WO2022049452A1

WO2022049452A1 - Air cushioned sheet article

Info

Publication number: WO2022049452A1
Application number: PCT/IB2021/057764
Authority: WO
Inventors: Stephen M. Sanocki; Yaohua GAO; Michael D. Romano; Ignatius A. Kadoma; Scott M. Tapio; Sithya S. Khieu; Satinder K. Nayar; Stephen J. KUNCIO; John M. Brandner; Timothy J. Rowell; Verlin W. SCHELHAAS; Tien Yi T.H. WHITING; Aaron T. Nunberg
Original assignee: 3M Innovative Properties Company
Priority date: 2020-09-03
Filing date: 2021-08-24
Publication date: 2022-03-10

Abstract

Sheet article comprising a first wall, second wall, and porous scrim between the first and second walls, and at least one seal portion sealing the first wall, second wall, and porous scrim together, as well as packaging articles and constructions comprising the same, and methods of making and using the foregoing sheet articles, packaging articles, and constructions.

Description

AIR CUSHIONED SHEET ARTICLE

BACKGROUND

Packaging products that contain sealed air pockets within a multi-layer construction, such as bubble wrapping, are commercially available under the trade designation BUBBLE WRAP, as well as under other brands and labels.

DETAILED DESCRIPTION

Figures 1A and IB are side and top views, respectively, of an exemplary sheet article;

Figure 1C is a top view of another exemplary sheet article;

Figure 2 is a top view of yet another exemplary sheet article;

Figure 3 is a view of an exemplary packaging construction;

Figure 4A and 4B depict a process of making an exemplary packaging constmction from a sheet article;

Figure 5 depicts another exemplary packaging construction;

Figure 6 is a top view of still another exemplary sheet article;

Figures 7A-7C are drawings of exemplary first or second walls with sealable coatings;

Figures 8A and 8B are respectively a drawing of an exemplary pleated porous scrim layer and a cross-section of an exemplary sheet article.

Figure 9 is a photograph of an exemplary scrim layer of the present invention.

Figure 10 is a photograph of a portion of an exemplary packaging construction of the present invention.

Throughout this disclosure, singular forms such as “a,” “an,” and “the” are often used for convenience; however, the singular forms are meant to include the plural unless the singular alone is explicitly specified or is clearly indicated by the context. When the singular alone is called for, the term “one and only one” is typically used.

Some terms in this disclosure are defined below. Other terms will be familiar to the person of skill in the art and should be afforded the meaning that a person of ordinary skill in the art would have ascribed to them.

Terms indicating a high frequency, such as (but not limited to) “common,” “typical,” and “usual,” as well as “commonly,” “typically,” and “usually” are used herein to refer to features that are often employed in the invention and, unless specifically used with reference to the prior art, are not intended to mean that the features are present in the prior art, much less that those features are common, usual, or typical in the prior art. The term “compostable” refers to materials, compositions, or articles that meet the ASTM D6400 standard, the ASTM D6868 standard, or both the ASTM D6400 standard and the ASTM D6868 standard. In addition, to meeting the ASTM D6400 or ASTM D6868 standard, compostable materials, compositions, or articles can optionally meet the ASTMD5338 standard. In addition, to meeting the ASTM D6400 or ASTM D6868 standard, compostable materials, compositions, or articles can optionally meet one or more of the EN 12432, AS 4736, or ISO 17088 standards. In addition, to meeting the ASTM D6400 or ASTM D6868 standard, compostable materials, compositions, or articles can optionally meet the ISO 14855 standard. The term “compostable” as used herein is not interchangeable with the term “biodegradable.” Something that is “compostable” must degrade within the time specified by the above standard or standards into materials having a toxicity, particularly plant toxicity, that conform with the above standard or standards. The term “biodegradable” does not specify the time in which a material must degrade, nor does it specify that the compounds into which it degrades pass any standard for toxicity or lack of harm to the environment. For example, materials that meet the ASTM D6400 standard must pass the test specified in ISO 17088, which addresses “the presence of high levels of regulated metals and other harmful components,” whereas a material that is “biodegradable” may have any level of harmful components.

The term “independently,” when used in reference to variables, means that the identity of one variable bears no relation to the identity of another. For example, if each variable X in item X-X is independently chosen from A and B, then X-X may be A-A, A-B, B-A, or B-B.

“Paper” as used herein refers to woven or non-woven sheet-shaped products or fabrics (which may be folded, and may be of various thicknesses) made from cellulose (particularly fibers of cellulose, (whether naturally or artificially derived)) or otherwise derivable from the pulp of plant sources such as wood, com, grass, rice, and the like. Paper includes products made from both traditional and non-traditional paper making processes, as well as materials of the type described above that have other types of fibers embedded in the sheet, for example, reinforcement fibers. Paper may have coatings on the sheet or on the fibers themselves. Examples of non-traditional products that are “paper” within the context of this disclosure include the material available under the trade designation TRINGA from PAPTIC (Espoo, Finland), and sheet forms of the material available under the trade designation SULAPAC.

The term “recyclable” refers to materials, compositions, or articles that meet at least one of the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FB A) part 1 (repulpability), Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 2 (recyclability), and ISO 18601 standards. Particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability). Particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 2 (recyclability). More particular recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability) and part 2 (recyclability). Still more particularly, recyclable items meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard part 1 (repulpability) and part 2 (recyclability) standards, as well as the ISO 18601 standard. Even more particularly, recyclable items additionally meet the ISO 18604:2013 standard. All references to the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard standard, whether to part 1 , part 2, or both, refer to the 2013 version of the standard. It should be noted that a recyclable material may include materials, such as adhesives, that do not meet one or more of the above standards. This is because materials, particularly adhesives, are commonly removed from paper products during the recycling process. Such materials, especially adhesives, that are not themselves recyclable but are readily removed from a product during the recycling process are referred to herein as “recycle-compatible.” A “recyclable” article thus may contain components that are recyclable as well as components that are recycle-compatible.

The use of air as a cushioning component in packaging is known, for example, in bubble wrapping, such as that available under the trade designation BUBBLE WRAP, as well as in airfilled plastic cushioning articles, bubble-containing mailers, and the like.

This disclosure identifies several problems with air-filled cushioning components. First, they typically require the use of plastics, such as polypropylene or polyethylene. Such plastics may not be recyclable and are not compostable. Even if they are recyclable it is established that plastic products are recycled at a much lower rate than paper-based products. Second, such plastic materials typically must be fdled with air during manufacture and then shipped to the end user, such as a packaging facility, warehouse, or the like. Thus, it is necessary to ship the air content, which increases the cost and fuel consumption during shipping, as opposed to shipping before inflation and then inflating at the site of use, such as at a warehouse. Third, a separate inflation step may be required during manufacture, which adds to the complexity and cost of manufacturing.

This disclosure also recognizes several problems with known cushioning materials, such as mailers, space-fillers, envelopes, and the like. First materials often use expensive or heavy materials to effect cushioning, and in any event their entire bulk usually needs to be shipped from the site of manufacture to the site of use, such as a warehouse or fulfilment center. Second, many known cushioning materials are neither compostable nor recyclable.

In brief, a solution lies in a sheet article comprising one or more edge portions defining the boundaries of the article, a sheet portion, a first wall having a first interior surface an opposing first exterior surface, a second wall having a second interior surface facing the first interior surface and an opposing second exterior surface, and a porous scrim disposed between the first wall and the second wall.

The first wall, second wall, and porous scrim are sealed together by one or more seals, each of the one or more seals located at seal portions. The seals may independently have any suitable shape, such as circular, oval, trapezoidal, cruciform, or the like. The sheet article also has unsealed portions, which are portions of the first wall, second wall, and porous scrim that are not sealed together by one or more seals. At least one, and particularly a plurality, of the seal portions are not located at an edge or edge portion of the sheet article.

A variety of configurations of sealed and unsealed portions are possible, mainly depending on the size and shape of the seals and seal portions and the size and shape of the unsealed portions. For example, the seals and corresponding seal portions can be distributed randomly on the sheet article, or they can be in one or more repeating patterns on the sheet article. The surface area of the sheet article is typically divided between sealed and unsealed portions, and usually most of the surface area comprises unsealed portions. Most commonly, the unsealed portions represent no less than 50%, no less than 60%, no less than 70%, no less than 80%, no less than 90%, or even no less than 95% of the surface area of the sheet article. In some cases the seal portions define channels or other geometric or random shapes in the unsealed portions, however, this is not required and in other cases the unsealed portions have other shapes, patterns, or configurations, or even no defined shapes or patterns.

In some configurations, the seal portions can define channels in the sheet article. When channels are defined, they can have any of a variety of suitable configurations. When both ends of the two or more channels are open, then the three or more seals typically run from an open edge portion to an opposing open edge portion. When one end of the two or more channels is open and the other is closed, then the three or more seals typically run from an open edge portion to an opposing closed edge portion. When both ends of the two or more channels are closed, then the three or more seals typically run from a closed edge portion to an opposing closed edge portion.

It is also possible for the seals to meet in the sheet portion, in which case the seals run from an edge portion, which may be open or closed, to the sheet portion. It is also possible for a cross-seal to intersect at least two of the three or more seals.

Notably, channels are not required. In some embodiments, there are no channels but rather the seals are disposed in other ways, such as those described above and elsewhere in this disclosure. The porous scrim is typically disposed between the first wall and the second wall, and may be joined to the first and second walls at the seal portions. The porous scrim may be disposed in all or part of the sheet article. When channels are present, the porous scrim may be disposed in the channels, either only in the channels or in the channels and in other portions of the sheet article.

An edge portion of the article can be in the form of a flap without channels. The flap may be created, for example, by having the first or second wall overhang the article.

Turning to the figures, exemplary sheet article 10 is depicted in Figures 1 A-C. Figure 1 A is a side-view of sheet article 10, depicting first wall 1100 having first interior surface 1101 and opposing first exterior surface 1102. Second wall 1200 features second interior surface 1200 having second interior surface 1201, which faces first interior surface 1101, and opposing second exterior surface 1202. Porous scrim 1300 is disposed between first wall 1100 and second wall 1200, and within channels 1400A and 1400B. Channels 1400A and 1400B are defined in part by seal portions 1500A, 1500B, and 1500C.

Figure IB, which is a top-down view of sheet article 10, depicts channels 1400A and 1400B which are defined by seal portions 1500 A, 1500B, and 1500C running from first edge portion 1601 to sheet portion 1700 and to second edge portion 1601. In this Figure, first edge portions 1601 is an open edge portion, meaning it is open at the edge of channels 1400 A, 1400B while second edge portion 1602 may be open or closed (if closed, it is not open at the edge of channels 1400 A, 1400B).

In Figure 1C, both first edge portion 1601 and second edge portion 1602 are closed such that channels 1400 A, 1400B are sealed or closed from the external environment. Thus, sealed channels 1400 A, 1400B retain trapped air (not visible in this Figure) within the channels 1400 A, 1400B. First edge portion 1601 is in the form of a flap which does not contain any channels. Adhesive portion 1700 is present on the flap/first edge portion 1601.

The articles as shown in Figures 1A-1C show continuous seals, however it is also possible for an article 10 to have discontinuous seals 1500 A, 1500B and 1500C.

While Figures 1 A-1C depict first wall 1100, second wall 1200, and porous scrim 1300 being sealed together in three seals 1500 A, 1500B, 1500C, to form channels, optionally these components to be sealed together in more than three seals, such as optionally four or more, optionally five or more, optionally six or more, optionally seven or more, optionally eight or more seals, which particularly are seals that do not intersect with one another. In a configuration similar to that shown in Figures 1A-1C, this would create additional channels beyond the two channels 1400 A, 1400B, that are depicted in these figures. Such a configuration could provide, for example three or more channels, optionally four or more channels, optionally five or more channels, optionally six or more channels, optionally seven or more channels.

Figure 2 is a top-down view of sheet article 20, depicting first wall 2100 and second wall 2200. Porous scrim 2300 is disposed between first wall 2100 and second wall 2200, and within channels 2400A and 2400B. Channels 2400 A, 2400B, 2400C, 2400D are defined in part by seal portions 2500 A, 2500B, 2500C and in part by cross-seal 2600, another seal portion that intersects seals 2500 A, 2500B, 2500C. First edge portion 2700, which here is defined at least in part by seal portion 2500 A, is in the form of a flap and does not have any channels.

Figure 3 is a depiction of packaging construction 30, which contains cavity 3200 defined first sheet article 3100 and second sheet article 3600 that are bound together at first edge portion 3700, as well as at seals 3301 and 3303 in second sheet article 3600 to take the form of a pouch, envelope, or mailer with flap 3500. Seal 3302, which does not bind the first sheet article 3100 to second sheet article 3600, defines part of the boundary of channels 3601A, 3601B. Object 31 is being placed within packaging construction 30, which can later be closed with flap 3500.

Figure 4A depicts sheet article 40, which is similar to, for example, sheet article 20 except that all four channels are sealed. Object 41 has been placed on sheet article 40. In use, sheet article 40 can be folded into a tube-like configuration by folding along a seal in direction D around object 41. The result, as shown in Figure 4B, is a tube-shaped configuration with object 41 (not visible in Figure 4B) in a cavity (also not visible in Figure 4B) the middle of the tube.

Figure 5 depicts packaging construction 50, which is a box 51 having sheet article 52, which is similar to sheet article 20 and has sealed channels, inside the box. Additional sheet articles (not shown) could also be placed inside box 51 as needed to fill space and provide cushioning.

Figure 10 depicts sheet article 101 which does not have channels. Instead, sheet article 101 includes a plurality of seal portions 1001 that, in this Figure 10, are generally circular in shape and are distributed in a repeating pattern in sheet article 101. Sheet article 101 also features optional seal portion 1002 at an edge of sheet article 101; however, unlike in the sheet articles depicted in Figures 1-5, no distinct channels are defined by the plurality of seal portions 1001.

The sheet articles shown in Figures 1-5 and 10 are generally rectangular in shape, but other shapes are possible. Figure 6 shows sheet article 60 having first wall 6100, second wall 6200, and porous scrim 6300. Seals 6401, 6402, 6403, 6404, 6405 seal first wall 6100, second wall 6200, and porous scrim 6300 and define channels 6500 A, 6500B, 6500C, 6500D, 6500E. In this Figure, the entirety of edge portion 6600 is open, but it would be possible to seal all or a part of edge portion 6600 thereby sealing channels 6500 A, 6500B, 6500C, 6500D, 6500E. Composabilitv and Recyclability

The sheet articles are typically compostable, recyclable, or both. When recyclable, the sheet articles typically meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 1 (repulpability). In addition, or in the alternative, the sheet articles meet the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 2 (recy ciability ).\

Particular recyclable sheet articles also meet the ISO 18601 standard. Particular recyclable sheet articles also meet the ISO 18604:2013 standard. Most particularly recyclable sheet articles also meet both the ISO 18601 and the ISO 18604:2013 standards.

The sheet articles may contain some components that are recycle-compatible rather than recyclable, in which case the sheet articles are still considered to be recyclable. It is also possible for the sheet articles to contain components, such as release liners, that are not recyclable but are designed to be removed from the sheet articles before recycling. In such cases, the sheet articles are still considered to be recyclable.

When the sheet articles are compostable, they can meet the ASTM D6400 standard. Additionally, or in the alternative, when the sheet articles are compostable they can mee the ASTM D6868 standard. In addition to meeting one or both of the aforementioned standards, compostable sheet articles can meet at least one of the EN 12432 standard, the AS 4736 standard, or the ISO 17088 standard. Particular compostable sheet articles also meet the ISO 14855 standard.

First and Second Wall

Any suitable material can be used for the first wall, the second wall, or both. Suitable materials include those that can be bent, folded, or otherwise shaped such that the sheet article can be made into a packaging article or packaging construction as described herein. The material that constitutes the first wall, second wall, or both, can comprise a compostable material, a recyclable material, or a material that is both compostable and recyclable. The first wall and the second wall are most commonly made from the same material or materials, but this is not necessary; for some applications it may be beneficial to make the first and second walls from different materials. For some applications, thermoplastic materials can be particularly useful for the first wall, second wall, or both, however this is not required and materials that are not thermoplastic can also be employed.

Particularly, the material that constitutes the first wall, second wall, or both, comprises a material that is independently selected from one or more of poly(lactic acid) (which is sometimes known as PLA, and as used herein is intended to encompass both poly(lactic acid) and poly(lactide)), poly(glycolic acid) (which as used herein is intended to encompass both poly(glycolic acid) and poly(glycolide)), poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic-aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), and cellulose. Of the foregoing, poly(lactic acid) and cellulose are most commonly employed.

When a material such as poly(lactic acid), polylactide, poly(glycolic acid), poly glycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, or poly(ester amide), particularly poly(lactic acid), polylactide, poly(glycolic acid), poly glycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, or caprolactone, and most particularly poly(lactic acid), is employed as part of the first wall, second wall, or both, it is typically in the form of a nonwoven sheet. Nonwoven sheets of such materials and their manufacture are known in the art. Spun bonding is one particularly useful method of manufacturing nonwoven sheets of such materials, particularly poly(lactic acid). Exemplary spun bonding processes that produce nonwovens useful for the packaging articles described herein are described in US3802817, but other processes may also be employed.

Another particular material that can constitute the first wall, second wall or both, is a water- soluble polymer. Examples include coagulants, such as quaternary polyamines, polydiallyl ammonium chloride (polyDADMAC), and dicyandiamide resins; flocculants, such as nonionic, anionic, and cationic materials; amphoteric polymers; polyethyleneimines; polyamide-amines; polyamine-based polymers; polyethylene oxides; sulphonated compounds; polyvinylpyrrolidone; polylactic acid; polylactones; polyacrylate-type dispersants; poly alcohols; cellulose derivatives; or combinations thereof. Non-liming examples of commercially available water soluble polymers include BVOH, sold as NICHIGO G-POLYMER™ by Nippon Goshei, poly-2-ethyloxazoline, sold as AQUAZOL™by Polymer Chemistry Innovations, Inc., and hydroxypropyl methylcellulose, sold as AFFINISOL™ by Dow Chemical Co. Another particular example is poly(vinyl alcohol).

Yet another particular example of a water soluble polymer is a water soluble copolymer comprising divalent hydroxyethylene monomer units (i.e., -CH2-CH(OH)-) and divalent dihydroxybutylene monomer units (referred to herein as a “hydroxy -ethylene-butylene copolymer”), the divalent dihydroxybutylene monomer units comprise 3,4-dihydroxybutan-l,2- diyl monomer units (i.e., monomer units of the structure

Optionally, but more particularly, the copolymer further comprises acetoxyethylene divalent monomeric units having the structure

The copolymer may be obtained by copolymerization of vinyl acetate and 3,4-dihydroxy-l- butene followed by partial or complete saponification of the acetoxy groups to form hydroxyl groups. Alternatively, in place of 3, 4-dihydroxy-l -butene, a carbonate such as:

can also be used. After copolymerization, this carbonate may be hydrolyzed simultaneously with saponification of the acetate groups. In another embodiment, in place of 3,4-dihydroxy-l-butene, an acetal or ketal having the formula:

can be used, where each R is independently hydrogen or alkyl (e.g., methyl or ethyl). After copolymerization, this carbonate may be hydrolyzed simultaneously with saponification of the acetate groups, or separately. The copolymer can be made according to known methods or obtained from a commercial supplier, for example.

Commercially available water-soluble copolymers that can be used include those available under the trade designation Nichigo G-Polymer (Nippon Gohsei Synthetic Chemical Industry, Osaka, Japan), a highly amorphous polyvinyl alcohol, that is believed to have divalent monomer units of hydroxy ethylene, 3,4- dihydroxybutan-l,2-diyl , and optionally acetoxy ethylene. Nippon Gohsei also refers to Nichigo G- Polymer by the chemical name butenediol vinyl alcohol (BVOH). Exemplary materials include Nichigo G-Polymer grades AZF8035W, OKS-1024, OKS-8041, OKS-8089, OKS-8118, OKS-6026, OKS-1011, OKS-8049, OKS-8074P, OKS-1028, OKS-1027, OKS-1109, OKS-1081, and OKS-1083. These hydroxy -ethylene-butylene copolymers are believed to have a saponification degree of 80 to 97.9 mole percent, and further contain an alkylene oxide adduct of a polyvalent alcohol containing 5 to 9 moles of an alkylene oxide per mole of the polyvalent alcohol. When a water soluble polymer or copolymer, such as any of the water soluble polymers or copolymers discussed herein, is used, it can be in the form of a fabric, such as a woven or nonwoven, or a film.

When the material that constitutes the first wall, the second wall, or both comprises cellulose, the material is most commonly in the form of paper. Any suitable type of paper can be used, examples include Kraft paper, bond paper, and creped paper.

The material that constitutes the first wall, second wall, or both, is in the form of a sheet, such as a nonwoven sheet. Particular nonwoven sheets that can be used have a basis weight that is sufficient to allow them to withstand weather conditions, such as heat, cold, rain, or snow, and other conditions and that may be encountered during a packaging and shipping process, as well as to withstand handling that may occur during packaging and shipping, such as dropping, jostling, banging against other objects, and the like. Any basis weight of nonwoven that is suitable for the intended use can be employed, and a variety of basis weights may be suitable depending on the needs of the users. Most commonly, the basis weight (in units of g/m²) will be no less than 20, optionally no less than 30, optionally no less than 40, optionally no less than 50, optionally no less than 75, optionally no less than 100, optionally no less than 125, optionally no less than 150, optionally no less than 175, optionally no less than 200, optionally no less than 225, or optionally no less than 250. Most commonly, the basis weight (in units of g/m²) will be no greater than 250, optionally no greater than 225, optionally no greater than 200, optionally no greater than 175, optionally no greater than 150, optionally no greater than 125, optionally no greater than 100, optionally no greater than 75, optionally no greater than 50, optionally no greater than 40, or optionally no greater than 30. Most commonly, the basis weight employed (in units of g/m²) can be 20 - 250, more particularly the basis weight for nonwovens that are used can be 20-100 for nonwoven, and more particularly the basis weight for a cellulose-based wall can be 50-250.

Another particularly useful material that can be employed as a component of the first wall, the second wall, or both, is cellulose. When used, the cellulose is typically a component of paper. Any form of paper can be employed in the first wall, the second wall, or both, as long as it is compostable. Kraft paper, bond paper, and crepe paper are exemplary papers that can be employed. Kraft paper is particularly useful.

In some cases, the first wall, second wall, or both can include a material that is not recyclable. In particular cases, such materials are recycle-compatible. Examples include polyethylene, polypropylene,

Other components can also be included in the first wall, second wall, or both. Colorings, such as pigments or dyes, are particular components that are used in many cases. Examples include PLA masterbatch colorings available from Clariant Corp. (Minneapolis, MN, USA) under the OM or OMB lines of products, or those available from Techmer PM LLC (Clinton, TN, USA) under the PLAM or PPM lines of products. Typically, when colorings are employed as a component of the first wall or second wall, as opposed to as a component of a coating on the first or second wall, they are present at an amount of 0.5% - 5% by weight and are blended with the other components of the first wall or second wall.

The first wall, second wall, or both may be constructed from a single layer or sheet of material or from multiple sheets. When a single layer or sheet is used, it is typically either PLA or paper.

When more than one sheet or layer is used for the first wall, second wall, or both, the sheets or layers can be bound together in any suitable way. Examples include a conductive, convective, radiative, inductive, resistive, or frictional form of heating. When the coatings are heat-sealable coatings, the layers or sheets can be bonded together by a heat-sealing process, such as impulse sealing. Ultrasonic welding can also be used. The adjoining sides of the sheets or layers can have adhesive which can be used to adhere the layers or sheets, for example, when the adhesive is a pressure sensitive adhesive then pressure can be used to bond the sheets or layers. A patterned calendar roll can also be used.

Coatings

The first wall and second wall typically have a sealable coating disposed over at least one surface of the first wall, second wall, or both. The coating may be disposed over less than all of such surface or surfaces, but is most commonly disposed over the entire surface.

Most commonly, the sealable coating is disposed on at least one surface of the first wall and at least one surface of the second wall, and particularly it is disposed on the interior surface of the first wall, the interior surface of the second wall, or the interior surfaces of both the first and second wall. In addition, or in the alternative, the sealable coating can be disposed on the exterior surface of the first wall, the exterior surface of the second wall, or the exterior surfaces of both the first wall and the second wall. Particularly, the sealable coating is disposed on both the interior and the exterior of both the first and second walls.

The sealable coating can serve several purposes. It can be useful in forming the packaging article by allowing the edge or edges where the first wall is attached to the second wall to be heat sealed. It can also serve to provide weather or water resistance to the packaging article. Further, it can play a function in the channels’ ability to retain air once they are closed.

The sealable coating typically comprises one or more of poly(butylene succinate), poly (butylene succinate adipate), polyethylene succinate), poly(tetramethylene adipate-co- terephthalate), castor wax, or thermoplastic starch. Particularly, the sealable coating comprises at least one of poly(butylene succinate), poly (butylene succinate adipate), polyethylene succinate), castor wax, or poly (tetramethylene adipate-co -terephthalate). More particularly, the coating comprises poly(butylene succinate), castor wax, or both.

Other components can also be included in the sealable coating. Particularly, compostable pigments and dyes can be used. Examples include PLA masterbatch colorings available from Clariant Corp. (Minneapolis, MN, USA) under the OM or OMB lines of products, or those available from Techmer PM LLC (Clinton, TN, USA) under the PLAM or PPM lines of products. Typically, when colorings are employed, they are blended with the other coating components at an amount of 0.5% - 5% by weight.

There are at least two ways that coatings can be disposed on a layer or sheet of the first wall, second wall, or both. Both of these are important, and either one of them can be used with any embodiment of the article as described herein.

The first particular way of applying the coating to the underlying sheet or layer materials after the underlying sheet or layer has been formed. This can be accomplished by any suitable method. Typically, extrusion is used, but depending on the nature of the sheet or layer material and the coating, other methods such as knife coating, dye coating, or spray coating, could be used.

The second particular way of applying the coating is to coat the individual fibers of the sheet or layer with the coating. This results in a core-sheath configuration with the core as the sheet or layer material (or materials) and the sheath as the coating. In this case, further coatings could in principle be applied to the sheath, and this is within the scope of the coatings as described herein.

Thus, it should be understood that a “coating” or a “coated” layer as described herein includes both embodiments wherein the coating is applied on the layer and to embodiments wherein the coating is in the form of a sheath over some or all of the individual fibers of the layer.

It is possible to use a combination of the foregoing two approaches in any embodiment of the articles described herein. Thus, in particular cases, the individual fibers are coated in a core-sheath type configuration and a coating, which can be the same or different coating from the sheath, is disposed on one or both sides of the layer or sheet of material made from the core-sheath fibers.

In either case, the coating need not be applied to the entirety of the first or second wall but can be on only part of the layer or sheet. More particularly however, the coating is applied to the entirety of at least one side of the layer or sheet. Even more particularly, the coating, and most particularly a coating comprising poly (butylene succinate), is applied to the entirety of both sides of the layer or sheet.

One particularly useful construction for one or more of the layers or sheets is a poly(lactic acid) layer or sheet that is completely coated on both sides with poly(butylene succinate). More particularly, the layers or sheets having a poly(lactic acid) layer or sheet that is completely coated on both sides with poly(butylene succinate) can be embossed. Another particularly useful construction for the layers or sheets is a paper layer or sheet that is completely coated on both sides with poly(butylene succinate). More particularly, the paper layer or sheet that is completely coated on both sides with poly(butylene succinate) can be embossed. In any of the layers or sheets that are completely coated on both sides, and particularly the foregoing poly(lactic acid) or paper layers or sheets that are completely coated on both sides with poly(butylene succinate), the coating can be in the form of a layer disposed on the layer or sheet of material or in the form of a sheath that is disposed on the fibers of the layer or sheet material.

Coating thicknesses, in micrometers, can be any thickness required to provide the desired properties but are typically between greater than 10, greater than 15, greater than 20, greater than 25, greater than 30, greater than 35, greater than 40, greater than 45, or even greater than 50. Coating thicknesses, in micrometers, are typically less than 60, less than 55, less than 50, less than 45, less than 40, less than 35, less than 30, less than 25, or even less than 20. An exemplary range for coating thickness, in micrometers, is 20 to 50. When the coating is a sheath over a core fiber, the “coating thickness” refers to the thickness of the sheath; when the coating is applied as a layer then it refers to the thickness of the layer.

An illustrative configuration of the sealable coating on a wall is depicted in Figures 7A-7C. As depicted in Figure 7A, wall 70, which can be a first wall or a second wall, has exterior surface 7001 and interior surface 7002. Interior surface 7002 is coated with sealable coating 7101, which can be any of the coatings described herein. Similarly, Figure 7B depicts wall 71 , which can be a first wall or a second wall, having sealable coating 7101 on interior surface 7002 and sealable coating 7102 in exterior surface 7101. Figure 7C depicts wall 72, which can be a first wall or a second wall, having sealable coating 7102 on exterior surface 7001.

Particularly, the sealable coating is on both the interior and exterior surfaces of the first wall, the second wall, or both. Most particularly, the sealable coating is on the interior and exterior surfaces of both the first wall and the second wall.

Porous Scrim

A porous scrim is typically present between the first wall and the second wall and is disposed in the two or more channels. The porous scrim is particularly a conformable porous scrim, in that it can be bent or folded. Further, the porous scrim is more particularly compliant, in that it can be deformed by the application of pressure, temperature, or both to remove some of the content of the pores, which is most commonly air. The porous scrim may be made of any porous material, and particularly material that is lofty and has a large volume of air within the pores. Examples include one or more of paper, textile, and foam. In some cases, elastic materials can be employed. When paper is used, the paper can be particularly tissue paper or towel paper, creped paper, embossed paper (Kraft, bond, or pleated paper) and most particularly towel paper (also known as paper towel), which is a particularly lofty, loose paper that contains a large volume of air within the pores.

When a textile is employed, the textile may be any suitable textile such as knits, woven, cross-laminated film, or nonwovens, particularly nonwoven textile.

When the textile is woven or knitted, it can be a fabric such as cotton, linen, or wool fabric. Fabrics used for clothing, such as jersey or flannel, or for blankets, such as batting, can be suitable, as can fabrics like gauze. Particularly useful fabrics include those with high volume per unit area.

More particularly, a nonwoven textile is employed. The nonwoven can be prepared by any suitable method, such as air-blown, spunbound, or the like. The fibers used to prepare the nonwoven is most commonly one or more of poly(lactic acid), poly(glycolic acid), poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, poly hydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), and cellulose. Of the foregoing, poly(lactic acid) is most commonly employed. In some particular cases, the nonwoven includes or is made of any of the water-soluble polymers discussed above with respect to the components of the first wall or second wall.

When foam is used, the foam is typically an open-cell foam, however a closed cell foam can also be employed depending on the intended use of the article. Most commonly, the foam has a light basis weight, such as 120 g/m² or less, 100 g/m² or less, 75 g/m² or less, 50 g/m² or less, or even 25 g/m² or less. The foam can be made of any suitable materials, but is particularly from materials that are recyclable, compostable, or both. The foam can be include or be made from water-soluble materials, such as any of the water-soluble polymers discussed above with respect to the components of the first wall or second wall.

The porous scrim can be coated or uncoated. When the porous scrim is made of fibers, particularly nonwoven, the coating can be in the form of a sheath on the fiber cores. In any type of porous scrim, the coating can be applied as a layer on one or both sides of the porous scrim. When fibers are used, the coating can be applied to the fibers before they are formed into the scrim, or it can be applied after they are formed into the scrim.

When the porous scrim is coated, any suitable coating can be used depending on the desired application. Exemplary coatings can comprise poly(butylene succinate), poly (butylene succinate adipate), poly(ethylene succinate), poly(tetramethylene adipate-co-terephthalate), castor wax, or thermoplastic starch. Particularly, the coating comprises at least one of poly(butylene succinate), poly (butylene succinate adipate), poly(ethylene succinate), castor wax, or poly (tetramethylene adipate-co-terephthalate). More particularly, the coating comprises poly(butylene succinate), castor wax, or both. Even more particularly the coating comprises poly(butylene succinate), and most particularly the coating is poly(butylene succinate).

The porous scrim can assist in filling the channels with air. When the first wall, second wall, and porous scrim are sealed to form the three or more seals, the portions of the first and second wall between the seals do not sit flat against one another but rather are separated by air-filled space. In some cases some of the air in the pores of the porous scrim can be pushed out of the pores when the three or more seals are formed, and that the air being pushed out of the porous scrim’s pores is at least in part responsible for this effect. However, this is not required because air that is present between the first and second wall during the sealing process can be sufficient to create some separation between the layers. Also, although it may be advantageous for the sealing process to create some separation between the first and second walls, it is not required that any particular amount of separation, or any separation at all, between the first and second walls be achieved during the sealing process. For some applications, it may be beneficial for the separation between the first and second walls to be minimized, for example, in order to the volume of the sheet article during shipping.

The porous scrim can have one or more layers of material. When only one layer is used, the layer can be made of only one type of material or it can be made of more than one type of material, such as any combination of the materials mentioned herein. When more than one layer is used, the porous scrim can have two, three, four, or even more layers of material. When the porous scrim is more than one layer, the multiple layers can be made of the same type material, for example, a multi-ply paper scrim. Alternatively, the multiple layers can each be made of different types materials. Any combination of suitable materials, such as any of the materials mentioned herein, can be employed.

Porous scrims can be structured. Exemplary structures include folds, pleats, dimples, embossments, and the like. Figure 8A is a schematic of a folded porous scrim 80. Figure 8B shows sheet article 8000, having folded porous scrim 80 between first wall 8001 and second wall 8002. Figure 9 is a photograph bottom view of a dimpled porous scrim. Specifically, this Figure is a photograph of a pillow web made of nonwoven PLA fibres that were melt blown onto a perforated collector.

Unsealed Portion

In some cases, optional channels can be present. Typically, if channels are present, there are two or more channels. The two or more channels can be open at one or both edge portions, or they can be closed at both edge portions. Depending on the intended use, the sheet articles can be manufactured and shipped to a packaging facility, such as a warehouse or fulfillment center, with the one or both of the edge portions open so as to minimize the shipping volume. The open edge portions can then be sealed, for example, with commercially available bag sealing machines, to create a sheet article with sealed, air-filled channels.

Once sealed, the channels contain a volume of trapped air within the sealed channels. The sealed channels are able to retain a significant portion of this air for a period of time. For example, the sealed channels retain at least 20% of the volume trapped air, optionally at least 25% of the volume of trapped air, optionally at least 30% of the volume of trapped air, optionally at least 40% of the volume of trapped air, optionally at least 50% of the volume of trapped air, optionally at least 60% of the volume of trapped air, optionally at least 70% of the volume of trapped air, optionally at least 75% of the volume of trapped air, optionally at least 80% of the volume of trapped air, or optionally at least 90% of the volume of trapped air for a time period of one day or more. The time period of one day or more can be two days or more, optionally three days or more, optionally four days or more, optionally five days or more, optionally six days or more, optionally seven days or more, optionally eight days or more, optionally nine days or more, optionally ten days or more, optionally eleven days or more, optionally twelve days or more, optionally thirteen days or more, or optionally fourteen days or more.

Adhesive Portions

In some embodiments, one or more adhesive portions can be provided, for example on an exterior surface of the first or second walls. The adhesive portions are not considered to be part of the first or second walls. If a flap is employed, the one or more adhesive portions are often on the flap, or on a portion of the exterior surface that can be reached by the flap when the flap is folded into the closed position, so as to allow the flap to be adhered into a closed position. In some cases two adhesive portions are provided.

The one or more adhesive portions are usually in the shape of a strip or strips that runs roughly parallel to the opening of the packaging article, but this is not required.

The one or more adhesive portions can be any suitable adhesive depending on the desired use but are most commonly compostable adhesive. In particular cases, the one or more adhesive portions consist of compostable adhesive. The one or more adhesive portions can be a water- activated adhesive or a pressure sensitive adhesive. Most particularly, a compostable pressure sensitive adhesive is employed. Exemplary compostable adhesives are known, and examples include a copolymer of 2-octylacrylate and acrylic acid; a copolymer of sugar-modified acrylates; a blend of poly(lactic acid), polycaprolactone, and resin; a blend of; poly(hydroxyalkanoate) and resin; protein adhesive; natural rubber adhesive; and polyamides containing dimer acid. One or more release liners can be disposed over any or all the one or more adhesive portions. While it is advantageous that the release liners be compostable or at least recyclable, this is not required because the release liners can be disposed of separately from the packaging article after use and do not have to be placed with the packaging article in a composting environment. Thus, if the packaging articles as described herein have one or more release liners, the packaging articles can be “compostable” even if any or all the release liners are not compostable.

Methods of Making Sheet Articles

The sheet articles described herein can be made by forming the seal portions that seal the first wall, the porous scrim, and the second wall by sealing portions of the first wall, porous scrim, and second wall. The sealing can be accomplished by any suitable method. Examples include a conductive, convective, radiative, inductive, resistive, or frictional form of heating. When the sealable coatings are heat-sealable coatings, the layers or sheets can be bonded together by a heatsealing process, such as impulse sealing. Ultrasonic welding can also be used. The adjoining sides of the sheets or layers can have adhesive which can be used to adhere the layers or sheets, for example, when the adhesive is a pressure sensitive adhesive then pressure can be used to bond the sheets or layers. A patterned calendar roll can also be used.

The method can optionally further comprise sealing at least one edge portion, for example, to close at least one end of the channels, or to close both ends of the channels. Sealing the at least one edge portion can be accomplished by any suitable sealing method, including those mentioned herein with respect to forming the three or more seals. If a flap is employed, the method can further comprise applying an adhesive portion to the flap.

A method of making a sheet article with channels that are sealed closed, can comprise sealing along one or more edge portions that define the boundaries of an unsealed article, the first wall, the second wall, and the porous scrim to create two or more closed channels. The method can comprise blowing air into the channels to inflate them, but this is typically not needed because even unsealed there is typically enough air between the first and second walls such that the sealed channel will have sufficient air to provide cushioning. Thus, the step of blowing air is typically omitted.

Packaging Articles and Packaging Constructions

The sheet articles as described herein can be used in a variety of packaging articles and packaging constructions. Particularly, sheet articles used to form packaging articles or packaging constructions have sealed channels.

Some packaging articles can be manufactured by forming one or more sheet article as described herein into the form of a pouch or envelope having a cavity within the pouch or envelope. For example, a packaging article can be conveniently formed by starting with a sheet article as described herein, folding the sheet article, and then sealing two of the edges of the sheet article to form an envelope or pouch-like packaging article wherein the fold is one edge of the packaging article, the two sealed edges are two other edges of the packaging article, and a remaining unsealed edge is an opening in the packaging article. The folding can be done in a way that leaves a flap that can be used to later close the envelope or pouch, or a flap can be omitted. Packaging articles can be formed by folding or rolling one or more sheet articles into a tube shape, wherein the tube has a cavity inside the tube. Other packaging articles can be formed by disposing a sheet article within a box, pouch, envelope, or mailer, and particularly a box; in such packaging articles the sheet articles as described herein add cushioning.

Packaging constructions can comprise an object placed within any of the foregoing packaging articles. For example, an object can be placed in the cavity of a tube, envelope, pouch, or mailer that is made from the sheet articles, or within a box, pouch, envelope, or mailer that also contains a sheet article.

EXAMPLES

The following examples illustrate particular aspects of the disclosure. Not every aspect of the disclosure is exemplified, so the examples should not be deemed limiting except where otherwise indicated. Unless otherwise noted, all parts, percentages, ratios, etc. in the examples and the rest of the specification are by weight, and all materials used in the examples were obtained, or are available, from general suppliers such as, for example, Georgia-Pacific, Atlanta, GA, US, unless otherwise specified. The following abbreviations are used herein: gsm = g/m² = grams per square meter, mm = millimeters, cm = centimeters, m = meters, in = inches, pm = microns = 10'⁶ m, min = minutes, hr = hours, kg = kilograms, kPa = kilopascals, °C = degrees Celsius, kHz = kilohertz, J = Joules.

Sample Preparation

Table 1. Materials

Example 1A

Nonwoven Web: A dual-layer web of spunbond nonwoven fabric was prepared using INGEO 6202D PLA according to the general method disclosed in US3802817. The apparatus included a first station and a second station, each including an extmsion head, an attenuator, and a quenching stream. Both stations shared a collector surface. The INGEO 6202D was melted in the first extruder of the first station and pumped into an extrusion head that included multiple orifices arranged in rows of straight lines. Filaments were formed in a core/sheath configuration; even though the core and sheath were both made from INGEO 6202D PLA, a boundary existed between the two concentric layers to form a core and a sheath. Quenching streams of air were directed toward the extruded filaments, which were passed through the attenuator then deposited onto a generally flat collector surface to form a first mass of fibers (first nonwoven layer). Filaments produced by the second station were deposited on the surface of the first fiber mass on the collector as a second nonwoven layer.

Specific processing conditions were as follows. The first nonwoven layer was made by first extruding INGEO 6202D PLA sheath/core filaments at temperatures of 200°C to 230°C (sheath) and 230°C (core), which were then drawn by a quenching air stream at 10°C and flowrates of 23 m³/min in Zone 1 and 23 m³/min in Zone 2. A second layer of INGEO 6202D PLA monocomponent filaments were extruded at 230°C, then drawn by quench air at 15°C and a flow rate of 12 m³/min and were laid on the first composite layer to form a dual-layer web. The duallayer web was then passed through a through-air bonding station (i.e., were autogenously bonded), where hot air of 100°C-125°C-130°C was blown on the dual-layer web to thermally bond the layers. Web speed was adjusted to obtain the desired basis weight of 30 gsm.

Nonwoven Web Coating Process: The INGEO 6202D PLA web was coated by melt extrusion of the coating material using a 58-mm twin screw extruder (obtained under the trade designation “DTEX58” from Davis-Standard, Pawcatuck, CT, USA), operated at a 260°C extrusion temperature, with a heated hose (260°C) leading to a 760 mm drop die (obtained from Cloeren, Orange, TX, USA) with 686 mm deckles, a 0-1 mm adjustable die lip, and a single layer feed-block system. Solid coating material was fed at a rate of 22.7 kg/hr into the twin-screw system at the conditions described above. The resultant molten resin formed a thin sheet as it exited the die and was cast onto the web. The surface roughness was set at 75 Roughness Average by use of a sleeve (available from American Roller, Union Grove, WI, USA) against the cast film side, and a silicone rubber nip roll (80-85 durometer; from American Roller) was against the spunbond side. The layered composite was pressed between the two nip rolls with a nip force of about 70 KPa, at a line speed that was adjusted to provide the desired coating thickness. One side was coated with a topcoat composition of 90 wt% BioPBS FZ71 and 10% PL AM 69962 at a thickness of 42 pm, and the other side was coated with an undercoat composition of 90% PBS FZ71, 5% OM0364246 PLA white masterbatch, and 5% OM93642451 PLA Black masterbatch on the inner side at a thickness of 42 pm.

Porous Scrim Layer: The inner layer was a single sheet of WYPALL paper towel, which was used as received.

Air-Cushioned Sheet Article: The scrim layer was placed between two layers of the coated PLA nonwoven fabric, which were oriented such that the undercoated layer was on the inside of the layered stack and the topcoat was on the outside. The dimensions of the sheets were 22.9 cm (9 in) by 45.7 cm (18 in). The layered structure was then heat sealed using a model H-458 manual impulse sealer (available from Uline, Pleasant Prairie, WI, USA). Sealing was done across the width of the sheet assembly in lines spaced approximately 5 cm (2 in) apart. Example IB

Example IB was prepared similarly to Example 1 A, except that the porous scrim layer consisted of 2 sheets of WYPALL paper towel, which were used as received. Example 1C

Example 1C was prepared similarly to Example 1A, except that the porous scrim layer consisted of 3 sheets of WYPALL paper towel, which were used as received. Example ID

Example ID was prepared similarly to Example 1 A, except that the sheet of WYPALL paper towel was folded into pleats as shown in Figure 8A prior to being placed between the two layers of coated PL A nonwoven fabric prior to being sealed. Figure 8B shows the layered sheet article in a cross-sectional view taken between the sealed areas, and demonstrates the orientation of the pleated scrim layer.

Example IE

Example IE was prepared similarly to Example 1 A, except that sealing of the layered structure was done by ultrasonic plunge welding using a Branson 2000X 20 kHz Ultrasonic Welder (Emerson Automation Solutions, St. Louis, MN, US) with a 13.3 cm x 15.2 cm x 1.27 cm titanium horn, a horn gain of 3.00 with dimensions on the side view of 3.81 cm x 1.27 cm, a booster gain of 1.5, 75-100% amplitude, an anvil with coarse knurl pattern for a 15.2 cm x 0.89 cm weld, a 91 kg pressure trigger, a weld energy of 300-400 J, a pressure range of 483-620 kPa over a 7.6 cm diameter cylinder, and a hold time of 2.0 seconds.

Example 2A

Coated Paper: Two sheets of #064450 Kraft paper were coated on both sides using the melt extmsion procedures described above for Example 1 A. Both sides were coated with a composition of 95% PBS FZ91 and 5% MP-80 Castor wax at a thickness of 42 pm.

Air-Cushioned Sheet Article: The scrim layer was placed between two layers of the coated Kraft paper, which were oriented such that the undercoated layer was on the inside of the layered stack and the topcoat was on the outside. The dimensions of the sheets were 22.9 cm (9 in) by 45.7 cm (18 in). The layered structure was then heat sealed as described for Example 1A. Example 2B

Example 2B was prepared similarly to Example 2A, except that the porous scrim layer consisted of 2 sheets of WYPALL paper towel, which were used as received.

Example 2C

Example 2C was prepared similarly to Example 2A, except that the porous scrim layer consisted of 3 sheets of WYPALL paper towel, which were used as received.

Example 2D

Example 2D was prepared similarly to Example 2A, except that the sheet of WYPALL paper towel was folded into pleats as shown in Figure 8A prior to being placed between the two layers of coated PLA nonwoven fabric (as shown in Figure 8B) prior to being sealed. Example 2E

Example 2E was prepared similarly to Example 2A, except that sealing of the layered structure was done by ultrasonic plunge welding using a Branson 2000X 20 kHz Ultrasonic Welder (Emerson Automation Solutions, St. Louis, MN, US) with a 13.3 cm x 15.2 cm x 1.27 cm titanium horn, a horn gain of 3.00 with dimensions on the side view of 3.81 cm x 1.27 cm, a booster gain of 1.5, 75-100% amplitude, an anvil with coarse knurl pattern for a 15.2 cm x 0.89 cm weld, a 91 kg pressure trigger, a weld energy of 300-400 J, a pressure range of 483-620 kPa over a 7.6 cm diameter cylinder, and a hold time of 2.0 seconds.

Example 3 A

Porous Scrim Layer: A structured blown microfiber nonwoven web was made as follows. INGEO 6252D PLA polymer was fed to a Model 20 DAVIS STANDARD 50.8 mm (2 in) single screw extmder (available from the Davis Standard Division of Crompton & Knowles Corp., Fulton, NY, USA). The extruder had a 20: 1 length:diameter ratio and a 3 : 1 compression ratio. A Zenith 10 cm³/rev melt pump (Zenith Pumps, Monroe, NC, USA) metered the flow of polymer to a 50.8 cm (20 in) wide meltblowing die with 0.38 mm (0.015 in) drilled orifices. The orifices were spaced apart at 10 holes per cm (25 holes/inch) in a line. Heated air attenuated the fibers at the die tip. The airknife employed a 0.25 mm (0.010 in) positive set back and a 0.76 mm (0.030 in) air gap. The polymer output rate from the extruder was varied from 0.18 to 0.27 kg/cm/hr (1.0-1.5 Ibs/in/hr), the DCD (die-to-collector distance) was varied from 20.3 to 30.5 cm (8.0-12.0 in) as needed to yield a roughly flat web structure with an effective fiber diameter (EFD) of 35 pm, a basis weight of 60 gsm, and a thickness of 0.7 mm.

Air-Cushioned Sheet Article: The nonwoven web scrim layer was placed between two layers of the EARTHFIRST UL 120 polymer film. Each layer was approximately 22.9 cm (9 in) by 45.7 cm (18 in). The layered structure was then heat sealed as described for Example 1A. Example 3B

Example 3B was similar to Example 3 A, except that the nonwoven scrim layer was a 3- dimensional web, as shown in Figure 9. Instead of using a flat collector, the INGEO 6252D PLA microfibers were blown onto a 500 mm long by 750 mm wide perforated metal collector with 8 mm holes spaced 10 mm center to center, which was placed about 225 mm from the blown microfiber die. Moderate vacuum was pulled through the perforated collector at the point of web formation. The vacuum was adjusted as needed to gently pull portions of the web through the 8 mm holes in the metal collector to form 3 -dimensional structures in the web that were shaped roughly like round domes or dimples. The 3 -dimensional web was 4.3 mm thick, including the domed structures. The air-cushioned sheet article was layered and sealed as described for Example 3 A. Example 3C

Example 3C was identical to Example 3 A, except that the scrim layer had a basis weight of 100 gsm. Example 4A

Two sheets of natural Kraft paper #064450 were coated on both sides using the melt extrusion procedures and coating compositions described above for Example 2A. A 0.7 mm thick microfiber nonwoven web scrim layer was made using the procedures and materials described above for Example 3 A. The scrim layer was placed between two layers of the coated paper. Each sheet was 22.9 cm (9 in) by 45.7 cm (18 in). The layered structure was then heat sealed with a manual impulse sealer using the procedures described for Example 1 A.

Example 4B

Example 4B was identical to Example 4 A, except that scrim layer was 4.3 mm thick.

Example 5A

Two sheets of coated PLA nonwoven web were prepared and coated on both sides using the materials and melt extrusion procedures described above for Example 1 A. A 0.7 mm thick microfiber nonwoven web scrim layer was made using the procedures and materials described above for Example 3 A. The scrim layer was placed between two layers of the coated paper. Each layer was 22.9 cm (9 in) by 45.7 cm (18 in). The layered structure was then heat sealed using a manual impulse sealer as described for Example 1 A.

Example 5B

Example 5B was identical to Example 5A, except that scrim layer was 4.3 mm thick.

Example 6

Example 6 was prepared similarly to Example 1 A, except that the two outer layers of the layered stack were EARTHFIRST WUL 120 PLA film, which were used as received, and the porous scrim layer consisted of 3 sheets of WYPALL paper towel, used as received.

Example 7A

Example 7A was prepared similarly to Example 2A, except that the porous scrim layer consisted of a single layer of Italian crepe paper streamer having a basis weight of 70 gsm. Example 7B

Example 7B was prepared similarly to Example 2A, except that the porous scrim layer consisted of a single layer of Italian crepe paper streamer having a basis weight of 90 gsm. Example 7C

Example 7C was prepared similarly to Example 2 A, except that the porous scrim layer consisted of a single layer of Italian crepe paper streamer having a basis weight of 180 gsm. Example 8A

Coated Paper: Two sheets of #064450 Kraft paper were coated on one side with FZ91 PBS using the melt extrusion procedures described above for Example 1 A, at a coating weight of 30 gsm. Porous Scrim Layer: The inner layer consisted of a single sheet of Shopper Value singleply paper towel, which was used as received.

Nonwoven Web: A sheet of spunbond nonwoven fabric prepared using INGEO 6202D PL A according to the method provided in Example 1 A.

Air-Cushioned Sheet Article: An approximately 53 cm by 28 cm (21 in by 11 in) sheet of the porous scrim was placed on top of an approximately 61 cm by 28 cm (24 in by 11 in) sheet of coated Kraft paper, with the coated side of the Kraft paper facing the scrim, and leaving a 7.6 cm (3 in) strip of Kraft paper uncovered. An approximately 53 cm by 28 cm (21 in by 11 in) sheet of the nonwoven fabric was then placed on top of the porous scrim. The edge of the nonwoven closest to the uncovered portion of the Kraft paper was then heat sealed across the width of the sheet assembly using a model H-458 manual impulse sealer. The layered stack was sealed in the pattern of dots 1001 shown in Figure 10 by ultrasonic plunge welding using a Branson AED 20 kHz Ultrasonic Welder (available from Emerson Automation Solutions, St. Louis, MN, US) with a 30 cm x 6.4 cm (12 in x 2.5 in) titanium horn, 1:1.5 booster, 100% amplitude, a 113 kg (250 lb) trigger, a pressure of 483 kPa (70 psi) over a 7.6 cm (3 in) diameter cylinder, a weld energy of 800 J, and a hold time of 0.50 seconds. The anvil of the welder had a pattern of tapered pins, each having a 2.5 mm (0.10 in) end diameter, a 3.8 mm (0.15 in) base diameter, and a height of 6.4 mm (0.250 in).

Air-Cushioned Mailing Pouch: The approximately 61 cm by 28 cm (24 in by 11 in) aircushioned sheet was folded with the side with the nonwoven layer on the inside, to form an overlapping area approximately 27 cm by 28 cm (10.5 in by 11 in) with a 7.6 cm (3 in) wide coated Kraft paper flap. The side edges 1002 of pouch 101 were sealed as shown in Figure 10 using a Branson AED 20 kHz Ultrasonic Welder (available from Emerson Automation Solutions, St. Louis, MN, US) with a 36 cm x 3.8 cm x 1.3 cm (14.25 x 1.5 x 0.5 in) titanium horn, booster of 1 gain, 100% amplitude, a 50 kg (110 lb) trigger, a pressure of 496 kPa (72 psi) over a 7.6 cm (3 in) diameter cylinder, a weld energy of 800 J, and a hold time of 0.50 seconds. The anvil had a trapezoidal stitch 3.8 mm (0.15 in) wide angled at 45° as shown in Figure 10. Example 8B

Example 8B was prepared similarly to Example 8A, except that the porous inner layer consisted of a sheet of 6.4 mm (0.25 in) thick cellulose wadding, which was used as received.

Claims

1. A sheet article comprising one or more edge portions defining the boundaries of the article; a sheet portion; a first wall having a first interior surface and an opposing first exterior surface; a second wall having a second interior surface facing the first interior surface; a porous scrim disposed between the first wall and the second wall; the first wall, second wall, and porous scrim being sealed together at one or more seal portions that are not located at an edge of the sheet article.

2. The sheet article of claim 1, wherein at least some of the seal portions are located on the sheet portion and are separated by unsealed portions, and optionally wherein at least some of the seal portions are disposed in a repeating pattern on the article.

3. The sheet article of claim 1, wherein at least some of the seal portions define two or more channels that run from a closed edge portion of the article to an opposing edge portion of the article.

4. The sheet article of any of claims 1-3, wherein the opposing edge portion of the article is closed such that at least one of the two or more channels, and optionally two or more of the two or more sealed channels, is a sealed channel or are sealed channels.

5. The sheet article of claim 4, wherein the sealed channels contain a volume of trapped air disposed within the sealed channels; and wherein the sealed channels retain at least 20% of the volume trapped air, optionally at least 25% of the volume of trapped air, optionally at least 30% of the volume of trapped air, optionally at least 40% of the volume of trapped air, optionally at least 50% of the volume of trapped air, optionally at least 60% of the volume of trapped air, optionally at least 70% of the volume of trapped air, optionally at least 75% of the volume of trapped air, optionally at least 80% of the volume of trapped air, or optionally at least 90% of the volume of trapped air for a time period of one day or more.

6. The sheet article of claim 5, wherein the time period of one day or more is two days or more, optionally three days or more, optionally four days or more, optionally five days or more, optionally six days or more, optionally seven days or more, optionally eight days or more, optionally nine days or more, optionally ten days or more, optionally eleven days or more, optionally twelve days or more, optionally thirteen days or more, or optionally fourteen days or more.

7. The sheet article of any of claims 1-3, wherein the opposing edge portion of the article is open such that at least one of the two or more channels, and optionally the two or more channels, is an open channel or are open channels.

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8. The sheet article of any of the preceding claims, wherein the at least one of the one or more seal portions does not define a channel.

9. The sheet article of any of the preceding claims, wherein the porous scrim is disposed within the two or more channels.

10. The sheet article of any of the preceding claims, wherein at least one edge portion is in the form of a flap without channels.

11. The sheet article of any of the preceding claims, wherein the first wall comprises one or more of poly(lactic acid), poly(glycolic acid) (which as used herein is intended to encompass both poly(glycolic acid) and poly(glycolide)), poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), or ulstra.

12. The sheet article of any of the preceding claims, wherein the first wall comprises one or more of poly(lactic acid), polylactide, poly(glycolic acid), polyglycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, or poly(ester amide), particularly poly(lactic acid), polylactide, poly(glycolic acid), poly glycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, or caprolactone, and most particularly poly(lactic acid).

13. The sheet article of any of the preceding claims, wherein the first wall comprises paper, and wherein the paper optionally comprises one or more of Kraft paper, bond paper, and crepe paper.

14. The sheet article of any of the preceding claims, wherein the first wall comprises a nonwoven.

15. The sheet article of any of the preceding claims, wherein the second wall comprises one or more of poly(lactic acid), poly(glycolic acid) (which as used herein is intended to encompass both poly(glycolic acid) and poly(glycolide)), poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), or cellulose.

16. The sheet article of any of the preceding claims, wherein the second wall comprises one or more of poly(lactic acid), polylactide, poly(glycolic acid), poly glycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, or poly(ester amide), particularly poly(lactic acid), polylactide, poly(glycolic acid), poly glycolide, poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, or caprolactone, and most particularly poly(lactic acid).

17. The sheet article of any of the preceding claims, wherein the second wall comprises paper, and wherein the paper optionally comprises one or more of Kraft paper, bond paper, and crepe paper.

18. The sheet article of any of the preceding claims, wherein the second wall comprises a nonwoven.

19. The sheet article of any of the preceding claims, wherein the basis weight of the first wall, in units of g/m², is be no less than 5, optionally no less than 10, optionally no less than 15, optionally no less than 20, optionally no less than 25, optionally no less than 30, optionally no less than 40, optionally no less than 45, optionally no less than 50, optionally no less than 55, optionally no less than 60, optionally no less than 65, or optionally no less than 70.

20. The sheet article of any of the preceding claims, wherein the basis weight of the first wall, in units of g/m², is no greater than 75, optionally no greater than 70, optionally no greater than 65, optionally no greater than 60, optionally no greater than 55, optionally no greater than 50, optionally no greater than 45, optionally no greater than 40, optionally no greater than 35, optionally no greater than 30, or optionally no greater than 25.

21. The sheet article of any of the preceding claims, wherein the basis weight of the first wall, in units of g/m², is 15 to 60, more particularly 20-50, and most particularly 25-45.

22. The sheet article of any of the preceding claims, wherein the basis weight of the second wall, in units of g/m², is be no less than 5, optionally no less than 10, optionally no less than 15, optionally no less than 20, optionally no less than 25, optionally no less than 30, optionally no less than 40, optionally no less than 45, optionally no less than 50, optionally no less than 55, optionally no less than 60, optionally no less than 65, or optionally no less than 70.

23. The sheet article of any of the preceding claims, wherein the basis weight of the second wall, in units of g/m², is no greater than 75, optionally no greater than 70, optionally no greater than 65, optionally no greater than 60, optionally no greater than 55, optionally no greater than 50, optionally no greater than 45, optionally no greater than 40, optionally no greater than 35, optionally no greater than 30, or optionally no greater than 25.

24. The sheet article of any of the preceding claims, wherein the basis weight of the second wall, in units of g/m², is 15 to 60, more particularly 20-50, and most particularly 25-45.

25. The sheet article of any of the preceding claims, wherein the first wall is a single layer.

26. The sheet article of any of the preceding claims, wherein the first wall is more than one layer.

27. The sheet article of any of the preceding claims, wherein the second wall is a single layer.

28. The sheet article of any of the preceding claims, wherein the second wall is more than one layer.

29. The sheet article of any of the preceding claims, wherein a sealable coating is disposed on the interior surface of the first wall, the interior surface of the second wall, or both.

30. The sheet article of any of the preceding claims, wherein a sealable coating is disposed on the exterior surface of the first wall, the exterior surface of the second wall, or both.

31. The sheet article of any of the preceding claims, wherein a sealable coating is disposed on the interior and exterior surfaces of the first wall.

32. The sheet article of any of the preceding claims, wherein a sealable coating is disposed on the interior and exterior surfaces of the second wall.

33. The sheet article of any of claims 29-32, wherein the sealable coating comprises one or more of poly(butylene succinate), poly (butylene succinate adipate), polyethylene succinate), poly(tetramethylene adipate-co-terephthalate), castor wax, thermoplastic starch, polylactide, poly(glycolic acid), polyglycolide, poly(caprolactone), poly(lactide-co-glycolide), or copolymers of two or more of lactic acid, glycolic acid, and caprolactone.

34. The sheet article of any of claims 29-32, wherein the sealable coating comprises poly (butylene succinate).

35. The sheet article of any of the preceding claims, wherein the porous scrim comprises one or more of paper, textile, or foam.

36. The sheet article of any of the preceding claims, wherein the porous scrim comprises one or more of tissue paper, paper towel, or crepe paper.

37. The sheet article of any of the preceding claims, wherein the porous scrim comprises a woven or knitted textile.

38. The sheet article of any of the preceding claims, wherein the porous scrim comprises one or more of cotton, linen, or wool.

39. The sheet article of any of the preceding claims, wherein the porous scrim comprises a fabric, the fabric optionally comprising jersey, flannel, batting, or gauze.

40. The sheet article of any of the preceding claims, wherein the porous scrim comprises a nonwoven, wherein the nonwoven optionally comprises fibers comprising one or more of poly(lactic acid), poly(glycolic acid), poly(caprolactone), poly(lactide-co-glycolide), copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradeable aliphatic -aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), and cellulose.

41. The sheet article of claim 40, wherein the nonwoven comprises poly(lactide) fibers.

42. The sheet article of any of claims 40-41, wherein the fibers are coated fibers.

43. The sheath article of claim 42, wherein the coating is a sheath.

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44. The sheet of article of any of the preceding claims, wherein the porous scrim comprises a foam.

45. The sheet article of claim 44, wherein the foam comprises an open cell foam, wherein the foam optionally has a basis weight of 120 g/m² or less, optionally 100 g/m² or less, optionally 75 g/m² or less, optionally 50 g/m² or less, or optionally 25 g/m² or less.

46. The sheet article of claim 44, wherein the foam comprises a closed cell foam, wherein the foam optionally has a basis weight of 120 g/m² or less, optionally 100 g/m² or less, optionally 75 g/m² or less, optionally 50 g/m² or less, or optionally 25 g/m² or less.

47. The sheet article of any of claims 42-45, wherein the foam is recyclable, compostable, or both compostable and recyclable.

48. The sheet article of any of the preceding claims, wherein the porous scrim has a coating on at least part of the porous scrim.

49. The sheet article of claim 48, wherein the porous scrim comprises fibers.

50. The sheet article of claim 49, wherein the fibers comprise a core and a coating in the form of a sheath on the fibers.

51. The sheet article of claim 48, wherein the porous scrim has a first side and an opposing second side and the coating is on at least the first side.

52. The sheet article of claim 51, wherein the coating is on the second side.

53. The sheet article of claim 48, wherein the coating comprises poly(butylene succinate), poly (butylene succinate adipate), poly(ethylene succinate), poly(tetramethylene adipate-co- terephthalate), castor wax, or thermoplastic starch, optionally wherein the coating comprises poly(butylene succinate), poly (butylene succinate adipate), polyethylene succinate), castor wax, or poly(tetramethylene adipate-co-terephthalate), further optionally wherein the coating comprises poly(butylene succinate) or castor wax, and still further optionally wherein the coating comprises poly(butylene succinate).

54. The sheet article of any of the preceding claims, wherein the three or more seals do not intersect with one another.

55. The sheet article of any of the preceding claims, comprising four or more, optionally five or more, optionally six or more, optionally seven or more, optionally eight or more seals that do not intersect with one another.

56. The sheet article of any of the preceding claims, wherein each of the three or more seals is a continuous seal.

57. The sheet article of any of the preceding claims, wherein at least one of the three or more seals is a discontinuous seal.

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58. The sheet article of any of the preceding claims, comprising three or more channels, optionally four or more channels, optionally five or more channels, optionally six or more channels, optionally seven or more channels.

59. The sheet article of any of the preceding claims, wherein the sheet article is recyclable.

60. The sheet article of any of the preceding claims, wherein the sheet article meets the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 1 (repulpability).

61. The sheet article of any of the preceding claims, wherein the sheet article meets the Voluntary Standard for Repulping and Recycling Corrugated Fiberboard as promulgated by the Fibre Box Association (FBA) part 2 (recyclability).

62. The sheet article of any of the preceding claims, wherein the sheet article meets the ISO 18601 standard.

63. The sheet article of any of the preceding claims, wherein the sheet article meets the ISO 18604:2013 standard.

64. The sheet article of any of the preceding claims, wherein the sheet article is compostable.

65. The sheet article of any of the preceding claims, wherein the sheet article meets the ASTM D6400 standard.

66. The sheet article of any of the preceding claims, wherein the sheet article meets the ASTM D6868 standard.

67. The sheet article of any of the preceding claims, wherein the sheet article meets at least one of the EN 12432 standard, the AS 4736 standard, or the ISO 17088 standard.

68. The sheet article of any of the preceding claims, wherein the sheet article meets the ISO 14855 standard.

69. A packaging article comprising a sheet article of any of the preceding claims folded into the form of a pouch or envelope having a cavity within the pouch or envelope.

70. A packaging construction comprising a sheet article of any of the preceding claims folded into a tube having a cavity within the tube.

71. A packaging article comprising an object disposed in the cavity of a packaging article of claim 69 or 70.

72. A packaging article comprising a box, pouch, envelope, or mailer, and particularly a box, comprising a sheet article of any of claims 1-68 within the box, pouch, or mailer, and particularly within the box.

73. A method of making a sheet article of any of claims 1-68, comprising disposing the porous scrim between the first and second walls and forming one or more seals that seal the first wall, second wall, and porous scrim at one or more seal portions, the step of forming one or more seals

- 30 - optionally comprising one or more of heat sealing, pressure sealing, adhesive sealing, impulse sealing, or ultrasonic welding.

74. A method of making a sheet article of any of claims 1-68, wherein the step of forming the three or more seals comprises heat sealing, pressure sealing, adhesive sealing, impulse sealing, or ultrasonic welding.

75. The method of any of claims 73-74, wherein the step of forming the three or more seals comprises ultrasonic welding.

76. The method of any of claims 73-75, wherein the method further comprises sealing at least one edge portion of the article, optionally by heat sealing, pressure sealing, adhesive sealing, or ultrasonic welding.

77. The method of any of claims 73-76, wherein the method further comprises folding a sheet to form an edge portion, a first wall, and a second wall, and placing a porous scrim between the first wall and the second wall.

78. The method of any of claims 73-77, wherein the method further comprises sealing all of the edge portions to seal the two or more channels and trap air within the two or more channels.

79. The method of any of claims 73-78, wherein the method further comprises coating the interior surface of the first wall, the interior surface of the second wall, or both, with a sealable coating.

80. The method of any of claims 73-79, comprising extruding the sealable coating onto the first wall, the second wall, or both the first and second walls.

81. The method of any of claims 73-80, comprising knife coating the sealable coating onto the first wall, the second wall, or both the first and second walls.

82. A method of making a sheet article of any of claims 1-68, the method comprising sealing, along one or more edge portions that define the boundaries of the unsealed article, a first wall of an unsealed sheet article, the first wall having a first interior surface and an opposing first exterior surface, a second wall of the unsealed sheet article, the second wall having a second interior surface facing the first interior surface, and and a porous scrim of the unsealed sheet article, the porous scrim being disposed between the first wall and the second wall; the unsealed article comprising the first wall, second wall, and porous scrim, wherein the first wall, second wall, and porous scrim are sealed together in three or more seals, each of the three or more seals running from at least one of the one or more edge portion to at least the sheet portion, and repeating pattern on the article

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83. The method of claim 82, wherein sealing step comprises sealing along two or more edge portions.

84. The method of claim 82 or 83, wherein the method comprises blowing air into at least one of the two or more channels before the sealing step.

85. The method of any of claims 82-84, wherein the method does not comprise blowing air into any of the two or more channels.

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