+

WO2022144579A1 - Emballage polymère injecté pour un produit sensible ou fragile et procédé associé - Google Patents

Emballage polymère injecté pour un produit sensible ou fragile et procédé associé Download PDF

Info

Publication number
WO2022144579A1
WO2022144579A1 PCT/IB2020/062592 IB2020062592W WO2022144579A1 WO 2022144579 A1 WO2022144579 A1 WO 2022144579A1 IB 2020062592 W IB2020062592 W IB 2020062592W WO 2022144579 A1 WO2022144579 A1 WO 2022144579A1
Authority
WO
WIPO (PCT)
Prior art keywords
polymeric
rigid structure
injected
resilient material
previous
Prior art date
Application number
PCT/IB2020/062592
Other languages
English (en)
Inventor
António José VILELA PONTES
Álvaro Miguel DO CÉU GRAMAXO OLIVEIRA SAMPAIO
André Manuel CARDOSO LIMA
Cátia Samanta RIBEIRO DA SILVA
Original Assignee
Universidade Do Minho
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Universidade Do Minho filed Critical Universidade Do Minho
Publication of WO2022144579A1 publication Critical patent/WO2022144579A1/fr

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D15/00—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials
    • B65D15/22—Containers having bodies formed by interconnecting or uniting two or more rigid, or substantially rigid, sections made of different materials of polygonal cross-section
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1635—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould cavities
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1635—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould cavities
    • B29C45/1639—Removable partitions between adjacent mould cavity portions
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Rigid or semi-rigid containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material or by deep-drawing operations performed on sheet material
    • B65D1/34—Trays or like shallow containers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/022—Containers made of shock-absorbing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1635—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould cavities
    • B29C2045/1637—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould cavities the first injected part and the movable mould part being movable together

Definitions

  • the present disclosure relates to a customizable packaging, based in a single structure, for the protection during the storage and transport of sensitive and fragile products and items, such as, for example, electronic systems, medical devices or perishable goods.
  • the storage and transport of products is always a challenge, especially when the product or item to stow and transport is sensitive and fragile.
  • the transport of products or items may occur in various situations. For instance, the transport may occur at the facilities of a company, between workstations, during the several stages of product production. In another situation, transport may be referent to shipping to distant locations.
  • polystyrene foam is somewhat rigid, relatively brittle, and thus has a minimum of structural flexibility.
  • mechanical degradation occurs with wear, hampering its performance for daily use applications, as for example, within a factory plant.
  • the use of carton dividers and packages presents the same problems of long-term durability by continuous daily use, and have little effectiveness in absorbing shocks caused by vibrations during transport.
  • polystyrene or other plastic foam stacking supports do not typically compactly nest together and thus storage of these supports usually takes up a considerable space.
  • trays Another commonly used solution for stowing and carrying fragile and sensitive products and items consists in trays.
  • the materials used in the manufacture of trays include carton (U.S. Pat. No. 2, 893,621), metal (U.S. Pat. No. 2,456,481) and several plastic materials (U.S. Pat. No. 3,843,009; U.S. Pat. No. 3,409,199; U.S. Pat. No. 6,186,328).
  • Trays can take many forms and may be used to carry a single product or item (U.S. Pat. No. 5,127,526) or multiple products or items simultaneously (U.S. Pat. No. 4,932,532).
  • trays are usually designed to carry a specific product or item, thus having a particular design which perfectly fits the product or items shape, providing this way, maximum cushioning. Examples of such specific trays have been used to carry elongated fragile fluorescent tubes (U.S. Pat. No. 4,932,532) and carry cylindrical fluid containers (U.S. Pat. No. 5,267,649).
  • packing trays usually have an array of cell pockets that are commonly used to package fragile objects to enable, not only transport, but also their safe storage and display. This solution is often used in fruit transport between long distances from where the fruit is harvested, to where it will be consumed.
  • Example patents of such packing trays include U.S. Pat. No. 3,049,259 of a dispatch tray for fruit and U.S. Pat. No. 4,298,156 for cushioning eggs. These types of trays are developed and used specifically with a particular fragile item to be transported. Items with different size and shape would need a different tray design.
  • An alternative possibility to the nestable and stackable specific trays consists in the use of a soft material that assures energy absorption from shocks and vibrations simultaneous to providing cushioning and protection to the fragile items.
  • soft materials include flexible foams made of polyurethane or other polymeric based materials. These materials are already employed in packing applications.
  • U.S. Pat. No. 4,851,286A is disclosed a cushioning element of a polymeric foam material for placement between an impacting surface and a surface of an object to be cushioned against damage caused by impact during transport or storage.
  • U.S. Pat. No. 2003/0102244 Al discloses a shipping and storage container for laptop computers, which includes an inner protective base insert and an inner protective cover insert, both inserts being fabricated from a protective foam material.
  • foams can be easily modified to present other important specific properties.
  • foams can be made electrostatic dissipative by adequate formulation (U.S. Pat. No. 2004/0259966 Al and U.S. Pat. No. 2015/0274924 Al) and used in the transport of devices that are sensitive to electric discharges.
  • applications for static dissipative flexible foams include U.S. Pat. No. 5,273,158A that discloses a package fabricated from flexible polyurethane foam for the storing and the transportation of small electronic components (e.g. capacitors, resistors, diodes, transistors).
  • the majority of the flexible foams presented can release foam particles, which could lead to the contamination of sensitive items. This matter could be avoided by resourcing to integral skin foams.
  • the integral skin foam consists of a low-density foamed core surrounded by a high-density skin of the same material.
  • thermoformed trays, custom foams are developed to present design features for cushioning specific products being quite advantageous in the perfect fit of a product, allowing the preservation of its shape and components while avoiding hampering its functionality.
  • this type of solution approach is too specific in regarding to one or few products and consequently, leads to large quantities of waste and increase cost.
  • the present disclosure relates to a customizable packaging solution, namely a tray, based in a stackable single structure, for the storage and transport of sensitive and fragile products and items (e.g. radio frequency identification systems, lenses, led, capacitors, among others).
  • the single structure packaging is based on a rigid structure formed by first polymeric rigid structure and a second polymeric rigid structure; and a resilient material, where the single structure contacts with the products to stow and transport.
  • the solution disclosed herein enables varying design features and combine materials as intended, to best correspond to the product and item to stow and transport and is based in a simpler and cost-efficient approach.
  • the single structure customizable packaging solution can be manufactured by means of injection moulding technology and/or variants (e.g. reaction injection moulding), with a single mould tool.
  • the mould tool presents a custom main structure and moulding inserts that shape the polymeric rigid structures and the resilient material, for example a soft layer(s), preferably selected from a list consisting of polymeric foams based in polyurethane (PU), polyethylene (PE), or polystyrene (PS) or mixtures thereof that compose the single structure packaging.
  • PU polyurethane
  • PE polyethylene
  • PS polystyrene
  • the moulding inserts are easily changed providing variable design possibilities and geometrical configurations, for both the rigid structures (i.e. first polymeric rigid structure and second polymeric rigid structure) and also the resilient material.
  • the moulding tool presents movements or movement ability. This means that, after a first injection step of the injection moulding process, that shapes the rigid structure, the mould changes the position of the moulding inserts by moving them within the mould structure, creating this way, space for a new injection step.
  • the new injection step enables the shaping of the resilient material and the obtaining of the single structure packaging in a single production process and, with a single moulding tool.
  • the injected polymeric packaging comprises a first polymeric rigid structure, for example a sidewall, preferably four sidewalls, designed to enable a comfortable handling and an easy stacking.
  • a second polymeric rigid structure for example a reinforcing structure layer, similar to a bottom, that may be positioned at different heights of the sidewalls, depending on the application purpose and requirements.
  • the first polymeric rigid structure and the second polymeric rigid structure provide structural stability and adequacy for sustaining the weight of the products or items to stow and carry, while allowing stacking over another single structure packaging.
  • the polymeric rigid structures may be manufactured with thermoplastic materials by conventional injection moulding or, with integral skin rigid foams by reaction injection moulding, as intended.
  • the foam material of the first polymeric rigid structure and the second polymeric rigid structure are preferably selected from a list consisting of polymeric foams based in polyurethane (PU), polyethylene (PE), or polystyrene (PS) or mixtures thereof.
  • PU polyurethane
  • PE polyethylene
  • PS polystyrene
  • the resilient material for example a soft layer, like a foam
  • this element of the single structure customizable packaging solution covers the first polymeric rigid structure and second polymeric rigid structure, at the area where there is contact with the items or products to be stowed namely, at the second polymeric rigid structure.
  • the resilient material may be defined and produced only for the top part of the second polymeric rigid structure.
  • resilient material may be defined and manufactured on both top and bottom of the second polymeric rigid structure to assure a secure and safe cushioning while avoiding unwanted movements of the products or items.
  • the resilient material may be built with flexible integral skin foams.
  • Integral skin flexible foams present a harder skin and softer core which enables the combination between a soft and flexible performance suitable for cushioning, while the harder skin avoids foam particles release and maintains product quality and resistance to wear and abrasion for longer periods.
  • Other type of soft and flexible materials may also be used (e.g. elastomers), if intended.
  • integral skin rigid foams may be employed.
  • the resilient material is also obtained by injection moulding.
  • reaction injection moulding is the manufacturing technique, as foams require a particular equipment for the combining of components (e.g. polyol, isocyanate, additives).
  • the single structure packaging is manufactured based in the injection moulding technique and by using a single mould structure with movements.
  • thermoplastic materials may be combined, in a single product, with foamy materials, or, in another hypothesis, only foamy materials may be used.
  • the versatility regarding the use of polymers is that various materials are available and with a wide range of properties (e.g. mechanical, thermal, electrical) that, with adequate selection, assure the suitable performance to best correspond to the application requirements.
  • polymeric materials allow the addition of, for example, additives and fillers during the manufacturing process, which allows to change the material properties as intended.
  • the present disclosure presents a series of improvements in comparison to what is already known and available.
  • the invention consists in a customizable packaging solution, based in a single structure, that provides both rigidity and softness, as intended, enabling structural adequacy and flexibility to safely stow and transport sensitive and fragile products or items, without requiring additional elements or components.
  • Customized performance and personalized fitting, for variable typologies and configurations of fragile and sensitive products and items, is achieved by material combinations and design configurations that are assured by a versatile moulding process and changeable moulding inserts of a single moulding tool.
  • the changeability of mould inserts and the movement ability of the mould enables and facilitates the generation of various single structure customized packaging solutions in a short-time frame.
  • the simplicity of the single structure packaging solution improves handling by the user, while also reducing time to perform stow and transport activities.
  • the solution is also lightweight due to the reduction of the number of components to a single one, and also, by the integration of foamy materials.
  • the resource to integral skin foams also provides a solution with longer service life, while avoiding contamination and damaging by possible particles' release, in comparison to common foam-based packaging solutions.
  • With the single structure customizable packaging solution it becomes unnecessary to employ tote boxes, lids, trays and custom components to provide a safe stow. This invention also improves logistics by reducing the total number of packaging required which leads to a diminishing of the allocated storage areas.
  • the single structure customizable packaging solution consists of a simple, single structure, lightweight, versatile, low-cost, and short-time to market solution suitable for stow and transport activities, for sensitive and fragile products and items.
  • An aspect of the present disclosure relates to an injected polymeric packaging for a sensitive or fragile product comprising at least two different polymeric materials, wherein at least one of the materials is resilient material selected from a list of: a foam, an elastomeric material, or combinations thereof, wherein the resilient material is configured to be in contact with the product; a first polymeric rigid structure for supporting the resilient material; wherein the first polymeric rigid structure covers the side of the resilient material; wherein the first polymeric rigid structure is bound to the resilient material by interlock or chemical bounding; a second polymeric rigid structure for support the resilient material, wherein said second polymeric rigid structure layer is connected to the first polymeric rigid structure, wherein said second polymeric rigid structure is placed in the bottom, in the top or in the interior of the first polymeric rigid structure (i.e. in the interior of the sidewall of the first polymeric rigid structure).
  • the second polymeric rigid structure comprises the resilient material on an upper surface or on a lower surface of said second polymeric structure.
  • the first polymeric rigid structure and the second polymeric rigid structure is in the same material.
  • the resilient material is a foam, preferably a soft foam.
  • the resilient material may be selected from a list consisting of polyurethane, polyethylene, or polystyrene or mixtures thereof. [0034] In an embodiment, the resilient material is an integral skin flexible foam.
  • first polymeric rigid structure and the second polymeric structure are thermoplastic.
  • the first polymeric rigid structure and the second polymeric structure are a rigid foam.
  • the rigid foam is an integral skin rigid foam.
  • the first polymeric rigid structure extends upwardly from the second polymeric rigid structure.
  • the first polymeric rigid structure is a sidewall being a single-wall or double-wall or multi-wall.
  • the first polymeric rigid structure comprises an upper rim at the end.
  • the upper rim comprises a smooth surface or a surface with protrusions.
  • the second polymeric rigid structure comprise cavities, convoluted shapes or gridded structures.
  • the resilient material comprises a smooth or a convoluted shape surface.
  • the convoluted shapes are cylindrical, conical, pyramidal, oval, cubic or their combinations.
  • the injected polymeric packaging further comprises a grip section on the sidewalls.
  • the injected polymeric packaging further comprises at least two handles on the sidewalls.
  • Another aspect of the disclosure comprises a method to produce an injected polymeric packaging for a sensitive or fragile product comprising the steps of: a first injection of a material into a closed mould that comprises a plurality of exchangeable inserts for the production of a first and a second polymeric rigid structure; moving the moulding exchangeable inserts within the mould to create a cavity on the material first injected, by the movement of the exchangeable inserts; a further injection of a resilient material into the cavity in order to bound said resilient material to the first and second polymeric rigid structure; demoulding and curing.
  • the first injection material is a thermoplastic material or a rigid foam.
  • the resilient material injected to the cavity is an elastomer or a foam.
  • the plurality of exchangeable inserts of the mould are manufactured by conventional subtractive manufacturing processes or additive manufacturing processes.
  • the packaging solution may be based on a single structure that is customizable in terms of materials and design and may be composed by a readily stackable polymeric rigid structures and soft layer(s).
  • the packaging solution may be manufactured with a single moulding tool that may comprise movements and changeable moulding inserts.
  • the packaging solution may be manufactured by conventional injection moulding or variant(s), or other processing approaches, if intended.
  • the packaging solution may be a single structure for the safe stow and transport of sensitive and fragile products and items, being also suitable for other typologies of products and systems.
  • first polymeric rigid structure and the second polymeric rigid structure may provide structural stability and adequacy for sustaining the weight of the products and items to stow and carry.
  • first polymeric rigid structure and the second polymeric rigid structure may comprise, four sidewalls connected by an upper rim and round edges in each corner.
  • first polymeric rigid structure and the second polymeric rigid structure may be manufactured with thermoplastic materials or integral skin rigid foams, or other materials, if intended.
  • first polymeric rigid structure and the second polymeric rigid structure may be manufactured based in conventional injection moulding or reaction injection moulding or others, if intended.
  • the resilient material may provide a safe cushioning by directly contacting with the products to stow and transport.
  • the soft layer(s) may be manufactured above or below or, if intended, on both sides of the reinforcing structure that the rigid structure comprises.
  • the packaging solution may be a single where the customizable characteristic regarding design may be achieved by resourcing to variable and versatile design configuration to best address particular needs of the item or product to stow and carry.
  • the packaging solution may be based in a single structure where the variable and versatile design configuration, for the first and second polymeric rigid structures, includes solutions based in handling by gripped surfaces or by the inclusion of handles, single-wall to multi-walled sidewalls, smooth surfaces or with features (e.g. protrusions, cavities) to facilitate stacking or improve structural performance, amongst other design possibilities.
  • the packaging solution may be based in a single structure wherein the variable and versatile design for the resilient material may be a smooth surface or convoluted shapes (e.g. cylindrical, conical, pyramid, oval, cubic) and may present variable features across the surface of a single soft layer, or variable configurations between bottom and top soft layer(s), amongst other possibilities.
  • the variable and versatile design for the resilient material may be a smooth surface or convoluted shapes (e.g. cylindrical, conical, pyramid, oval, cubic) and may present variable features across the surface of a single soft layer, or variable configurations between bottom and top soft layer(s), amongst other possibilities.
  • the packaging solution may be a single structure, wherein the variable and versatile design configuration may include dimensions' variations (e.g. height, width, radius, opening angles) of both polymeric rigid structures and resilient material (i.e. soft layers).
  • the packaging solution may be a single wherein the customizable characteristic is achieved by altering the moulding inserts, as intended.
  • the packaging solution may be a single structure wherein the customizable characteristic regarding material may be achieved by resourcing variable materials selected based in specific material properties and for the application purpose or by compounding and functionalization activities during the manufacturing activity to achieve a particular property value range (e.g. hardness, electrical conductivity).
  • a particular property value range e.g. hardness, electrical conductivity
  • the packaging solution may be a single structure which may be lightweight by reducing the total number of components to a single one, and by using lightweight materials with low density, as for example, foamy materials.
  • the packaging solution may be single structure with the possibility of embedding systems (e.g. piezoelectric sensors, radiofrequency identification systems) during the manufacturing process, in order to add functionality and thus produce a smart single structure customizable packaging solution.
  • embedding systems e.g. piezoelectric sensors, radiofrequency identification systems
  • These systems may be located in the first polymeric rigid structure, in the second polymeric rigid structure or in the resistive material, or in their combinations.
  • Figure 1 Schematic representation of an embodiment of the package, which is a top perspective view of a possible design configuration for the single structure customizable packaging design.
  • Figure 2 Schematic representation of an embodiment of the package, which is a partial cross-sectional view, through the length sidewalls for a possible design configuration of the single structure customizable packaging.
  • Figure 3 Schematic representation of an embodiment of the package consisting of a diagram representing the main steps of the manufacturing process possibilities for the production of a single structure customizable packaging.
  • the present disclosure relates to a packaging solution, based in a customizable single structure, for the safe storage and transportation of sensitive and fragile products and items such as printed circuit boards, integrated circuits, medical devices or perishable goods among other.
  • the single structure packaging disclosed herein is customizable in terms of materials and design, assuring therefore, a versatile protection and cushioning for a multiplicity of delicate products and items.
  • the single structure, manufactured by a single process may be simply described as a readily stackable rigid structure and a layer of a resilient material or layers, where the sensitive and fragile products and items are to be placed.
  • the present disclosure is a single structure customizable packaging solution that is lightweight, stackable, and provides a versatile cushioning assuring protection during storage and transport activities, for sensitive and fragile products and items.
  • Three figures were defined to depict design possibilities for the single structure customizable packaging solution and also, to present processing approaches based in the building materials.
  • Figure 1 in which is depicted a perspective top view of a possible design configuration for the single structure customizable packaging, it is possible to visualize the composing elements.
  • Figure 2 is presented a partial cross-section view of a possible design configuration for the present disclosure.
  • the single structure customizable packaging solution comprehends a rigid structure (1) that comprises a second polymeric rigid structure (2) and a first polymeric rigid structure (3), for example four walls, connected by an upper rim (4) and, with round edges (5) in each corner.
  • Resilient material (6) may be present above or below the second polymeric structure (2). If intended, the resilient material (6) may be manufactured on both sides of the second polymeric structure (2).
  • the single structure customizable packaging solution is manufactured by injection moulding technique and variant(s).
  • a mould structure is necessary to shape the part to inject.
  • the rigid structure (1) and the resilient material (6) are necessary for such manufacturing process. The movements allow that, after a first injection process, a new cavity space is formed to enable a second injection step.
  • the rigid structure (1) including the second polymeric rigid structure (2), four sidewalls as example of first polymeric rigid structure (3) , an upper rim (4) and the round edges (5), may be manufactured with a thermoplastic material by means of conventional injection moulding or, by integral skin rigid foam by means of reaction injection moulding.
  • the manufacturing of the rigid structure (1) is correspondent to the first injection step, after which, the movement is activated and the moulding inserts are readjusted within the mould structure to create a new cavity. In this cavity, by a second injection step, it if formed the resilient material (6), entirely composed by an integral skin flexible foam.
  • the resilient material may also be formed with other building materials, if intended. Elastomeric materials as flexible building material alternatives are feasible.
  • foams without integral skin may be employed.
  • foams without integral skin will hamper the main purpose of this disclosure by releasing foam particles which may contaminate and damage the products or items, while rigid foams should only be employed in specific cases, if building cavities specific for a particular item, or in cases in which the item or product is not fragile to mechanical efforts.
  • the design configuration of the first polymeric rigid structure and the second polymeric rigid structure that form the rigid structure (1) and the resilient material (6) is variable and versatile to best address particular needs of a sensitive and fragile item or product.
  • This design flexibility is assured by the use of a mould with moulding inserts that are easily changed.
  • Moulding inserts may be manufactured by, for example, conventional subtractive manufacturing processes or additive manufacturing processes. The variety of available manufacturing processes greatly improves the versatility and speed of manufacturing and changing mould inserts.
  • Each sidewall (3) may be composed by double-walls interconnected by a plurality of structural vertical ribs that protrude from the upper rim (4). Variants from the presented design configurations are feasible. The easy handling may be achieved by grip sections defined across the surface of the sidewalls (3).
  • the upper rim (4) corresponds to the available area that enables an easy stacking.
  • the surface of the upper rim (4) may be smooth or present features (e.g. protrusions, cavities) to facilitate stacking.
  • Other design configurations are possible.
  • the second polymeric rigid structure (2) may be placed at variable heights in relation to the first polymeric rigid structure (3) in order to best suit particular requirements and facilitate the stacking and cushioning in specific situations, while making the best use of the available space, to provide an easy and adequate stow for a multitude of fragile and sensitive products and items. Cavities, convoluted shapes, gridded structures, amongst other design configurations may be defined for the second polymeric rigid structure (2), as intended.
  • the surface design configuration for the resilient material (6) is also variable, as intended. From a smooth surface to convoluted shapes (e.g. cylindrical, conical, pyramid, oval or cubic), the design configuration may be varied between single structure customizable packaging solutions, while also may vary across a single layer(s) of resilient material (6) surface or between a top layer of resilient material (6.1) and bottom layer of resilient material (6.2). Configurations are free based in the purpose and by changing the moulding inserts.
  • the dimensions (e.g. height, width, radius, opening angles) of the described elements composing the single structure customizable packaging solution may vary in accordance to the need. Materials are also variable as needed based in specific material properties and the application purpose. Compounding and functionalization activities may occur, if needed, during the manufacturing activity in order to achieve a particular property value range (e.g. hardness, electrical conductivity).
  • a particular property value range e.g. hardness, electrical conductivity.
  • the second polymeric rigid structure (2) provides support and a connection area for an improved attachment with the resilient material (6).
  • the configuration for the positioning of the second polymeric rigid structure (2) is merely an example, as it may vary in position based in the available height of the sidewalls (3).
  • double-walled sidewalls (3) are presented, also as an example of the first polymeric rigid structure.
  • Figure 1 and Figure 2 related to the design of the single structure customizable packaging design are free to be personalized as intended.
  • Figure 3 depicts a diagram of an embodiment which represents the main steps of the manufacturing process for the production of the single structure customizable packaging solution.
  • the flowchart is divided in two, in order to describe in parallel, the case where the rigid structure is built with a thermoplastic material (left schematic flowchart) and, when it is built with an integral skin rigid foam (right schematic flowchart).
  • the first approach resources to conventional injection moulding and reaction injection moulding to obtain a product combining thermoplastic and integral skin flexible foam materials.
  • the second manufacturing approach resorts to solely reaction injection moulding to fabricate a single structure customizable packaging solution entirely based in integral skin foamy materials with varied densities, rigid for the rigid structure, and flexible for the soft layer(s). For both approaches, a single mould with movements is sufficient.
  • the mould inserts are easily changeable to generate variable features and configurations, for both the second polymeric rigid structure and resilient material. Also, the movements within the mould structure allow the generation of new space, enabling multiple injection steps. For both approaches, a single injection machine is sufficient. The only requirement is related to the need for at least two barrels (for material mixing, homogenization and injection), one per type of material to inject. [0085] Focusing on the flowchart of the left, now explaining with more detail, the production process begins when the mould tool closes and generates an empty space, named cavity.
  • the injection step occurs, in which, molten thermoplastic material such as polypropylene (PP), acrylonitrile butadiene styrene (ABS) or polycarbonate (PC) inside the barrel is forced, under pressure, into the moulding cavity. Inside the moulding cavity, the molten thermoplastic material cools under pressure to acquire the cavity shape. Once dimensional stability is achieved by cooling, the mould movement is activated, the moulding inserts change position, and a new cavity space is generated. Then, a new injection step occurs.
  • molten thermoplastic material such as polypropylene (PP), acrylonitrile butadiene styrene (ABS) or polycarbonate (PC) inside the barrel is forced, under pressure, into the moulding cavity.
  • ABS acrylonitrile butadiene styrene
  • PC polycarbonate
  • the components that compose the integral skin flexible foam preferably a foam selected from polyurethane (PU); polyethylene (PE) or polystyrene (PS) or mixtures thereof, mixed previously to the injection step, are injected under pressure into the newly generated mould cavity.
  • PU polyurethane
  • PE polyethylene
  • PS polystyrene
  • the typical reaction steps and phenomena associated to foam production e.g. cream time, gel time, gas generation.
  • foams are being used, a cure time must be accounted, in a controlled environment. Typically, 24 hours are suitable however, this time may change depending on the foam material.
  • the process similarly begins with the mould closing. Once the mould is closed and the cavity is generated, the injection of the mixed components that will result in an integral skin rigid foam are injected under pressure. Inside the mould cavity occurs a reaction between the components and corresponding typical foaming phenomena. Once foamy consistency is achieved for the rigid structure, the mould movement is activated and a new cavity space is generated. A similar injection step occurs, this time with integral skin flexible foam components, previously mixed in the barrel of the reaction injection moulding machine. Once the injection step for the soft layer(s) is completed, a new sequence of foaming stages and phenomena occurs. Once achieved the consistency enough that assures an easy removal without damaging, the ejection of the foamy-based single structure customizable packaging solution occurs.
  • the present disclosure provides a safe, simple and comfortable packaging solution based in a single structure that is customizable in terms of material type (e.g. thermoplastic and foamy materials), material properties (e.g. electrical properties, hardness, biodegradable), and design configuration (e.g. handles, dimensions, features) to best fit the requirements related to the application purpose.
  • the single structure customizable packaging solution corresponds to a product which consists of a unique structure.
  • the unique structure is composed by a rigid structure of a first polymeric rigid structure and a second polymeric rigid structure, and resilient material which are produced in a single mould with movements and changeable moulding inserts, by means of injection based moulding processes. When ejected from the mould, the product is complete and independent, meaning that it does not require additional components or steps (e.g. assembly operations) to perform its purpose.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Buffer Packaging (AREA)

Abstract

La présente invention concerne un emballage polymère injecté pour un produit sensible ou fragile et un procédé associé. L'emballage polymère injecté pour un produit sensible ou fragile comprend au moins deux matériaux polymères différents, au moins l'un des matériaux étant un matériau élastique choisi parmi une liste comprenant : une mousse, un matériau élastomère et des combinaisons de ceux-ci, le matériau élastique étant configuré pour être en contact avec le produit ; une première structure rigide polymère pour supporter le matériau élastique ; la première structure rigide polymère couvrant le côté du matériau élastique ; la première structure rigide polymère étant liée au matériau élastique par interverrouillage ou liaison chimique ; une seconde structure rigide polymère pour supporter le matériau élastique, ladite seconde structure rigide polymère étant reliée à la première structure rigide polymère, ladite seconde structure rigide polymère étant placée au fond, en haut ou à l'intérieur de la première structure rigide polymère.
PCT/IB2020/062592 2020-12-30 2020-12-31 Emballage polymère injecté pour un produit sensible ou fragile et procédé associé WO2022144579A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
PT116983 2020-12-30
PT11698320 2020-12-30

Publications (1)

Publication Number Publication Date
WO2022144579A1 true WO2022144579A1 (fr) 2022-07-07

Family

ID=82258691

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/IB2020/062592 WO2022144579A1 (fr) 2020-12-30 2020-12-31 Emballage polymère injecté pour un produit sensible ou fragile et procédé associé

Country Status (1)

Country Link
WO (1) WO2022144579A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2025141327A1 (fr) 2023-12-29 2025-07-03 Universidade Do Minho Récipient à cils viscoélastiques pour l'emballage de produits

Citations (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2456481A (en) 1946-04-25 1948-12-14 Ballantyne William Gammell Rigid lightweight metal tray
US2893621A (en) 1955-05-25 1959-07-07 Crown Zellerbach Corp Nestable berry tray
US3049259A (en) 1960-06-29 1962-08-14 Mazzi Angelo Cupped tray for holding fruits and the like
US3270913A (en) 1964-10-05 1966-09-06 Phillips Petroleum Co Nestable and stackable container
US3272371A (en) 1965-03-12 1966-09-13 Chase Instr Corp Tube tray
US3409199A (en) 1966-09-29 1968-11-05 Mobil Oil Corp Packaging tray
US3520769A (en) 1968-04-09 1970-07-14 Pacific Foam Packaging Packaging material and method of making same
US3638827A (en) 1969-06-12 1972-02-01 T O Plastics Inc Nestable tray
US3843009A (en) 1973-06-25 1974-10-22 R Emery Shallow packing tray
US4093070A (en) 1977-03-09 1978-06-06 Pinckney Molded Plastics, Inc. Stacking and nesting container
US4298156A (en) 1980-06-20 1981-11-03 Diamond International Corporation Nestable and denestable molded egg cartons
US4803031A (en) * 1982-06-03 1989-02-07 Anchor Hocking Corporation Method and apparatus for molding a closure cap
US4851286A (en) 1986-11-18 1989-07-25 United Foam Plastics Foamed plastic cushioning materials
US4932532A (en) 1988-11-15 1990-06-12 Rehrig-Pacific Company, Inc. Reusable stackable tray for cans
US5127526A (en) 1991-07-01 1992-07-07 Keyes Fibre Company Package for fragile articles
US5132329A (en) 1990-04-05 1992-07-21 Basf Corporation Integral skin polyurethane foam
US5236960A (en) 1992-06-22 1993-08-17 Basf Corporation Water-blown polyurethane integral skin foam
US5267649A (en) 1988-11-15 1993-12-07 Rehrig Pacific Co., Inc. Nestable tray for cylindrical containers
US5273158A (en) 1992-11-20 1993-12-28 Nolan John B Package for storing and transporting electronic components
US5449698A (en) 1991-09-26 1995-09-12 Toyoda Gosei Co., Ltd. Method and apparatus for producing integral skin polyurethane foam
DE19638239A1 (de) * 1996-09-19 1998-03-26 Linpac Technologie Gmbh Schale zur Aufnahme von Flüssigkeit absondernden Nahrungs- und Genußmitteln
US5816409A (en) 1992-08-06 1998-10-06 Moulded Fibre Technology, Inc. Molded pulp fiber interior package cushioning structures
US6186328B1 (en) 1997-03-31 2001-02-13 Rehrig Pacific Company Nestable can tray with contoured wall structure
US20030102244A1 (en) 1997-04-18 2003-06-05 Sanders C. W. Shipping and storage container for laptop computers
US20040031711A1 (en) 2002-04-09 2004-02-19 O'malley Joseph Bottle cradle stacking support
US6820743B2 (en) 1996-02-27 2004-11-23 Richard D. Hurley Shipping protector for bottles or the like
US20040259966A1 (en) 2003-06-20 2004-12-23 Foamex L.P. Static dissipative polyurethane foams
US20050210665A1 (en) * 2004-03-25 2005-09-29 Nigg James R Tray for storing and transporting semi-conductor and other microelectronic components
EP1582328A1 (fr) * 2002-11-11 2005-10-05 Sunstar Giken Kabushiki Kaisha Procede et dispositif de moulage de produit gonflant
US7207458B1 (en) 1999-07-02 2007-04-24 Rehrig Pacific Company Low-depth nestable tray for fluid containers
WO2009123226A1 (fr) * 2008-04-03 2009-10-08 日本写真印刷株式会社 Moule pour un moulage par injection et procédé de fabrication d'une résine moulée à l'aide de ce moule
US7922001B2 (en) 2006-10-10 2011-04-12 Rehrig Pacific Company Stackable and nestable tray
EP2319675A1 (fr) * 2009-11-06 2011-05-11 Cryovac, Inc. Procédé de fabrication d'un ensemble récipient et ensemble récipient
US20120111238A1 (en) * 2010-11-09 2012-05-10 Jason Frankenberg Rigid Urethane Self-Skinning Foam Top Frame, Pallet Support Board, and Pallet
US20150000231A1 (en) 2013-06-26 2015-01-01 Tekni-Plex, Inc. Packing tray having cell pockets with expandable sidewalls and floating base, and method of manufacture
US20150274924A1 (en) 2014-04-01 2015-10-01 Council Of Scientific & Industrial Research Electrostatic dissipative foams and process for the preparation thereof

Patent Citations (36)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2456481A (en) 1946-04-25 1948-12-14 Ballantyne William Gammell Rigid lightweight metal tray
US2893621A (en) 1955-05-25 1959-07-07 Crown Zellerbach Corp Nestable berry tray
US3049259A (en) 1960-06-29 1962-08-14 Mazzi Angelo Cupped tray for holding fruits and the like
US3270913A (en) 1964-10-05 1966-09-06 Phillips Petroleum Co Nestable and stackable container
US3272371A (en) 1965-03-12 1966-09-13 Chase Instr Corp Tube tray
US3409199A (en) 1966-09-29 1968-11-05 Mobil Oil Corp Packaging tray
US3520769A (en) 1968-04-09 1970-07-14 Pacific Foam Packaging Packaging material and method of making same
US3638827A (en) 1969-06-12 1972-02-01 T O Plastics Inc Nestable tray
US3843009A (en) 1973-06-25 1974-10-22 R Emery Shallow packing tray
US4093070A (en) 1977-03-09 1978-06-06 Pinckney Molded Plastics, Inc. Stacking and nesting container
US4298156A (en) 1980-06-20 1981-11-03 Diamond International Corporation Nestable and denestable molded egg cartons
US4803031A (en) * 1982-06-03 1989-02-07 Anchor Hocking Corporation Method and apparatus for molding a closure cap
US4851286A (en) 1986-11-18 1989-07-25 United Foam Plastics Foamed plastic cushioning materials
US4932532A (en) 1988-11-15 1990-06-12 Rehrig-Pacific Company, Inc. Reusable stackable tray for cans
US5267649A (en) 1988-11-15 1993-12-07 Rehrig Pacific Co., Inc. Nestable tray for cylindrical containers
US5132329A (en) 1990-04-05 1992-07-21 Basf Corporation Integral skin polyurethane foam
US5127526A (en) 1991-07-01 1992-07-07 Keyes Fibre Company Package for fragile articles
US5449698A (en) 1991-09-26 1995-09-12 Toyoda Gosei Co., Ltd. Method and apparatus for producing integral skin polyurethane foam
US5236960A (en) 1992-06-22 1993-08-17 Basf Corporation Water-blown polyurethane integral skin foam
US5816409A (en) 1992-08-06 1998-10-06 Moulded Fibre Technology, Inc. Molded pulp fiber interior package cushioning structures
US5273158A (en) 1992-11-20 1993-12-28 Nolan John B Package for storing and transporting electronic components
US6820743B2 (en) 1996-02-27 2004-11-23 Richard D. Hurley Shipping protector for bottles or the like
DE19638239A1 (de) * 1996-09-19 1998-03-26 Linpac Technologie Gmbh Schale zur Aufnahme von Flüssigkeit absondernden Nahrungs- und Genußmitteln
US6186328B1 (en) 1997-03-31 2001-02-13 Rehrig Pacific Company Nestable can tray with contoured wall structure
US20030102244A1 (en) 1997-04-18 2003-06-05 Sanders C. W. Shipping and storage container for laptop computers
US7207458B1 (en) 1999-07-02 2007-04-24 Rehrig Pacific Company Low-depth nestable tray for fluid containers
US20040031711A1 (en) 2002-04-09 2004-02-19 O'malley Joseph Bottle cradle stacking support
EP1582328A1 (fr) * 2002-11-11 2005-10-05 Sunstar Giken Kabushiki Kaisha Procede et dispositif de moulage de produit gonflant
US20040259966A1 (en) 2003-06-20 2004-12-23 Foamex L.P. Static dissipative polyurethane foams
US20050210665A1 (en) * 2004-03-25 2005-09-29 Nigg James R Tray for storing and transporting semi-conductor and other microelectronic components
US7922001B2 (en) 2006-10-10 2011-04-12 Rehrig Pacific Company Stackable and nestable tray
WO2009123226A1 (fr) * 2008-04-03 2009-10-08 日本写真印刷株式会社 Moule pour un moulage par injection et procédé de fabrication d'une résine moulée à l'aide de ce moule
EP2319675A1 (fr) * 2009-11-06 2011-05-11 Cryovac, Inc. Procédé de fabrication d'un ensemble récipient et ensemble récipient
US20120111238A1 (en) * 2010-11-09 2012-05-10 Jason Frankenberg Rigid Urethane Self-Skinning Foam Top Frame, Pallet Support Board, and Pallet
US20150000231A1 (en) 2013-06-26 2015-01-01 Tekni-Plex, Inc. Packing tray having cell pockets with expandable sidewalls and floating base, and method of manufacture
US20150274924A1 (en) 2014-04-01 2015-10-01 Council Of Scientific & Industrial Research Electrostatic dissipative foams and process for the preparation thereof

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2025141327A1 (fr) 2023-12-29 2025-07-03 Universidade Do Minho Récipient à cils viscoélastiques pour l'emballage de produits

Similar Documents

Publication Publication Date Title
US8999415B2 (en) Tri-fold egg carton for jumbo eggs
US20080302691A1 (en) Bottle shipping system with multipurpose insert
US10351287B2 (en) Method for using a package insert for cushioning an object
CA2404860C (fr) Structure d'amortissement de produit unitaire
US10472164B2 (en) Tri-fold egg carton for various size jumbo eggs
US6193090B1 (en) Reusable container
US9580223B2 (en) Product cushioning device for packaging shock sensitive products
GB2032886A (en) Packing Trays
CN102700064A (zh) 一种塑胶产品成型模具及其使用方法、液晶玻璃包装盒
WO2022144579A1 (fr) Emballage polymère injecté pour un produit sensible ou fragile et procédé associé
US5779055A (en) Protective package for delicate items
EP1551726B1 (fr) Piece rapportee d'emballage absorbant les chocs
US20180155079A1 (en) Egg carton with diagonal lid panel
US11051485B2 (en) Stackable and pallet-transportable cheese log forming and holding tray
WO2012058676A2 (fr) Emballage d'expédition pour substrats
GB2472434A (en) Packaging material for protecting articles
KR101134298B1 (ko) 과일 포장용 수지트레이
JP7465117B2 (ja) 集合包装容器
JP6691413B2 (ja) 集合包装容器及びその積層体
CN212048722U (zh) 一种晶圆包装盒保护装置
JP3181309U (ja) 果実用トレー
JP6652100B2 (ja) 果菜類輸送容器
JP2010070196A (ja) 機械部品用梱包資材
JP2000191051A (ja) 中仕切り緩衝材及びその製造方法
JP2008247434A (ja) 梱包箱

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 20845628

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 20845628

Country of ref document: EP

Kind code of ref document: A1

点击 这是indexloc提供的php浏览器服务，不要输入任何密码和下载