Packaging with Three-Dimensional Loop Material

Abstract

The present disclosure provides a packaging article. In an embodiment, the packaging article includes (A) a container having (i) a top wall and a bottom wall and (ii) a plurality sidewalls extending between the top wall and bottom wall. The walls define a compartment. The packaging article includes (B) an upper sheet in the compartment, the upper sheet composed of 3-dimensional random loop material (3DRLM). The upper sheet extends between and contacts two opposing sidewalls of the container. The packaging article includes (C) a lower sheet in the compartment, the lower sheet composed of 3DRLM. The lower sheet extends between and contacts two opposing sidewalls of the container. The two sheets are in opposing relation to each other. The packaging article includes (D) a product disposed between the upper sheet and the lower sheet.

Claims

1. A packaging article comprising: A. a container having (i) a top wall and a bottom wall; (ii) a plurality sidewalls extending between the top wall and bottom wall, the walls defining a compartment; B. an upper sheet in the compartment, the upper sheet composed of 3-dimensional random loop material (3DRLM), the upper sheet extending between and contacting two opposing sidewalls of the container; C. a lower sheet in the compartment, the lower sheet composed of 3DRLM, the lower sheet extending between and contacting two opposing sidewalls of the container, the two sheets in opposing relation to each other; and D. a product disposed between the upper sheet and the lower sheet.

2. The article of claim 1 wherein the container comprises four sidewalls; and at least one sheet extends between and contacts each of the four sidewalls.

3. The article of claim 1 wherein at least one of the first sheet and the second sheet move from a neutral state to a compressed state around the product, when the container is in a closed configuration.

4. The article of claim 3 wherein a portion of the first sleeve contacts a portion of the second sleeve when the container is in a closed configuration.

5. The article of claim 4 wherein 3DRLM from the first sheet and 3DRLM from the second sheet completely surrounds a perimeter of the product when the container is viewed from (i) a plan view and (ii) from a sectional view.

6. The article of claim 5 wherein the two sheets compressively hold the product in a stationary position in the container.

7. The article of claim 1 wherein at least one sheet comprises a cut-out portion, the cut-out portion configured to receive at least a portion the product.

8. The article of claim 1 wherein the product is a consumer electronics product.

9. The article of claim 1 wherein the product is a comestible.

10. A packaging article comprising: A. a container having (i) a top wall and a bottom wall; (ii) an optional sidewall extending between the top wall and the bottom wall, the walls defining a compartment with four corners; B. a first set of mated strips and a second set of mated strips in the compartment, each set comprising an upper strip and a lower strip, the upper strip and the lower strip in opposing relation to each other, each strip composed of 3-dimensional random loop material (3DRLM); C. each set extending between two opposing sides of the compartment, the sets spaced apart and in parallel relation to each other; and D. a product extending across the two sets, the product disposed between the upper strips and the lower strips.

11. The article of claim 10 wherein at least one strip moves from a neutral state to a compressed state around the product, when the container is in a closed configuration; and the sets compressively hold the product in a stationary position in the container.

12. The article of claim 11 wherein for each set a portion of the upper strip contacts a portion of the lower strip when the container is in the closed configuration.

13. The article of claim 10 wherein each strip comprises a cut-out portion for receiving the product.

14. The article of claim 10 wherein the product is a consumer electronics product.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] FIG. 1 is an exploded perspective view of a packaging article for a product in accordance with an embodiment of the present disclosure.

[0048] FIG. 2 is a sectional view taken along line 2-2 of FIG. 1 showing the packaging article of FIG. 1 in an open configuration.

[0049] FIG. 3 is a sectional view taken along line 2-2 of FIG. 1 showing the packaging article of FIG. 1 in a closed configuration.

[0050] FIG. 4 is an exploded perspective view of a packaging article for a product in accordance with an embodiment of the present disclosure.

[0051] FIG. 5 is an exploded perspective view of a packaging article, including a product, and a band element in accordance with an embodiment of the present disclosure.

[0052] FIG. 6 is a perspective view of the packaging article with the band element of FIG. 5.

[0053] FIG. 7 is an elevational view of the packaging article of FIG. 5 in an open configuration.

[0054] FIG. 8 is a sectional view taken along line 8-8 of FIG. 6 showing the packaging article of FIG. 6 in the closed configuration.

[0055] FIG. 9 is an exploded perspective view of a packaging article for a product in accordance with an embodiment of the present disclosure.

DETAILED DESCRIPTION

[0056] The present disclosure provides a packaging article. In an embodiment, the packaging article includes (A) a container having (i) a top wall and a bottom wall, and (ii) a plurality of sidewalls extending between the top wall and bottom wall, the walls defining a compartment. The packaging article includes (B) an upper sheet and (C) a lower sheet located in the compartment. Each sheet is composed of 3-dimensional random loop material (3DRLM). The upper sheet extends between and contacts two opposing sidewalls of the container. The lower sheet extends between and contacts two opposing sidewalls of the container. The upper sheet is in opposing relation to the lower sheet. The packaging article includes (D) a product disposed between the upper sheet and the lower sheet in the compartment.

1. Container

[0057] Referring to the drawings and initially to FIG. 1, a packaging article is indicated generally by the reference numeral 10. The packaging article 10 includes a container 12, an upper sheet 14, a lower sheet 16, and a product 18.

[0058] The container 12 includes a top wall 20, a bottom wall 22, and sidewalls 24 extending between the top wall and the bottom wall. The walls 20-24 form a compartment 26. The container 12 can have from, three, or four, to five, or six, or seven, or eight, or more sidewalls.

[0059] In an embodiment, the container 12 has four sidewalls 24 as shown in FIG. 1.

[0060] The top wall 20 and/or the bottom wall 22 may or may not be attached to one or more sidewalls. For example, the top wall 20 may be a discrete stand-alone component, that is placed on the sidewalls, forming a closed compartment (along with the bottom wall). In an embodiment, the top wall is attached by way of a hinge to one of the sidewalls (i.e., a fold between the top wall and the sidewall) as shown in FIGS. 1-4.

[0061] The top wall and/or the bottom wall 20, 22 may comprise one, two, or more flaps attached to respective one, two, or more sidewalls.

[0062] The container 12 and the format compartment 26 have a geometric shape. A geometric shape, as used herein, is a three dimensional shape or a three dimensional configuration having a length, a width, and a height. The geometric shape can be a regular three dimensional shape, an irregular three dimensional shape, and combinations thereof. Nonlimiting examples of regular three-dimensional shapes include cube, prism, sphere, cone, and cylinder. It is understood that when the geometric shape of the container is a prism, the prism can have a cross-sectional shape that is a regular polygon, or an irregular polygon having three, four, five, six, seven, eight, nine, 10 or more sides.

[0063] The top wall and/or the bottom 20, 22 wall may comprise one, two, or more flaps attached to respective one, two, or more sidewalls.

[0064] The container 12 can be openable from the top wall, the bottom wall, or a sidewall. In an embodiment, the container 12 is openable by way of the top wall.

[0065] The walls 20-24 are made of a rigid material. Nonlimiting examples of suitable material for the walls include cardboard, polymeric material, metal, wood, fiberglass, and any combination thereof. In an embodiment, container 12 has top/bottom walls and four sidewalls the walls 20-24 are made of a corrugated cardboard.

[0066] In an embodiment, the container 12 is a roll end lock front container or a RELF container. The RELF container may or may not include dust flaps.

[0067] The container 12 is openable and closable between an open configuration and a closed configuration. An open configuration is an arrangement of the walls which allows access to the compartment. A closed configuration is an arrangement of the walls preventing, or otherwise denying, access to the compartment. When the container 12 is in the closed configuration, the walls form a completely enclosed compartment. For example, FIG. 1 shows the container 12 in an open configuration with top wall retracted, permitting access to the compartment 26. FIG. 3 shows a cross-sectional view of container 12 in the closed configuration.

2. 3-Dimensional Random Loop Material

[0068] The packaging article 10 includes upper sheet 14 and lower sheet 16. Each sheet is composed of a 3-dimensional random loop material 30. A 3-dimensional random loop material (or 3DRLM) is a mass or a structure of a multitude of loops 32 formed by allowing continuous fibers 34, to wind, permitting respective loops to come in contact with one another in a molten state and to be heat-bonded at most of the contact points 36. Even when a great stress to cause significant deformation is given, the 3DRLM 30 absorbs the stress with the entire net structure composed of three-dimensional random loops melt-integrated, by deforming itself; and once the stress is lifted, elastic resilience of the polymer manifests itself to allow recovery to the original shape of the structure. When a net structure composed of continuous fibers made from a known non-elastic polymer is used as a cushioning material, plastic deformation is developed and the recovery cannot be achieved, thus resulting in poor heat-resisting durability. When the fibers are not melt-bonded at contact points, the shape cannot be retained and the structure does not integrally change its shape, with the result that a fatigue phenomenon occurs due to the concentration of stress, thus unbeneficially degrading durability and deformation resistance. In certain embodiments, melt-bonding is the state where all contact points are melt-bonded.

[0069] A nonlimiting method for producing 3DRLM 30 includes the steps of (a) heating a molten olefin-based polymer, at a temperature 10 C.140 C. higher than the melting point of the polymer in a typical melt-extruder; (b) discharging the molten interpolymer to the downward direction from a nozzle with plural orifices to form loops by allowing the fibers to fall naturally (due to gravity). The polymer may be used in combination with a thermoplastic elastomer, thermoplastic non-elastic polymer or a combination thereof. The distance between the nozzle surface and take-off conveyors installed on a cooling unit for solidifying the fibers, melt viscosity of the polymer, diameter of orifice and the amount to be discharged are the elements which decide loop diameter and fineness of the fibers. Loops are formed by holding and allowing the delivered molten fibers to reside between a pair of take-off conveyors (belts, or rollers) set on a cooling unit (the distance therebetween being adjustable), bringing the loops thus formed into contact with one another by adjusting the distance between the orifices to this end such that the loops in contact are heat-bonded as they form a three-dimensional random loop structure. Then, the continuous fibers, wherein contact points have been heat-bonded as the loops form a three-dimensional random loop structure, are continuously taken into a cooling unit for solidification to give a net structure. Thereafter, the structure is cut into a desired length and shape. The method is characterized in that the olefin-based polymer is melted and heated at a temperature 10 C.-140 C. higher than the melting point of the interpolymer and delivered to the downward direction in a molten state from a nozzle having plural orifices. When the polymer is discharged at a temperature less than 10 C. higher than the melting point, the fiber delivered becomes cool and less fluidic to result in insufficient heat-bonding of the contact points of fibers.

[0070] Properties, such as, the loop diameter and fineness of the fibers constituting the cushioning net structure provided herein depend on the distance between the nozzle surface and the take-off conveyor installed on a cooling unit for solidifying the interpolymer, melt viscosity of the interpolymer, diameter of orifice and the amount of the interpolymer to be delivered therefrom. For example, a decreased amount of the interpolymer to be delivered and a lower melt viscosity upon delivery result in smaller fineness of the fibers and smaller average loop diameter of the random loop. On the contrary, a shortened distance between the nozzle surface and the take-off conveyor installed on the cooling unit for solidifying the interpolymer results in a slightly greater fineness of the fiber and a greater average loop diameter of the random loop. These conditions in combination afford the desirable fineness of the continuous fibers of from 100 denier to 100000 denier and an average diameter of the random loop of not more than 100 mm, or from 1 millimeter (mm), or 2 mm, or 10 mm to 25 mm, or 50 mm. By adjusting the distance to the aforementioned conveyor, the thickness of the structure can be controlled while the heat-bonded net structure is in a molten state and a structure having a desirable thickness and flat surface formed by the conveyors can be obtained. Too great a conveyor speed results in failure to heat-bond the contact points, since cooling proceeds before the heat-bonding. On the other hand, too slow a speed can cause higher density resulting from excessively long dwelling of the molten material. In some embodiments the distance to the conveyor and the conveyor speed should be selected such that the desired apparent density of 0.005-0.1 g/cc or 0.01-0.05 g/cc can be achieved.

[0071] In an embodiment, the 3DRLM 30 has, one, some, or all of the properties (i)-(iii) below: [0072] (i) an apparent density from 0.016 g/cc, or 0.024 g/cc, or 0.032 g/cc to 0.040 g/cc, or 0.048 g/cc; and/or [0073] (ii) a fiber diameter from 0.1 mm, or 0.5 mm, or 0.7 mm, or 1.0 mm or 1.5 mm to 2.0 mm to 2.5 mm, or 3.0 mm; and/or [0074] (iii) a thickness (machine direction) from 1.0 cm, 2.0 cm, or 3.0, cm, or 4.0 cm, or 5.0 cm, or 10 cm, or 20 cm, to 50 cm, or 75 cm, or 100 cm, or more. It is understood that the thickness of the 3DRLM 30 will vary based on the type of product to be packaged.

[0075] The 3DRLM 30 is formed into a three dimensional geometric shape to form each sheet (i.e., a prism). The 3DRLM 30 is an elastic material which can be compressed and stretched and return to its original geometric shape. An elastic material, as used herein, is a rubber-like material that can be compressed and/or stretched and which expands/retracts very rapidly to approximately its original shape/length when the force exerting the compression and/or the stretching is released. The three dimensional random loop material 30 has a neutral state when no compressive force and no stretch force is imparted upon the 3DRLM 30. The three dimensional random loop material 30 has a compressed state when a compressive force is imparted upon the 3DRLM 30. The three dimensional random loop material 30 has a stretched state when a stretching force is imparted upon the 3DRLM 30. The sheets 14, 16 can be compressed (compressed state), be neutral (neutral state), and be stretched (stretched state) in a similar manner.

[0076] The three dimensional random loop material 30 is composed of one or more olefin-based polymers. The olefin-based polymer can be one or more ethylene-based polymers, one or more propylene-based polymers, and blends thereof.

[0077] In an embodiment, the ethylene-based polymer is an ethylene/-olefin polymer. Ethylene/-olefin polymer may be a random ethylene/-olefin polymer or an ethylene/-olefin multi-block polymer. The -olefin is a C.sub.3-C.sub.20 -olefin, or a C.sub.4-C.sub.12 -olefin, or a C.sub.4-C.sub.8 -olefin. Nonlimiting examples of suitable -olefin comonomer include propylene, butene, methyl-1-pentene, hexene, octene, decene, dodecene, tetradecene, hexadecene, octadecene, cyclohexyl-1-propene (allyl cyclohexane), vinyl cyclohexane, and combinations thereof.

[0078] In an embodiment, the ethylene-based polymer is a homogeneously branched random ethylene/-olefin copolymer.

[0079] Random copolymer is a copolymer wherein the at least two different monomers are arranged in a non-uniform order. The term random copolymer specifically excludes block copolymers. The term homogeneous ethylene polymer as used to describe ethylene polymers is used in the conventional sense in accordance with the original disclosure by Elston in U.S. Pat. No. 3,645,992, the disclosure of which is incorporated herein by reference, to refer to an ethylene polymer in which the comonomer is randomly distributed within a given polymer molecule and wherein substantially all of the polymer molecules have substantially the same ethylene to comonomer molar ratio. As defined herein, both substantially linear ethylene polymers and homogeneously branched linear ethylene are homogeneous ethylene polymers.

[0080] The homogeneously branched random ethylene/-olefin copolymer may be a random homogeneously branched linear ethylene/-olefin copolymer or a random homogeneously branched substantially linear ethylene/-olefin copolymer. The term substantially linear ethylene/-olefin copolymer means that the polymer backbone is substituted with from 0.01 long chain branches/1000 carbons to 3 long chain branches/1000 carbons, or from 0.01 long chain branches/1000 carbons to 1 long chain branches/1000 carbons, or from 0.05 long chain branches/1000 carbons to 1 long chain branches/1000 carbons. In contrast, the term linear ethylene/-olefin copolymer means that the polymer backbone has no long chain branching.

[0081] The homogeneously branched random ethylene/-olefin copolymers may have the same ethylene/-olefin comonomer ratio within all copolymer molecules. The homogeneity of the copolymers may be described by the SCBDI (Short Chain Branch Distribution Index) or CDBI (Composition Distribution Branch Index) and is defined as the weight percent of the polymer molecules having a comonomer content within 50 percent of the median total molar comonomer content. The CDBI of a polymer is readily calculated from data obtained from techniques known in the art, such as, for example, temperature rising elution fractionation (abbreviated herein as TREF) as described in U.S. Pat. No. 4,798,081 (Hazlitt et al.), or in U.S. Pat. No. 5,089,321 (Chum et al.) the disclosures of all of which are incorporated herein by reference. The SCBDI or CDBI for the homogeneously branched random ethylene/-olefin copolymers is preferably greater than about 30 percent, or greater than about 50 percent.

[0082] The homogeneously branched random ethylene/-olefin copolymer may include at least one ethylene comonomer and at least one C.sub.3-C.sub.20 -olefin, or at least one C.sub.4-C.sub.12 -olefin comonomer. For example and not by way of limitation, the C.sub.3-C.sub.20 -olefins may include but are not limited to propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, and 1-decene, or, in some embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene.

[0083] The homogeneously branched random ethylene/-olefin copolymer may have one, some, or all of the following properties (i)-(iii) below: [0084] (i) a melt index (1.sub.2) from 1 g/10 min, or 5 g/10 min, or 10 g/10 min, or 20 g/10 min to 30 g/10 min, or 40 g/10 min, or 50 g/10 min, and/or [0085] (ii) a density from 0.075 g/cc, or 0.880 g/cc, or 0.890 g/cc to 0.90 g/cc, or 0.91 g/cc, or 0.920 g/cc, or 0.925 g/cc; and/or [0086] (iii) a molecular weight distribution (Mw/Mn) from 2.0, or 2.5, or 3.0 to 3.5, or 4.0.

[0087] In an embodiment, the ethylene-based polymer is a heterogeneously branched random ethylene/-olefin copolymer.

[0088] The heterogeneously branched random ethylene/-olefin copolymers differ from the homogeneously branched random ethylene/-olefin copolymers primarily in their branching distribution. For example, heterogeneously branched random ethylene/-olefin copolymers have a distribution of branching, including a highly branched portion (similar to a very low density polyethylene), a medium branched portion (similar to a medium branched polyethylene) and an essentially linear portion (similar to linear homopolymer polyethylene).

[0089] Like the homogeneously branched random ethylene/-olefin copolymer, the heterogeneously branched random ethylene/-olefin copolymer may include at least one ethylene comonomer and at least one C.sub.3-C.sub.20 -olefin comonomer, or at least one C.sub.4-C.sub.12 -olefin comonomer. For example and not by way of limitation, the C.sub.3-C.sub.20 -olefins may include but are not limited to, propylene, isobutylene, 1-butene, 1-hexene, 4-methyl-1-pentene, 1-heptene, 1-octene, 1-nonene, and 1-decene, or, in some embodiments, 1-butene, 1-hexene, 4-methyl-1-pentene and 1-octene. In one embodiment, the heterogeneously branched ethylene/-olefin copolymer may comprise greater than about 50% by wt ethylene comonomer, or greater than about 60% by wt., or greater than about 70% by wt. Similarly, the heterogeneously branched ethylene/-olefin copolymer may comprise less than about 50% by wt -olefin monomer, or less than about 40% by wt., or less than about 30% by wt.

[0090] The heterogeneously branched random ethylene/-olefin copolymer may have one, some, or all of the following properties (i)-(iii) below: [0091] (i) a density from 0.900 g/cc, or 0.0910 g/cc, or 0.920 g/cc to 0.930 g/cc, or 0.094 g/cc; [0092] (ii) a melt index (I.sub.2) from 1 g/10 min, or 5 g/10 min, or 10 g/10 min, or 20 g/10 min to 30 g/10 min, or 40 g/10 min, or 50 g/10 min; and/or [0093] (iii) an Mw/Mn from 3.0, or 3.5 to 4.0, or 4.5.

[0094] In an embodiment, the 3DRLM 30 is composed of a blend of a homogeneously branched random ethylene/-olefin copolymer and a heterogeneously branched ethylene/-olefin copolymer, the blend having one, some, or all of the properties (i)-(v) below: [0095] (i) a Mw/Mn from 2.5, or 3.0 to 3.5, or 4.0, or 4.5; [0096] (ii) a melt index (I.sub.2) from 3.0 g/10 min, or 4.0 g/10 min, or 5.0 g/10 min, or 10 g/10 min to 15 g/10 min, or 20 g/10 min, or 25 g/10 min; [0097] (iii) a density from 0.895 g/cc, or 0.900 g/cc, or 0.910 g/cc, or 0.915 g/cc to 0.920 g/cc, or 0.925 g/cc; and or [0098] (iv) an I.sub.10/I.sub.2 ratio from 5 g/10 min, or 7 g/10 min to 10 g/10 min, or 15 g/10 min; and/or [0099] (v) a percent crystallinity from 25%, or 30%, or 35%, or 40% to 45%, or 50%, or 55%.

[0100] According to Crystallization Elution Fractionation (CEF), the ethylene/-olefin copolymer blend may have a weight fraction in a temperature zone from 90 C. to 115 C. or about 5% to about 15% by wt., or about 6% to about 12%, or about 8% to about 12%, or greater than about 8%, or greater than about 9%. Additionally, as detailed below, the copolymer blend may have a Comonomer Distribution Constant (CDC) of at least about 100, or at least about 110.

[0101] The present ethylene/-olefin copolymer blend may have at least two, or three melting peaks when measured using Differential Scanning calorimetry (DSC) below a temperature of 130 C. In one or more embodiments, the ethylene/-olefin copolymer blend may include a highest temperature melting peak of at least 115 C., or at least 120 C., or from about 120 C. to about 125 C., or from about from 122 to about 124 C. Without being bound by theory, the heterogeneously branched ethylene/-olefin copolymer is characterized by two melting peaks, and the homogeneously branched ethylene/-olefin copolymer is characterized by one melting peak, thus making up the three melting peaks.

[0102] Additionally, the ethylene/-olefin copolymer blend may comprise from about 10 to about 90% by weight, or about 30 to about 70% by weight, or about 40 to about 60% by weight of the homogeneously branched ethylene/-olefin copolymer. Similarly, the ethylene/-olefin copolymer blend may comprise from about 10 to about 90% by weight, about 30 to about 70% by weight, or about 40 to about 60% by weight of the heterogeneously branched ethylene/-olefin copolymer. In a specific embodiment, the ethylene/-olefin copolymer blend may comprise from about 50% to about 60% by weight of the homogeneously branched ethylene/-olefin copolymer, and 40% to about 50% of the heterogeneously branched ethylene/-olefin copolymer.

[0103] Moreover, the strength of the ethylene/-olefin copolymer blend may be characterized by one or more of the following metrics. One such metric is elastic recovery. Here, the ethylene/-olefin copolymer blend has an elastic recovery, Re, in percent at 100 percent strain at 1 cycle of between 50-80%. Additional details regarding elastic recovery are provided in U.S. Pat. No. 7,803,728, which is incorporated by reference herein in its entirety.

[0104] The ethylene/-olefin copolymer blend may also be characterized by its storage modulus. In some embodiments, the ethylene/-olefin copolymer blend may have a ratio of storage modulus at 25 C., G (25 C.) to storage modulus at 100 C., G (100 C.) of about 20 to about 60, or from about 20 to about 50, or about 30 to about 50, or about 30 to about 40.

[0105] Moreover, the ethylene/-olefin copolymer blend may also be characterized by a bending stiffness of at least about 1.15 Nmm at 6 s, or at least about 1.20 Nmm at 6 s, or at least about 1.25 Nmm at 6 s, or at least about 1.35 Nmm at 6 s. Without being bound by theory, it is believed that these stiffness values demonstrate how the ethylene/-olefin copolymer blend will provide cushioning support when incorporated into 3DRLM fibers bonded to form a cushioning net structure.

[0106] In an embodiment, the ethylene-based polymer is an ethylene/-olefin interpolymer composition having one, some, or all of the following properties (i)-(v) below: [0107] (i) a highest DSC temperature melting peak from 90.0 C. to 115.0 C.; and/or [0108] (ii) a zero shear viscosity ratio (ZSVR) from 1.40 to 2.10; and/or [0109] (iii) a density in the range of from 0.860 to 0.925 g/cc; and/or [0110] (iv) a melt index (I.sub.2) from 1 g/10 min to 25 g/10 min; and/or [0111] (v) a molecular weight distribution (Mw/Mn) in the range of from 2.0 to 4.5.

[0112] In an embodiment, the ethylene-based polymer contains a functionalized commoner such as an ester. The functionalized comonomer can be an acetate commoner or an acrylate comonomer. Nonlimiting examples of suitable ethylene-based polymer with functionalized comonomer include ethylene vinyl acetate (EVA), ethylene methyl acrylate EMA, ethylene ethyl acrylate (EEA), and any combination thereof.

[0113] In an embodiment, the olefin-based polymer is a propylene-based polymer. The propylene-based polymer can be a propylene homopolymer or a propylene/-olefin polymer. The -olefin is a C.sub.2 -olefin (ethylene) or a C.sub.4-C.sub.12 -olefin, or a C.sub.4-C.sub.8 -olefin. Nonlimiting examples of suitable -olefin comonomer include ethylene, butene, methyl-1-pentene, hexene, octene, decene, dodecene, tetradecene, hexadecene, octadecene, cyclohexyl-1-propene (allyl cyclohexane), vinyl cyclohexane, and combinations thereof.

[0114] In an embodiment, the propylene interpolymer includes from 82 wt % to 99 wt % units derived from propylene and from 18 wt % to 1 wt % units derived from ethylene, having one, some, or all of the properties (i)-(vi) below: [0115] (i) a density of from 0.840 g/cc, or 0.850 g/cc to 0.900 g/cc; and/or [0116] (ii) a highest DSC melting peak temperature from 50.0 C. to 120.0 C.; and/or [0117] (iii) a melt flow rate (MFR) from 1 g/10 min, or 2 g/10 min to 50 g/10 min, or 100 g/10 min; and/or [0118] (iv) a Mw/Mn of less than 4; and/or [0119] (v) a percent crystallinity in the range of from 0.5% to 45%; and/or [0120] (vi) a DSC crystallization onset temperature, Tc-Onset, of less than 85 C.

[0121] In an embodiment, the olefin-based polymer used in the manufacture of the 3DRLM 14 contains one or more optional additives. Nonlimiting examples of suitable additives include stabilizer, antimicrobial agent, antifungal agent, antioxidant, processing aid, ultraviolet (UV) stabilizer, slip additive, antiblocking agent, color pigment or dyes, antistatic agent, filler, flame retardant, and any combination thereof.

3. Sheets

[0122] The packaging article 10 includes upper sheet 14 and lower sheet 16. Each sheet 14, 16, is made of 3DRLM 30. The composition, and/or the size, and/or the shape of each sheet 14, 16 may be the same or different. In an embodiment, the composition, the size, and the shape of upper sheet 14 is the same as, or substantially the same as, the composition, size, and shape of the lower sheet 16. In a further embodiment, each sheet 14, 16 has the same shape that is a prism.

[0123] The upper sheet 14 extends between and contacts at least two opposing sidewalls of the container 12. The lower sheet 16 extends between and contacts at least two opposing sidewalls of the container 12. Upper sheet 14 is in opposing relation to lower sheet 16.

[0124] In an embodiment, each sheet 14, 16 is sized and shaped to friction fit against opposing sidewalls when placed in the compartment 26. In a further embodiment, each sheet 14,16 is removable from the container. Each sheet 14,16 is thereby reusable and/or recyclable.

4. Product

[0125] The packaging article 10 includes the product 18. A product, as used herein, is a tangible object with a mass of at least one gram and having three dimensionsnamely, a length, a width, and a height. Nonlimiting examples of suitable products include consumer electronics products, household goods, medical products, comestibles, and any combination thereof.

[0126] Nonlimiting examples of suitable consumer electronics products include computer disk drives, computer input and output (I/O) devices, such as a keyboard, a mouse; speakers; and video display/monitor; computer; laptop computer; tablet computer; cellphone; smartphone; camera; handheld computing device; television; audio device; computer printer; 3-D printer; wearable technology; drone; virtual reality equipment; video game equipment; media device; accessories such as power cord and power pack; and any combination thereof.

[0127] Nonlimiting examples of suitable household goods include cutlery, glassware, glass picture frames, dishware, small appliances (hair dryer, microwave oven, toaster, food processing device, blender), light bulbs, hardware such as screwdrivers and hammers, and decorative items such as candle holders or vases, and any combination thereof.

[0128] Nonlimiting examples of suitable medical products include vials, ampules, syringes, intravenous (IV) bags, medical devices used in surgical suites including trocars, forceps, clamps, retractors, endoscopes, staplers, specula, drills, and any combination thereof.

[0129] Nonlimiting examples of suitable comestibles include produce such as fruit and vegetables. Nonlimiting examples of suitable fruit and vegetables include apple; apricot; artichoke; asparagus; avocado; banana; beans; beets; bell peppers; blackberries; blueberries; bok choy; boniato; boysenberries; broccoli; Brussel sprouts; cabbage; cantaloupe; carambola; carrots; cauliflower; celery; chayote; cherimoya; cherries; citrus; clementines; collard greens; coconuts; corn; cranberries; cucumber; dates; dragon fruits; durian; eggplant; endive; escarole; feijoa; fennel; figs; garlic; gooseberries; grapefruit; grapes; green beans; green onions; greens (turnip, beet, collard, mustard); guava; horminy; honeydew melon; horned melon; lettuce (iceberg, leaf and romaine); jackfruit; jicama; kale, kiwifruit; kohirabi; kumquat; leeks; lemons; lettuce; lima beans; limes; longan; loquat; lychee; mandarins; malanga; mandarin oranges; mangos; mangosteen; mulberries; mushrooms; mustard greens; napa; nectarines; okra; onion; oranges; papayas; parsnip; passion fruit; peaches; pears; peas; peppers (bellred, yellow, green, chili); persimmons; pineapple; plantains; plums; pomegranate; potatoes; prickly pear; prunes; pummel; pumpkin; quince; radicchio; radishes; raisins; rambutan; raspberries; red cabbage; rhubarb; romaine lettuce; rutabaga; shallots; snap peas; snow peas; spinach; sprouts; squash (acorn, banana, buttercup, butternut, hubbard, summer); strawberries; starfruit; string beans; stone fruits; sweet potato; tamarind; tomatoes, tangelo; tangerines; tomatilio; tomato; turnip; ugli fruit; water chestnuts; waxed beans; yams; yellow squash; yucca/cassava; zucchini; and any combination thereof.

[0130] The product 18 is disposed between the upper sheet 14 and the lower sheet 16. A bottom surface of the upper sheet 14 contacts the product 18 and a top surface of the lower sheet 16 contacts the product 18.

[0131] In an embodiment, the container 12 has four sidewalls as shown in FIG. 1. At least one of the sheets 14, 16 extends between and contacts each of the four sidewalls. In a further embodiment, each sheet 14, 16 extends between and contacts each of the four sidewalls. The sheets 14, 16 are sized and shaped to fit, or friction fit, within the compartment 26, the 3DRLM of each sheet in contact with the inner surface of each sidewall. The product 18 is located between, or otherwise sandwiched by, upper sheet 14 and lower sheet 16.

[0132] Collectively, the sheets 14, 16 have a perimeter that is greater than the perimeter of the product 18 when viewed both (i) from plan view and (ii) when viewed from sectional view. FIG. 1 shows that sheets 14, 16 each have a perimeter greater than the perimeter of the product 18 from top plan view. In this way, the sheets provide a border of 3DRLM protective cushion around the product providing cushioning and protection from vertical shock of the product 18 in the container 12.

[0133] In an embodiment, FIG. 2 shows the container 12 in an open configuration and the sheets 14, 16, each in the neutral state, each sheet having a height, N. The product 18 is disposed between the sheets 14, 16 (hereafter referred to as the sheet-product-sheet sandwich or SPS sandwich), the SPS sandwich having a height H1 that is greater than the depth D of the compartment 26. When the container 12 is moved from the open configuration in FIG. 2 to the closed configuration in FIG. 3, the walls of the container impart a compressive force upon the sheets 14, 16. The SPS sandwich is compressed to a height, H2 equal to, or substantially equal to, the depth D of the compartment 26. Height H1 (open configuration) is greater than height H2 (closed configuration). One (or both) sheets 14, 16 move from the neutral state (N) to a compressed state, C when the container is moved from the open configuration (FIG. 2) to the closed configuration (FIG. 3). In the closed configuration of FIG. 3, the elastic nature of the 3DRLM 30 enables one (or both) sheets 14, 16 contort under the compression force of the walls, the 3DRLM 30 of the sheet(s), intimately conforming around the product 18. In other words, the sheets 14, 16 form a reciprocal shape of the product, when the container 12 is in the closed configuration.

[0134] In the closed configuration, the opposing relation of the sheets 14, 16 compressively holds the product 18 in a stationary position within the container 12. The fibers 34 of sheet 14 contact, or otherwise touch, the fibers 34 of the sheet 16. The 3DRLM 30 of sheets 14, 16 surround, and contact substantially every surface, or contact every surface, of the product 18. The product 18 is completely surrounded, or fully engulfed, in protective 3DRLM 30 such that the product 18 is immobilized within the 3DRLM 30 and within the container 12. In the closed configuration, the compressed sheet(s) 14, 16 provide both vertical and lateral support to the product 18, (i) preventing the product 18 from moving up and down, and (ii) preventing the product 18 from moving side to side within the container, when a lateral shock load, or other shock is imparted to the packaging article, for example. The 3DRLM 30 of sheets 14, 16 prevents the product 18 from hitting the sidewalls (and the top/bottom walls) when the container is subject to a lateral shock load, or other force.

[0135] FIG. 3 further shows sheets 14, 16 collectively also have a perimeter greater than the perimeter of the product 18 along a cross-sectional view. In this way, the sheets 14, 16 hold the product 18 stationary, or otherwise hold the product 18 firmly in place, in the compartment 26. The sheets prevent lateral, longitudinal, and/or vertical movement of the product within the container 12. The polymeric material of the 3DRLM also contributes to impart frictional force, or a holding force upon the product 18 within the container 12.

[0136] In an embodiment, the packaging article 10 includes product 18 that is a laptop computer and an accessory 40 as shown in FIGS. 1-3. The accessory is located in the compartment 26 along with the product 18. The 3DRLM 30 of sheet 14 and/or sheet 16 compresses upon the accessory 40 to immobilize the accessory 40 within the container 12. In a further embodiment, the size, and/or shape, and/or dimension of one or both sheets 14, 16 is/are adjusted to accommodate the size, and/or shape of the accessory 40 within the compartment 26.

5. Cut-Out

[0137] FIG. 4 shows another embodiment of the packaging article. In this embodiment, one or both of upper sheet/lower sheet 14a, 16a includes a respective cut-out portion. A cut-out is a shape formed into the 3DRLM of a sheet, the shape creating a void in the 3DRLM, the shaped-void pre-determined and adapted to receive at least a portion of, or all of, the product. The size and shape of the shaped-void is adapted to the size and shape of the product to be packaged. The cut-out may be formed in a molding process, a cutting procedure, and combinations thereof. The cut-out is present when the 3DRLM is in the neutral state, the cut-out portion being distinct from the compressed state and/or the stretched state of the 3DRLM 30. In this sense, the cut-out is a void shape that is reciprocal in shape to the positive space and shape (or a portion of the positive space and shape) occupied by the product 18.

[0138] One or both sheets 14a, 16a can have a cut-out. Although FIG. 4 shows lower sheet 16a having a cut-out 50, it is understood that upper sheet 14a may also have a cut-out, alone, or in combination with the cut-out 50.

[0139] In an embodiment, the product 18 is a laptop computer, having a rectangular prism shape. In FIG. 4, the lower sheet 16a has a cut-out 50 that is the void of a rectangular prism, the cut-out 50 a void-shape sized and shaped to receive the product 18a rectangular prism. The cut-out 50 is sized and configured to receive, or otherwise accommodate, the entire product 18. The upper sheet 14a is placed over lower sheet 16a, and over the cut-out 50 so that the 3DRLM 30 of the two sheets 14a, 16a fully encompasses, or otherwise fully surrounds, the product 18. The 3DRLM fibers 34 of upper sheet 14a contact, or otherwise touch, the fibers 34 of the lower sheet 16a. In this way, the two sheets 14a, 16a provide a protective border around the entire outer surface of the product. In other words, the sheets 14a, 16a collectively completely surround the product with 3DRLM because the perimeter of collective sheets 14a, 16a is (i) greater than the perimeter of the product from plan view and (ii) greater than the perimeter of the product from sectional view.

[0140] In an embodiment, the cut-out is sized and shaped to receive the product 18 (such as a laptop computer, for example) and the cut-out is also sized and shaped to receive an accessory (such as a cord and/or a power pack, for example).

[0141] In an embodiment, one or both sheets 14a, 16a include a cut-out and the product is a comestible, such as a fruit or a vegetable, for example. The void-shape of the cut-out is adapted to receive a portion of, or all of, the comestible. In other words, the void-shape of the cut-out is reciprocal to (or substantially reciprocal to) the positive space and shape occupied by the comestible.

6. Sets of Strips

[0142] FIGS. 5-9 show other embodiments of the present packaging article. In an embodiment, another packaging article 110 is provided. The packaging article 110 includes (A) a container 112, (B) a first set 114 of strips and a second set 116 of strips, and (C) a product 118. The container 112 includes (i) a top wall 120 and a bottom wall 122, and an optional sidewall 124 extending between the top wall and the bottom wall. The walls define a compartment 126.

[0143] In an embodiment, the top wall 120 and the bottom wall 122 each is attached by way of a hinge to the sidewall 124 (i.e., folds between the sidewall and each of the top wall and the bottom wall). Alternatively, the top wall 120 is detached from the bottom wall 122.

[0144] Each set 114, 116 includes a respective pair of mated strips. FIG. 5 shows set 114 having strip 115a and strip 115b. Set 116 includes strip 117a and strip 117b. For each set 114, 116, an upper strip (115a, 117a) contacts, or is otherwise attached to, to the top wall 120. For each set 114, 116, lower strip (115b, 117b) contacts, or is otherwise attached to, the bottom wall 122. In each set 114, 116, the strips are mated whereby the strips are in opposing relation to each other. FIGS. 7-8 show strip 115a (117a) in contact with the top wall, strip 115a (117a) opposing strip 115b (117b) and strip 115b (117b) being in contact with the bottom wall 122. In each set, the strips are sized, shaped and positioned to be mirror images of each other in the compartment 126. In an embodiment, strip 115a (117a) has the same, or substantially the same, size and shape of strip 115b (117b). Each strip 115a, 115b, 117a, 117b is made of the 3DRLM 130 as disclosed above.

[0145] The walls 120, 122, 124 define compartment 126 corners I, J, K, L. Each set of strips 114, 116 extends between two opposing corners of the compartment 126. Set 114 extends between corner I and opposing corner J. Set 116 extends between corner K and opposing corner L. Set 114 is spaced apart from set 116. Set 114 is parallel to, or substantially parallel to, set 116. In other words, the sets 114, 116 are in parallel relation to each other in a spaced-apart manner.

[0146] The product 118 is supported by the sets, the product 118 extending from set 114 to set 116. The product is sandwiched between upper strips 115a, 117a and lower strips 115b, 117b. In FIG. 8, the container 112 is placed into a closed configuration and one, some, or all of the strips 115a, 115b, 117a, 117b move from the neutral state to a compressed state and conform around, and to the shape of, the product 118. In this way, the strips 115a, 115b, compressively hold the product 118 in a stationary position (vertically, horizontally, and laterally) within the compartment 126.

[0147] In an embodiment, the packaging article 110 includes a third set 128 of strips. The set 128 includes mated strips 129a, 129b, each made of the 3DRLM 130. The set 128 is located between set 114 and set 116 in a spaced-apart manner, with space between set 114 and set 128, and space between set 128 and set 116. Set 128 is parallel to set 114 and set 128 is parallel to set 116. The strips 129a, 129b are mated as discussed above with respect to strips 115a, 115b and 117a, 117b.

[0148] FIG. 6 illustrates an embodiment wherein a band element 140 maintains the container 112 in the closed configuration. Nonlimiting examples of a suitable band element include a sleeve, rope, twine, string, cable, belt, adhesive tape, stretch film, shrink film, and any combination thereof. In a further embodiment, the container 112 is a sub-container that is placed within a larger container 160. In a further embodiment, the band element 140 is a sleeve composed of a polymeric material the sleeve surrounding the container 112 as shown in FIG. 6.

[0149] FIG. 9 shows another embodiment of the packaging article 110. In this embodiment, one, some, or all of the strips include a respective cut-out portion 150a-f.

[0150] In an embodiment, the product 118 is a laptop computer, with a rectangular prism shape. In FIG. 9, strips 115a, 115b, 117a, 117b, and 129a, 129b each have a respective cut-out portion 150a, 150b, 150c, 150d, 150e, 150f shaped to receive a portion of the rectangular prism shape of the product 118, the laptop computer.

[0151] For sets 114, 116, the cut-out includes ends 152a, 152b, 152c, 152d. The ends 152a-d prevent lateral movement of the product 118 within the container 112 as previously disclosed herein. The strips 115a, 115b, 117a, 117b, 129a, and 129b prevent vertical movement, prevent horizontal movement, and prevent lateral movement of the product 118 within the container 112 as previously disclosed herein.

[0152] In an embodiment, the packaging article 110 includes an accessory. The accessory may be located in the void space in the compartment 126 that is present between the spaced-apart strips. Alternatively, some or all of the accessory is sandwiched between opposing strips of one or more sets, along with the sandwiching of the product. In a further embodiment, one or more cut-outs 150a-150f are sized and/or shaped to receive the accessory.

[0153] It is specifically intended that the present disclosure not be limited to the embodiments and illustrations contained herein, but include modified forms of those embodiments including portions of the embodiments and combinations of elements of different embodiments as come with the scope of the following claims.