Molded Pulp for 3D Package Forms
Modern molded pulp packaging must achieve precise dimensional tolerances while maintaining structural integrity under load. Current manufacturing processes struggle to create complex three-dimensional forms with wall thicknesses below 2mm, especially in areas requiring detailed features or load-bearing capacity. When subjected to compression testing, traditional molded pulp designs show structural weakness at corner joints and experience deformation under loads as low as 150N.
The fundamental challenge lies in balancing the material's formability and strength characteristics while achieving the precision and consistency needed for industrial applications.
This page brings together solutions from recent research—including digital twin optimization for fiber distribution, thermoplastic binder integration for enhanced structural properties, and novel geometric designs for improved load-bearing capacity. These and other approaches focus on creating commercially viable alternatives to traditional plastic packaging while maintaining or exceeding current performance standards.
1. Pulp Mold Packaging with Interlocking Cover and Main Body Featuring Internal Insulation and Anti-Distortion Grooves
THERMO LAB KOREA CO LTD, 2024
Pulp mold packaging with improved strength, insulation and stackability for fresh product transportation. The packaging has a main body with a cover that attaches inside the main body. This allows for insulation between the main body and cover. The cover has a top and bottom mold with an internal space. The main body has a top mold with an internal space. The cover and main body molds are made of pulp material with a binder, antifoaming agent, and water repellent. Grooves on the molds prevent distortion. A fixed coupling connects the cover bottom to the main body. This prevents jamming when stacked. The internal spaces between the molds can be filled with cellulose foam insulation.
2. Molded Pulp Packaging System with Foldable Edges for Heating Devices
BDR THERMEA GROUP B V, 2024
Eco-friendly packaging solution for heating devices like water heaters and tanks that reduces plastic usage and improves protection during transportation. The packaging uses molded pulp materials like recycled paper to make a base element that surrounds and supports the bottom of the device. The base engages into a pallet and has foldable edges to secure it. This replaces single-use plastic wedges and strapping. A covering element goes on top and side elements on the sides. The molded pulp provides cushioning and stability without plastic, reducing environmental impact compared to expanded polystyrene.
3. Modular Pulp-Molded Packaging Structure with Interlocking Corner and Side Guards
TES TOUCH EMBEDDED SOLUTIONS CO LTD, 2023
A modular packaging structure for display devices that provides high protection, meets environmental regulations, and allows customization for different device sizes. The packaging uses modular corner and side guards made by pulp molding. The corner guards protect the device corners and fold together to create a corner receiving groove. Multiple corner guards can cover all device corners. The side guards protect the sides and have a side receiving groove. The modular guards can be shared between devices of similar size. This allows customizing the number and orientation of guards for different devices. The pulp molded guards are recyclable and meet environmental standards.
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