Expanded Polypropylene for Package Protection

Packaging material that can be compactly shipped and then expanded on demand to provide cushioning for fragile items during shipping. The packaging material is made by consolidating a web of overlaid plies with interior cavities filled with unexpanded expansion material. The material is shipped in this dense, compact configuration. To expand the material for cushioning, conditions like heat or mixing are applied to the expansion material to cause it to expand and fill the cavities. This provides cushioning for the enclosed items. The expansion material can be expandable foams, gels, or other materials that can be expanded when activated.

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Packaging material that expands in size after shipping to provide cushioning. The material is consolidated into a high-density configuration for shipping. It contains expansion material that expands when conditions like heat or pressure are applied. This allows the material to be compactly stored and shipped, then expanded on-demand to cushion items during transport. The expansion material is sandwiched between layers of the packaging web. An expansion device can initiate expansion.

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Multi-layered pressure packaging with improved drop resistance, impact resistance, weight, stiffness, and environmental impact compared to traditional packaging. The packaging has a stretch blow molded container with a foam layer enclosing the body and bottom. The foam is formed in place by injecting foamable material between the molded container and an outer enclosure. This provides a sandwich structure with the foam layer sandwiched between the container and outer enclosure. A second layer can be applied over the foam to hold it together with the container. This reduces weight, provides improved stiffness and strength, and improved drop and impact resistance compared to just molding the container from foam. The foam layer can also have a polymer layer inside the container for chemical resistance to the filling material.

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Manufacturing packing material that provides sufficient cushioning effects at an affordable cost. The packing material includes a plurality of discrete cushioning elements and a flexible linkage connecting the discrete cushioning elements in the packing material.

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Protective packaging device for preventing damage to products during storage, shipping, and handling. The device is designed to provide comprehensive protection without the need for multiple types of packaging. It can be used for products of all sizes and shapes. The protective packaging device combines features like shock absorption, cushioning, and impact resistance in a single unit. The device may have components like foam inserts, bubble wrap, dunnage, or other materials to absorb shock and cushion the product. It can also have features like corner and edge protectors, impact-resistant shells, or reinforced areas to prevent damage. The aim is to provide a simplified and effective protective packaging solution that reduces the need for multiple types of packaging.

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Structural foam packaging material with vertical voids that reduces cost and volume compared to solid foam while maintaining protection. The foam plank has a height and interior voids with height and diameter between 60-65% of the plank height. The voids have conical bottoms. This foam configuration exhibits properties of denser foams, like 4.0#, even when the foam density is 1.2# or 2.2#.

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A method to manufacture a packaging sheet with improved insulation properties and reduced volume without opening the cells. The method involves forming a sheet with closed cells, bonding a lower film below it, filling fluid into the cells, closing the cells, bonding an upper film, and winding the sheet. This seals the cells without cutting them, reducing volume compared to opening cells. The fluid filling provides insulation.

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Foamed laminated sheet used for packaging containers with improved heat insulation, heat resistance, and cold resistance compared to conventional foamed laminated sheets. The sheet has a foamed layer sandwiched between reinforcing layers. The foamed layer is made of polypropylene resin. The reinforcing layers contain both polypropylene and polyethylene resins in specific ratios. This composite composition provides the desired heat, cold, and insulation properties. The polyethylene in the reinforcing layers improves heat resistance and cold resistance while the polypropylene maintains heat sealing properties. The foamed laminated sheet can be thermoformed into containers with smooth surfaces that are easy to seal and peel.

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Foamed polypropylene EPP material for packaging boxes that improves compression strength, dimensional stability, and welding properties compared to conventional EPP. The process involves impregnating the polypropylene particles with the foaming agent under pressure before expansion. This improves cell structure and network continuity, resulting in better compression strength and dimensional stability. The impregnation step also aids in welding by preventing cell collapse during molding.

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Recyclable plastic containers with higher filler loadings that float during recycling. The containers have layers made of foamed polyolefin with mineral filler. The foamed polyolefin reduces specific gravity below 1.0, allowing floatation during recycling. The mineral filler increases strength and reduces resin usage. By foaming the polyolefin, higher filler loadings can be used while still keeping the overall specific gravity below 1.0 for floatation.

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Lightweight, drop-resistant, impact-resistant pressure packaging with improved strength and stiffness, and reduced environmental impact compared to traditional packaging. The packaging has a stretch blow molded inner container enclosed by a foam layer formed in place. An outer layer holds the foam and container together. The foam layer provides impact and drop protection while the stretch blow molded container provides strength and stiffness. The foam layer also reduces weight compared to a fully molded foam container.

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Recyclable plastic containers with reduced polymer usage and improved recyclability by incorporating mineral filler and foaming. The containers have layers with mineral filler like calcium carbonate to replace some of the polymer. Foaming a layer further reduces density below 1.0 so the container floats. This allows higher filler levels compared to unfilled containers. The filler and foaming offset the increased density from filler, allowing lower polymer usage overall. The containers have specific gravity <1.0 for easy floatation recycling.

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A packing sheet with improved insulation and storage properties, produced by a method that minimizes volume during storage and transportation while greatly increasing insulation. The packing sheet has a three-dimensional cellular structure with ridges connecting adjacent cells. The method involves forming the ridges without connecting bridges between rows. This prevents leakage if one cell is damaged.

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Polypropylene-based resin foam sheet with improved properties for food packaging applications. The foam sheet has a unique composition of two high melt tension polypropylene resins with specific melt tension and elongation values. The resin ratio is 20 parts of resin A with Mt=20-80 cN and Me=4-10 m/min, and 80 parts of resin B with Mt=3-5.5 cN and Me=9-15 m/min. The foam sheet has high foam ratio (6-10x), thin thickness (1-3 mm), many cells (10-14/mm), and high closed cell ratio (85%). This combination of resins allows optimal foam properties for light weight, heat insulation, designability, moldability, and rigidity.

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High impact strength polypropylene foam with improved properties for applications like automotive components, packaging, and building insulation. The foam is made by supercritical fluid foaming of a specific polypropylene resin with improved melt strength. The resin is a blend of propylene homopolymer and ethylene/1-butene copolymer. The copolymer component provides impact resistance while the homopolymer enhances melt strength. The foaming agent is a supercritical fluid like carbon dioxide or nitrogen. This allows uniform cell structure and high density foam with improved physical properties compared to traditional polypropylene foam.

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Packaging bags that better protect fragile contents from impact without causing indentations. The bags have a laminated structure with a foamed polyolefin sheet sandwiched between a paper substrate and a sealant layer. The foamed sheet has specific thickness and expansion ratio ranges to provide cushioning. The paper substrate has a specific bending stiffness. This configuration allows the bags to absorb impact without transferring it to the contents. The foamed sheet prevents indentations. The sealant layer adheres the parts together. The bag can be resealed without evidence of opening.

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High impact strength expanded polypropylene with improved foam properties for applications like automotive components, packaging, insulation, and sports equipment. The foam is made by expanding a specific type of high impact strength polypropylene resin. The resin is prepared by copolymerizing propylene with ethylene and a small amount of butene, followed by catalytic chain extension with propylene and an external donor. The resulting resin has good melt strength and impact resistance. When expanded, the foam retains fine cell structure, high expansion ratio, and low density. The key factors for achieving these properties are the specific copolymer composition, catalyst system, and processing conditions. The expanded foam material has lower ethylene content in the polypropylene matrix compared to conventional impact PP foams.

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Deep-drawn molded packaging container that can withstand temperature changes and protect packaged products. The container is made by molding a polypropylene resin-containing foam sheet. This foam sheet has higher melting points and better heat insulation compared to polystyrene foams. The container retains shape at high temps, prevents deformation in microwaves, and prevents quality loss during frozen storage. The foam sheet can be laminated with other films for additional properties like heat resistance, rigidity, and barrier functions.

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Buffer packing material for protecting fragile items during shipping to prevent damage. The packing material is made of a flexible, compressible material that absorbs shock and vibration during transportation. It is used inside shipping boxes to cushion and protect the contents from impact during transit. The material is designed to compress and expand as the package is handled and moved, providing buffering and shock absorption. The material can be cut to fit specific item shapes and sizes inside the box.

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A glass substrate protective pad and container that significantly reduce the breakage rate of glass substrates during handling and transportation. The protective pad has multiple layers with the innermost layer in contact with the glass substrate containing foamed polymer. This foamed layer provides cushioning to absorb impact and prevent surface pressure/imprinting that can break the glass. The container uses these pads to protect the glass substrates during packing and unpacking. The pads' foamed innermost layer reduces breakage compared to solid pads, and the multiple layers prevent sliding between the substrate and pad. The pads' cushioning also endures longer compared to solid pads, reducing wear and damage.

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