form the panel system are disposed in a flat configuration and joined 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 interface and form a seal at the interfacing edges. That is, the seal may be formed when the living hinges are in a closed configuration.

[0058] In some embodiments, the plurality of foam panels that form the panel system include three foam panels positioned in series, with adjacent panels connected by living hinges to form a panel system that is configured to fold into a C-shaped assembly. In some embodiments, two of the C-shaped assemblies are configured to be connected together to form the foam structure.

[0059] In some embodiments, the plurality of foam panels that form the panel system include five foam panels, with adjacent panels connected by living hinges to form a panel system that is configured to fold into a 5-panel box. In some embodiments, the 5-panel box is configured to be connected to a foam panel lid form the foam structure.

[0060] In some embodiments, the plurality of foam panels that form the panel system include six foam panels, with adjacent panels connected by living hinges to form a panel system that is configured to fold into a 6-panel box. For example, when folded, the 6- panel box is a foam structure that may be used as a shipper, with or without the addition of a corrugated cardboard box.

[0061] In some embodiments, the plurality of foam panels that form the panel system include two foam panels connected to each other by a living hinge to form a panel system that is configured to fold into an edge protector that may be used alone or in conjunction with other edge protectors as the foam structure. [0062] While reference has been made to configurations wherein the plurality of foam panels that form the panel system includes 2, 3, 5, or 6 foam panels configured to be folded into a panel sub-assembly and, in some embodiments, connected to one or more other panel sub-assemblies or foam panels to form the foam structure, it is understood that the foam structure of the present disclosure may include more than 6 foam panels, such as 7 foam panels, 8 foam panels, or more, and fewer than 6 foam panels, such as 1 foam panel or 4 foam panels.

[0063] In some embodiments, the foam panels include structural elements configured to secure one or more internal walls. For example, the one or more internal walls can separate the foam structure into two or more separate compartments. As used herein, “structural elements” means lips, notches, ledges, grooves, or other physical features that form, align, and/or secure one or more internal walls in the foam structure.

[0064] In some embodiments, one or more of the foam panels includes one or more break-points. As used and described herein, the living hinges are not break points. For example, the break-points may permit the foam panel to be broken at a specific point into one or more foam panel fragments, reducing the size of the foam panel in order to facilitate disposal and compost. As used herein, “break-point” means an engineered, machined, or molded feature where the foam panel will preferentially break when force is applied. For example, the break-points may be in the form of a line or array of indentations.

[0065] In some embodiments, the plurality of foam panels are molded, such as by any suitable molding processes known for such materials. An example of a suitable molding process includes forming polymer particles from a melt-processable extrudate, infusing air into the polymer particles, and feeding the particles into a mold. The particles may then be subjected to a series of cross-steam and purge steps resulting in a single, monolithic molded article.

[0066] In some embodiments, the plurality of foam panels are machined from a block of foam. As used herein, “machined” means shaving, 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 via a molding process.

[0067] In some embodiments, the foam structure is in the form of an insulated shipper that includes no 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 inside walls of the outer box creating an internal space. This internal space may be surrounded on all sides first by the foam structure, and second by the corrugated cardboard box.

[0068] FIG. 1A shows a foam structure 100 including a plurality of foam panels 102 having edges 104. The panels are connected by living hinges 106 defined by channels 108. A common surface 110 joins 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 way, the common surface 110 is continuous across the adjacent panels 102 and the living hinge 106. In some instances, the foam structure has two panels joined at interfacing edges by a living hinge. In other instances, the foam structure has more than two panels, such as three panels, four panels, five panels, or more panels, where each pair of interfacing edges is joined by a living hinge. The panels may have a square shape having four edges of equal length, a rectangular shape having two pairs of edges of varying lengths, or another shape having a corresponding number of edges with suitable lengths. In some instances, the channel has a “V” shape in cross-section. In other instances, the channel has a rectilinear or other suitable shape. In other instances, the edges of the channel have curved or undulating surfaces.

[0069] As used herein, a channel having a “‘V’ shape” refers generally to two panels having respective beveled or angled edges that are connected by a living hinge. The “V” shape may resemble a “V,” wherein the beveled edges of connected panels meet at a sharp, angled comer. Alternatively, the “V” shape may have a curved profile at the point where the connected panels meet resembling a “V” with a rounded point instead of a sharp comer (e.g., a “U” shape). Thus, the use of “V” throughout is in the interest of brevity, and any suitable geometry of the two panels connected by a living hinge may be used. Moreover, as explained above, the channel may have a rectilinear or other suitable shape. [0070] The interfacing edges of least two panels may be configured to be brought into contact in a manner so as to form a thermal seal between those panels, i.e., to prevent or reduce the thermal energy transfer between an internal volume defined by the panels and an external volume outside of the volume enclosed by the panels 102. The length of one edge may or may not be the same length as an interfacing edge so that a seal is formed between adjacent edges. The shape of one edge may correspond to the shape of an interfacing edge so that a seal is formed between adjacent edges. Various configurations of such corresponding edges are described below; however, any suitable mechanical edge connection that achieves the desired thermal seal between adjacent panels may be utilized. The shape of all edges of a panel may be the same, or some edges may have one shape, e.g., beveled, while other edges have another shape, e.g., rectilinear.

[0071] FIG. IB shows a foam structure 100 including two foam panels 102 having edges 104 and joined by living hinge 106 defined by channel 108, such as may be used to form an insulating insert or partial insulating container, or which may be combined with additional panels to form a container, as described herein.

[0072] FIG. 1C shows a foam structure 100 including two foam panels 102 having edges 104 and joined by living hinge 106 defined by channel 108. FIG 1C depicts foam structure 100 in an unfolded state, or open configuration. FIG ID depicts the foam structure 100 of FIG 1C in a folded state, or closed configuration. In some instances, the edges of the panel are shaped at an angle, such as through beveling, chamfering, scouring, or other process to increase the surface area available for the edges of adjacent panels to come into contact with each other. Thus, while the thickness of a panel may be one measurement, the process of forming the edge, e.g., beveling, results in a beveled surface having a length greater than the thickness of the panel, improving the thermal retention properties without substantially changing the panel dimensions or the dimensions of the foam structure.

[0073] While reference has been made to edges being “beveled” in some embodiments, it is understood that any suitably shaped edge that permits interfacing panels to form a thermally sufficient seal is contemplated. For example, in other embodiments, panel edges may have other suitable shapes, which may be used in place of or in addition to a beveled edge.

[0074] In some embodiments, the panel edges may be formed and shaped by a channel forming process, i.e., the creation of channels results in beveled edges, or rectilinear edges, or some other shaped edge. In some other embodiments, the panel edges may be shaped by a process after the channels are formed, i.e., panel edges are subsequently formed into beveled edges, or rectilinear edges, or some other shaped edge.

[0075] FIG. 2 shows a foam structure 100 including two foam panels 102 having edges 104 and joined by living hinge 106 defined by channel 108. Edges 104 have mechanical locking tabs 202 and corresponding mechanical locking slots 204. In some instances, there may be one set of mechanical locking tabs and corresponding slots that run the length of the edge of a panel. In other instances, there are multiple sets of discrete tabs and corresponding slots in particular positions 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 matching slots and tabs on the edge of an adjacent panel. The edges of a panel may vary in shape, with some edges being beveled and others being rectilinear, but both types of edges may have mechanical locking tabs and slots corresponding 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, i.e., 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, i.e., panel edges are subsequently processed to form edge features.

[0076] FIG. 3 shows a foam structure 100 including two foam panels 102 having edges 104 and joined by living hinge 106 defined by channel 108. Living hinge 106 is reinforced by reinforcing material 302. Reinforcing material 302 may be any suitable reinforcing material, such as tape, laminate, gumback, filament, or a mechanical support. The reinforcing material may run the entire length of the living hinge, or there may be multiple discrete pieces of reinforcing material at separate positions along the living hinge. In foam structures with multiple living hinges, all of the living hinges may include reinforcing material, or only particular living hinges may include reinforcing material. [0077] Reinforcing material may be used to strengthen the thermal or impact properties of the living hinge. Reinforcing material may be used to strengthen the hinge-properties of the living hinge, i.e., the reinforcing material may span from one panel to an adjacent connected panel and operate as a hinge in addition or as an alternative to the living hinge, or in the event the living hinge fails for any reason. In some instances, the reinforcing material runs the length of the living hinge with minimal encroachment on panels connected by the living hinge. In other instances, discrete pieces of reinforcing material may connect adjacent panels connected by living hinges. In other instances, lengths of reinforcing material may run from one edge of the foam structure to another, 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 by living hinges in series.

[0078] FIG. 4A shows three foam panels 102 connected by living hinges 106 to form a 3-panel system 402 that is configured to be folded into a C-shaped assembly. 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. FIG. 4B 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 foam structure 100. In some instances, two C-shaped assemblies are configured to be connected together to form the foam structure. In other instances, one C- shaped assembly constitutes the foam structure, depending on the circumstances. In other instances, one C-shaped assembly is used in conjunction with one or more foam panels that may or may not be joined by living hinges to form the foam structure. For example, one C-shaped assembly may be used in conjunction with two panels joined by a living hinge to form a 5 -sided open box. The edges of the panels may be beveled such that the gap between connected panels is minimal but the beveled surface permits the panels to fold against each other. The edges of the panels may have edge modifications such as mechanical locking tabs and/or slots, and these modifications may facilitate joining a C- shaped assembly with another C-shaped assembly.

[0079] FIG. 5A shows five foam panels 102 connected by living hinges 106 to form a 5-panel system 502 that is configured to be folded into a 5-panel box. FIG. 5B is a perspective view of a 5-panel system 502 that has been folded to form a 5-panel box 504. Foam lid 506 positioned against 5 -panel box 504 to form a foam structure 100. In some instances, the five panels may be connected to form a “T”-shaped panel system when positioned in a flat configuration, or blank, where three panels are connected in series by living hinges and the central panel is also connected by a living hinge on a third side to a fourth panel, and the fourth panel is connected by a living hinge on the opposite side to a fifth panel, as depicted in FIG. 5A. In other instances, the five panels may be connected to form a “+”-shaped or cross-shaped panel system when positioned in a flat configuration, or blank, where three panels are connected in series by living hinges and the central panel is also connected by living hinges on a third side to a fourth panel, and on a fourth side to a fifth panel. In other instances, the five panels may be connected to form an “S”-shaped panel system when positioned in a flat configuration, or blank, where a first panel is connected by a living hinge to a second panel, the second panel is connected on a side perpendicular to the first panel by a living hinge to a third panel, the third panel is connected on the opposite side of the second panel by a living hinge to a fourth panel, and the fourth panel is connected on a side perpendicular to the third panel by a living hinge to a fifth panel. Any suitable positioning of the five panels may be used to form the panel system that is configured to be folded into a 5-panel box. The five panels may be joined with living hinges. The panels may have beveled edges. A foam lid may have beveled edges, rectilinear edges, a combination of beveled edges and rectilinear edges, or any suitable shaped edge.

[0080] FIG. 6A shows six foam panels 102 connected by living hinges 106 to form a 6- panel system 602 that is configured to be folded into a 6-panel box. FIG. 6B is a perspective view of a 6-panel system 602 that has been folded to form a foam structure 100. In some instances, the six panels may be connected to form a “T”-shaped panel system when positioned in a flat configuration, or blank, where three panels are connected in series by living hinges and the central panel is also connected by a living hinge on a third side to a fourth panel, the fourth panel is connected by a living hinge on the opposite side to a fifth panel, and the fifth panel is connected by a living hinge on the opposite side to a sixth panel. In other instances, the six panels may be connected to form a “+”-shaped or cross-shaped panel system when positioned in a flat configuration, or blank, where three panels are connected in series by living hinges, the central panel is also connected by living hinges on a third side to a fourth panel and on a fourth side to a fifth panel, and either the fourth panel or the fifth panel is connected to a sixth panel. In other instances, the six panels may be connected to form an “S”-shaped panel system where a first panel is connected by a living hinge to a second panel, the second panel is connected on a side perpendicular to the first panel by a living hinge to a third panel, the third panel is connected on the opposite side of the second panel by a living hinge to a fourth panel, the fourth panel is connected on the opposite side of the third panel by a living hinge to a fifth panel, and the fifth panel is connected a side perpendicular to the fourth panel by a living hinge to a sixth panel. Any suitable positioning of the six panels may be used to form the panel system that is configured to be folded into a 6-panel box. Upon folding, the resulting foam structure may have a “lid” formed by one of the six panels such that the structure may be “opened” by unfolding the panel.

[0081] FIG. 7A shows two foam panels 102 connected by living hinges 106 to form a 2- panel system 702 that is configured to be folded into an edge protector. FIG. 7B is a perspective view of a 2-panel system 702 that has been folded to form an edge protector 704. In some instances, the two panels have an elongated-rectangular shape, and are connected on the long edge. In other instances, the panels are connected on the short edge. In other instances, the panels are the same size and connected on any edge. In other instances, the panels have different sizes. Any suitable size and shape of the two panels may be used to form the 2-panel system. Upon folding, the resulting edge protector may be used in isolation, or in conjunction with another edge protector, or in conjunction with another foam structure.

[0082] FIG. 8 shows the inside of a foam structure 100 including a plurality of foam panels 102. The foam panels 102 include structural elements 802 that align and secure internal walls 804. The structural elements may be lips, notches, ledges, grooves, or other physical features that form, align, and/or secure one or more internal walls in the foam structure. The structural elements may run the length of the panel, or there may be multiple discrete structural elements. There may be multiple sets of structural elements designed to separate the foam structure into two, three, four, or more separate compartments. The internal wall may be formed out of foam, corrugated cardboard, or any other material suitable for dividing the foam structure into multiple compartments.

The internal wall may be positioned vertically, horizontally, or in any orientation suitable for dividing the foam structure into multiple compartments. The internal wall may be positioned perpendicular to the panel having structural elements, or it may be positioned at any angle to the perpendicular.

[0083] FIG. 9A shows a foam panel 102 having break-points 902. FIG. 9B shows foam panel 102 after breakage along break-point 902 producing two foam panel fragments 904. In some instances, there is one break-point. In other instances, there are two, three, four, or more break-points. The break-point may result in two foam panel fragments of equal size, or the fragments may have different sizes. The break-point may be designed to result in fragments of a size and shape suitable for composting or other post-consumer processing.

[0084] FIG. 10 shows a foam structure 100 including a plurality of foam panels 102 surrounded by an outer box 1002. The outer box may be corrugated cardboard or any material suitable as a container. For example, the outer box may provide structural support and mechanical properties suitable for use as a shipping container. The outer box may have a lid that folds to cover the foam structure. The outer box may surround only a portion of the foam structure leaving one or more sides uncovered.

Methods of Manufacturing Foam Structures [0085] Methods of making a foam structure are also disclosed herein. As described herein, the foam structure may be any structure formed of foam particles and having a hinge or connection between adjacent components. In one aspect, a method includes providing a foam panel blank formed from a plurality of polymer foam particles. In some embodiments, the method further includes forming one or more channels in the foam panel blank to define a plurality of foam panels, the foam panels having a living hinge defined by the one or more channels between panels. In some embodiments, at least two of the plurality of foam panels are disposed next to one another and interfacing along at least one of the edges of each of the at least two panels, the interfacing edges forming a living hinge. Any suitable method and equipment known for forming a foam panel blank may be used to manufacture the panels described herein. For example, methods and equipment known for manufacturing EPS panels may be used. The panels manufactured by these methods may be the panels described herein, including any combination of features thereof.

[0086] In some embodiments, known methods are used to produce the foam blanks that used in the presently disclosed methods. For example, U.S. Pat. No. 10,518,444 to Pawloski et ak, discloses methods of producing compostable or biobased foams that are useful for fabricating foamed articles. In the disclosed method, foamed beads formed from a biobased polyester and a blowing agent are molded to form a molded article.

Those method can be used to produce the foam panel blanks used to produce the foam panels of the present disclosure. In another example, U.S. Pat. No. 10,688,698 to Bhargava et al. discloses methods for making molded foam articles, which can be used to produce the foam panel blanks used to produce the foam panels of the present disclosure. [0087] In some embodiments, molding the foam panel blank involves molding foam particles using standard molding without post-conditioning. Molding foam panel blanks using standard molding includes the use of a mold having the shape of the final product, including a space for the living hinge, such that the foam panel blank has a uniform density and composition across the living hinge. In other embodiments, molding the foam panel blank involves post-conditioning the foam particles in order to form the living hinge. Molding the foam panel blank with post-conditioning includes the use of a mold having a gap or space 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 localized pressure in order to change the density, strength, and flexibility of the polymer foam particles, e.g., in a region of the material forming the living hinge. [0088] In some embodiments, post-conditioning includes the use of a core pull. As used herein, a “core pull” refers to a movable element inserted into and extracted from a standard mold cavity in order to change the pressure and/or temperature at a specific location within the mold. The core pull may 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 pull may include a heating source such as an electrically heated plate or a showerhead for the distribution of steam. The core pull may include a cooling source such as a showerhead for the distribution of fluid such as cooling air.

[0089] In some embodiments, post-conditioning includes the use of an enhanced core pull that is equipped with a fill injector. The fill injector may enable the injection of polymer foam particles in a concentration location within the mold cavity.

[0090] In some embodiments, the enhanced core pull includes one or more guide rods that are bushed and sealed so that they can extend into and retract from the mold cavity without changing the pressure in the mold cavity, and without permitting steam to escape the mold cavity.

[0091] In some embodiments, forming the foam panel blank includes molding polymer foam particles in a mold cavity having a gap or space at the location where the living hinge is desired. A core pull may be designed to actuate and contact the polymer foam particles in the gap or space, packing and densifying the polymer foam particles in a specific location. After densifying the polymer foam particles using the core pull, steam may be applied to the mold cavity, expanding and fusing the polymer foam particles. During or after the steam process, the core pull may be heated and/or inserted to condition the living hinge portion. In some embodiments, the core pull is cooled to stabilize the living hinge portion prior to ejection from the mold.

[0092] In some embodiments, the method further includes assembling the foam structure out of the foam panels. In some embodiments, the step of assembling includes folding the foam panels at the living hinge, forming a seal between at least one pair of adjacent edges of the foam panels for retaining thermal energy at the edges.

[0093] 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 panels are molded or machined to form the desired edge geometry. [0094] In some embodiments, the channels defining the living hinge in the foam panel blank have a “V” cross-sectional shape in the open configuration. In other embodiments, the channels may have another shape, such as a rectilinear shape, or curved surfaces, as described herein.

[0095] Any suitable method of forming the one or more channels may be used. For example, the channel may be formed simultaneously with the molding of the foam panels using a mold cavity having the shape of a living hinge. In another embodiment, the channel may be formed immediately after the foam panels have been molded using a core pull configured to provide localized pressure and/or heat to compress and condition the living hinge. In another embodiment, forming the one or more channels may 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, forming the channels is performed by water-jet cutting. In another embodiment, the channel can be molded.

[0096] In some embodiments, forming the living hinge involves collapsing the beads in the channel to allow the hinge to bend. In some embodiments, collapsing the beads is performed by a heated scoring wheel. In another embodiment, collapsing the beads is performed by a core pull inserted into a mold after the foam panel blank and channels are formed. In another embodiment, collapsing the beads is performed by a core pull equipped with guide rods that are bushed and sealed so they may extend into and retract from the mold cavity without opening the mold cavity. In another embodiment, collapsing the beads is performed by moving the foam panel blank over a conveyor, aligning heated forming heads over the blank, and lowering the heated forming heads onto the blank to collapse the polymer foam particles and form the channels.

[0097] In embodiments in which the channels are molded 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 may increase the overall cycle time by less than about 3 seconds, such as less than 1 second or less than 10% of overall cycle time. In some embodiments, conditioning using a core pull does not increase the overall cycle time. [0098] In some embodiments, the foam panels include mechanical locking tabs and corresponding mechanical locking 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 surfaces of the beveled edges of panels, wherein those surfaces are interfacing surfaces when a living hinge between the panels is in the closed configuration.

[0099] In some embodiments, the foam structure, e.g., the foam panels, includes a reinforcing material secured to a surface of the living hinge. In some embodiments, the reinforcing material is tape, laminate, gumback, filament, or a mechanical support. In some embodiments, the reinforcing material may reinforce the living hinges without encroaching onto the surface of the panels joined by the living hinge. In other embodiments, discrete pieces of reinforcing material may extend onto the panels to operate 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, across the entire length of a central panel, to the edge of a third panel, in the example of three panels connected in series.

[0100] In some embodiments, the plurality of foam panels joined by living hinges are provided as a3-panel system configured to form a C-shaped assembly. In some embodiments, the assembling includes folding two of the 3-panel systems each into a C- shaped assembly and securing together the two C-shaped assemblies to form the foam structure.

[0101] In some embodiments, the plurality of foam panels are provided in a 5-panel system and the assembling includes folding the 5-panel system and securing edges of the panels to form a 5-panel box. In some embodiments, assembling the foam structure includes positioning a foam panel lid onto an open side of the 5-panel box to form the foam structure.

[0102] In some embodiments, the plurality of foam panels are provided in a 6-panel system and the assembling includes folding the 6-panel system and securing edges of the panels to form the foam structure.

[0103] In some embodiments, the plurality of foam panels are provided in a 2-panel system and the assembling includes folding the 2-panel system and securing edges of the panels to form an edge protector.

[0104] In some embodiments, the plurality of foam panels includes structural elements on one or more of the panels configured to secure one or more internal walls. In some embodiments, the assembling includes installing one or more internal walls for separating the foam structure into two or more separate compartments. [0105] In some embodiments, one or more of the plurality of foam panels includes one or more break-points to facilitate breakage of one or more of the foam panels into fragments for disposal and compost. For example, the break-points may be formed by scoring, indenting, perforating, or other suitable processes.

[0106] In some embodiments, the assembling includes surrounding the foam panels with an outer box. For example, the plurality of foam panels may be surrounded by a corrugated cardboard outer box. In particular, an outer box is useful where the foam structure is composed of fewer foam panels than is necessary to form a stand-alone container. For example, a foam structure formed out of three panels may be insufficient to be used as a stand-alone container, so an outer box would surround the foam structure. In some embodiments, the outer box may provide further structural support for the foam structure.

[0107] In some embodiments, the foam panel blank is molded 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 degrade by industrial compost within a time period of about 7 days to about 41 days, such as within about 7 to about 21 days.

[0108] In other embodiments, the foam panel blank is molded from a plurality of foam particles that are not biodegradable, such as particles that include polystyrene, polyethylene terephthalate, thermoplastic polyurethane, polyvinyl chloride, starch, poly(ethylene vinyl acetate), polyethylene, polypropylene, polyacrylic acid, or mixtures thereof.

[0109] FIG. 11 is a flowchart depicting a method 1100 for making a foam structure.

Step 1102 includes molding a foam panel blank in a mold from a plurality of polymer foam particles. Step 1104 includes forming one or more channels in the foam panel blank to define a plurality of foam panels having edges. Optional step 1106 includes assembling the foam structure by folding the plurality of foam panels at the living hinge. Optional step 1108 includes burning identifying marks into the plurality of foam panels for identifying a content, a destination, a source, an expiration date, and/or another identifying characteristic. In some instances, the method may include steps 1102 and 1104 but omit steps 1106 and 1108. For example, steps 1102 and 1104 may be performed in a single manufacturing 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 commodities packer or shipper.

In other instances, the method may include step 1106 but omit step 1108. In other instances, all of steps 1102, 1104, 1106, and 1108 are included.

[0110] FIG. 12A is an illustration of step 1104, in which foam panel blank including foam panels 102 is molded in mold 1202. FIG. 12B depicts core pulls 1204 post conditioning the foam panels 102 by pressing into and forming channel 108 and collapsing the beads to form living hinges 106. In some embodiments, the core pulls actuate while the foam panel blank is molded. In other embodiments, the core pulls actuate after the molding process has completed but while the foam panel blank is still hot. In some embodiments, the core pulls are “V” shaped such that the beads are collapsed in a “V” shape when the “V” shaped channel is formed. In other embodiments, the core pulls are rectilinear such that the beads are collapsed in a rectilinear shape when a rectilinear channel is formed. In other embodiments, the core pulls are rectilinear but collapse the beads after the beads have begun fusing, resulting in a sloped shape when the channel is formed. In some embodiments, the mold is configured to form one 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.

[0111] FIG. 13 is an alternate illustration of step 1104, in which foam panel blank including foam panels 102 moves over a conveyor 1302. An array 1304 of heated forming heads 1306 is aligned over the foam panel blank. The array 1304 is lowered onto the foam panel blank and the heated forming heads collapse the polymer foam particles to form the channels and living hinges. Cutoff head 1308 is subsequently lowered through one of the one or more channels to fully separate one foam panel from the next foam panel (e.g., to separate one foam structure from the next foam structure), resulting in foam structure 100.

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

[0112] Polymer foam panels joined by living hinges were stress-tested to determine the longevity of the living hinge. Each panel set tested had a thickness of 1.5 inches (38.1 mm) and a living hinge formed at an angle of 45°. The panels had living hinge thicknesses and widths as described below. Each panel was formed from polylactic acid as described in U.S. Patent No. 10,688,698. Three tests were performed. The first test was a cycle-test, in which the living hinge was cycled between an open configuration where the panels were substantially parallel with each other at an angle of 180°, and a closed position where the panels were substantial perpendicular to each other at an angle of 90°. The living hinge was cycled between the open and closed configuration until failure, in the form of cracks in the polymer foam, occurred. The number of cycles before failure was recorded and compared. [0113] The second test was an open-strength test. It was discovered that after post conditioning, the living hinges of the present disclosure could withstand hundreds of cycles. In order to more expeditiously study the strength of the conditioned living hinges, the living hinge was opened beyond 180°, i.e., the living hinge was bent in the opposite direction from the closed position. The angle at which failure occurs was discovered to correlate to the number of cycles the living hinge could withstand before failure.

[0114] The third test was a closed-strength test. In this test, the living hinge was folded to the closed position, i.e., 90°, and then force was applied as if to close the living hinge farther than 90° until the hinge failed. The force at failure was recorded and compared.

The results of the cycle, open-strength, and closed-strength tests are shown in Table 1. Table 1

[0115] As shown in Table 1, a living hinge made using a standard molding process having a thickness of 0.16 inches (4.06 mm) withstood more cycles than a living hinge made using a standard molding process having a thickness of 0.0625 inches (1.59 mm). However, the use of post-conditioning as described herein significantly improved both the number of cycles and the strength of the living hinge, while maintaining the thinner 0.0625 inches (1.59 mm).

Example 2: Exemplary living hinge dimensions

[0116] Two foam panels joined by a living hinge were manufactured and conditioned as described herein. A Ving 31” x 39” Pneumatic Single Station Flat Heat Press Machine was used with a heated ram bar. The heated ram bar had a cross-section of 0.375 inches (9.52 mm) with chamfer edges at 45°. The flat pressing surface of the ram bar had a width of 0.0625 inches (1.59 mm). The ram bar was heated to 300 °C and pressed against the foam panels for 5 seconds at a pressure of 0.5 MPa. The dimensions of the resulting living hinge are illustrated in FIG. 14.

[0117] While the disclosure has been described with reference to a number of embodiments, it will be understood by those skilled in the art that the disclosure is not limited to such disclosed embodiments. Rather, the disclosure can be modified to incorporate any number of variations, alterations, substitutions, or equivalent arrangements not described herein, but which are commensurate with the spirit and scope of the disclosure. Conditional language used herein, such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, generally is intended to convey that certain embodiments include, while other embodiments do not include, certain features, elements or functional capabilities. Additionally, while various embodiments of the disclosure have been described, it is to be understood that aspects of the disclosure may include only some of the described embodiments. Accordingly, the disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.

Claims

CLAIMS What is claimed is:

1. A foam structure, comprising: a plurality of foam panels, each of the plurality of foam panels being formed of a plurality of polymer foam particles; wherein at least two of the plurality of foam panels are connected by a living hinge defined by a channel between the at least two foam panels, such that the plurality of foam panels is foldable along the living hinge.

2. The foam structure of claim 1, wherein: the living hinge has a thickness equal to from one to six of the polymer foam particles, and the polymer foam particles in the living hinge are at least partially collapsed.

3. The foam structure of claim 1, wherein the channel is defined between interfacing edges of the at least two foam panels and the interfacing edges are beveled.

4. The foam structure of claim 1, wherein the at least two foam panels of the plurality of foam panels further comprise one or more edge features for facilitating interlock and alignment of the at least two foam panels when the living hinge is in the closed configuration.

5. The foam structure of claim 1, wherein: a common surface of the plurality of foam panels comprises a first surface of a first foam panel, a second surface of a second foam panel, and a living hinge surface of the living hinge connecting the first and second foam panels, and the common surface is continuous across the first and second foam panels and the living hinge.

6. The foam structure of claim 1, further a reinforcing material secured to a surface of the living hinge.

7. The foam structure of 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 living hinges forming a 3-panel system, and the 3-panel system is foldable to form a C-shaped assembly.

8. The foam structure of claim 7, wherein the C-shaped assembly is configured to be connected to an identical C-shaped assembly to form a box structure.

9. The foam structure of 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 living hinges forming a 5-panel system, and the 5-panel system is foldable to form a 5-panel box.

10. The foam structure of 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 living hinges forming a 6-panel system, and the 6-panel system is foldable to form a box structure.

11. The foam structure of claim 1, wherein: the plurality of foam panels comprises two foam panels connected to each other by a living hinge forming a 2-panel system, and the 2-panel system is foldable to form an edge protector.

12. The foam structure of claim 1, wherein the plurality of foam panels further comprises structural elements to secure one or more internal walls for separating the foam structure into two or more separate compartments.

13. The foam structure of claim 1, wherein at least one panel of the plurality of foam panels further comprises one or more break-points to facilitate breakage into one or more fragments to facilitate disposal and compost.

14. The foam structure of claim 1, wherein the plurality of foam panels are molded.

15. The foam structure of claim 14, wherein the living hinge is molded simultaneously with the molding of the plurality of foam panels.

16. The foam structure of claim 14, wherein the living hinge is molded using a core pull immediately after the molding of the plurality of foam panels.

17. The foam structure of claim 1, wherein the plurality of foam panels are machined from a block of foam.

18. The foam structure of claim 1, wherein: the foam structure forms an insulated shipper for shipping thermally sensitive articles, and no corrugated cardboard is used in forming the insulated shipper.

19. The foam structure of claim 1, further comprising an outer box surrounding the plurality of foam panels.

20. The foam structure of claim 19, wherein the outer box comprises corrugated cardboard.

21. The foam structure of claim 1, wherein the foam structure is in the form of an insulated shipper suitable for shipping fragile articles.

22. The foam structure of any one of claims 1 to 21, wherein the polymer foam particles comprise homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, polyhydroxyalkanoate, or mixtures thereof.

23. The foam structure of claim 22, wherein the foam structure degrades by industrial compost within a time period of about 42 days.

24. A method of making a foam structure, comprising: molding a foam panel blank in a mold from a plurality of polymer foam particles; and forming one or more channels in the foam panel blank to define at least two foam panels connected by a living hinge.

25. The method of claim 24, further comprising conditioning the polymer foam particles that form the one or more channels by heating and collapsing at least a portion of the polymer foam particles in the living hinge.

26. The method of claim 24, further comprising folding the at least two of the plurality of foam panels at the living hinge.

27. The method of claim 24, wherein the foam panel blank is rigid.

28. The method of claim 24, wherein the one or more channels have a V-shaped cross- sectional shape.

29. The method of claim 24, wherein forming the one or more channels comprises milling.

30. The method of claim 24, wherein forming the one or more channels comprises wire cutting.

31. The method of claim 24, wherein forming the one or more channels comprises laser cutting.

32. The method of claim 24, wherein forming the one or more channels comprises water-jet cutting.

33. The method of claim 24, wherein forming the one or more channels comprises applying a heated scoring wheel.

34. The method of claim 25, wherein the conditioning comprises molding the one or more channels simultaneously to molding the foam panel blank.

35. The method of claim 37, wherein the conditioning comprises actuating a core pull into the polymer foam particles in a mold.

36. The method of claim 35, wherein inserting the core pull into the mold increases an overall cycle time by less than 3 seconds.

37. The method of claim 36, wherein inserting the core pull into the mold increases an overall cycle time by less than 10% of an overall cycle time for the mold.

38. The method of claim 35, wherein inserting the core pull into the mold does not increase an overall cycle time for the mold.

39. The method of claim 24, wherein forming the one or more channels comprises: moving the foam panel blank over a conveyor; aligning an array of heated forming heads over the foam panel blank; lowering the heated forming heads onto the foam panel blank, wherein the heated forming heads form the one or more channels and collapse at least a portion of the polymer foam particles that define the living hinge.

40. The method of claim 39, further comprising lowering a cutoff head through one of the one or more channels to yield the plurality of the foam structures.

41. The method of claim 24, further comprising forming one or more mechanical locking tabs and mechanical locking slots configured to interlock edges of the plurality of foam panels when the living hinge is in a closed configuration.

42. The method of claim 24, further comprising forming beveled edges on at least one of the plurality of foam panels.

43. The method of claim 24, further comprising forming one or more break-points in one or more of the plurality of foam panels.

44. The method of any one of claims 24 to 43, wherein the polymer foam particles comprise homopolymers, graft polymers, or copolymers of polylactic acid, polyhydroxybutyrate, polyhydroxyalkanoate, or mixtures thereof.