Environmentally sustainable packaging and method of making thereof

Abstract

Sustainable packaging and a method of making sustainable packaging including forming the packaging from a predetermined needed material and using the packaging to ship a second part or product, whereby the packaging material is then used to form a first part or product. The packaging includes a plurality of spacer pads arranged in layers and configured to hold the second part or component between the spacer pads. The packaging may also include sheet layers or protective members located between the spacer pads and the parts, the sheet layers may include a volatile corrosion inhibitor. The packaging may also include a sleeve disposed around the spacer pads. A bottom tray located on one end of the sleeve and a lid located on the other end complete the packaging.

1 . A method of making sustainable packaging comprising the steps of: 
 determining a need for a raw material for making a first product;    determining shipping and packaging requirements for a second product and    designing packaging for said second product from the raw material used for making said first product.    
   
   
       2 . A method of making sustainable packaging as set forth in  claim 1  including the step of analyzing current packaging for said second product including identifying problems with current packaging.  
   
   
       3 . A method of making sustainable packaging as set forth in  claim 1  including the step of developing a problem statement to evaluate current issues with current packaging, said step including addressing issues related to contamination, environmental waste, non-value added steps and part quality.  
   
   
       4 . A method of making sustainable packaging as set forth in  claim 1  including the step of evaluating packaging design criteria for the second product.  
   
   
       5 . In method of making sustainable packaging as set forth in  claim 1  including the step of testing the packaging.  
   
   
       6 . A method of making sustainable packaging as set forth in  claim 5  wherein the step of testing the packaging includes the step of performing a finite element analysis on the proposed package design.  
   
   
       7 . A method of making sustainable packaging as set forth in  claim 1  including the step of preparing a prototype and testing the prototype.  
   
   
       8 . A method of making sustainable packaging as set forth in  claim 1  including the step of identifying accepted standards and criteria for assessing performance, reliability and manufacturing capability of the packaging; and 
 verifying that the packaging meets accepted standards and criteria.    
   
   
       9 . A method of making sustainable packaging as set forth in  claim 1  including using a polymer material as a raw material.  
   
   
       10 . A method of making sustainable packaging as set forth in  claim 1  wherein the step of the designing packaging for the second product includes providing a bottom member; a sleeve member, a lid and a plurality of bottom and top spacer pads sized to fit within the sleeve and configured for placement on opposite sides of the second product to form a layer.  
   
   
       11 . A method of making sustainable packaging as set forth in  claim 1  including using a protective sheet between the second product and the spacer pad.  
   
   
       12 . A method of making sustainable packaging as set forth in  claim 11  including using a protective sheet having a volatile corrosion inhibitor impregnated in the protective sheet.  
   
   
       13 . A method of forming a part or product from packaging material comprising: 
 determining a need for materials to manufacture a first product;    reviewing design criteria for packaging used to transport a second product;    designing packaging for use with the second product, the packaging constructed, at least in part, from the material used to manufacture the first product;    transporting the second product in the packaging ; and    removing the second product from the packaging and using the material of the packaging to form the first product.    
   
   
       14 . A method of obtaining material as set forth in  claim 13  wherein the step of determining need for materials to manufacture a first product includes assessing current material needs.  
   
   
       15 . The method of obtaining material as set forth in  claim 13  wherein the step of reviewing packaging for transporting a second product includes evaluating at least in part the following concerns: contamination issues, environmental waste, non-value added steps and quality issues associated with transporting the second product.  
   
   
       16 . The method of obtaining material as set forth in  claim 13  wherein the step of designing the packaging for use with the second product includes evaluating the proposed packaging at least in part based on several requirements, including international packaging, intermodal packaging, corrosion protection, contamination protection and ergonomic issues.  
   
   
       17 . The method of obtaining material as set forth in  claim 13  wherein the step of reviewing the packaging includes analyzing environmental costs including end-user costs relating to transportation and disposal; and 
 analyzing fabrication costs as a component of the overall packaging cost.    
   
   
       18 . The method of obtaining material as set forth in  claim 13  including the step of using a polymer material to form the packaging ; and 
 regrinding and reusing the polymer material to form the first product once a second product is removed from the packaging.    
   
   
       19 . Packaging for transporting a second product wherein at least a portion of the material forming the packaging is used to form a first product, said packaging comprising: 
 at least one layer formed of a plurality of members, said layer including first and second spacer pads, at least one of said spacer pads configured to fit the second product, said second product located between said spacer pads, sheet members located between said first and second spacer pads and the second product; and    a sleeve, said sleeve surrounding said layer.    
   
   
       20 . Packaging for transporting a second product as set forth in  claim 19  wherein said protective sheets include a volatile corrosion inhibitor.  
   
   
       21 . Packaging for transporting a second product as set forth in  claim 19  including a bottom tray; and 
 a lid, wherein said lid is located on one end of said sleeve and said bottom tray is located on said opposite end of said sleeve.    
   
   
       22 . Packaging for transporting a second product as set forth in  claim 21  wherein said bottom tray includes a plurality of legs.  
   
   
       23 . Packaging for transporting a second product as set forth in  claim 19  including a bottom tray and a lid, said spacer pads, bottom tray, sleeve, and lid made from a polypropylene material used to manufacture the first product.  
   
   
       24 . Packaging for transporting a second product as set forth in  claim 19  including a plurality of layers located within said sleeve, said protective sheets located in said layers including a volatile corrosion inhibitor; 
 a lid located on one end of said sleeve; and    a bottom tray having a plurality of legs located on an opposite end of said sleeve.    
   
   
       25 . Packaging for transporting a second product as set forth in  claim 24  including said first and second spacer pads configured to fit the first article.