Starch-based padding for roll stock and padded mailers and method of making the same

Abstract

Padded materials and corresponding systems and methods for forming the same are provided herein. A padded material comprises a first web of paper-based material defining a first and a second surface, and a second web of paper-based material defining a first and a second surface. A first layer of heat seal coating is disposed on the second surface of the first web, and a second layer of heat seal coating is disposed on the second surface of the second web. A starch-based padding is sandwiched between the first web and the second web such that the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web. The padded material may be formed into a roll stock that is used in an automated packaging machine, such as an automated mailer formation device.

1 . A packaging material for use in an automated packaging machine, the packaging material comprising:
 a first web of paper-based material defining a first surface and a second surface opposite the first surface;   a first layer of heat seal coating disposed on the second surface of the first web;   a second web of paper-based material defining a first surface and a second surface opposite the first surface;   a second layer of heat seal coating disposed on the second surface of the second web; and   a starch-based padding sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.   
     
     
         2 . The packaging material of  claim 1 , wherein the starch-based padding covers between about 20% to about 40% of the first surface of the first web. 
     
     
         3 . The packaging material of  claim 1 , wherein the starch-based padding is precrushed, and wherein the starch-based padding defines a final density between about 1.5 lbs/ft 3  to about 2.25 lbs/ft 3  after the starch-based padding is precrushed. 
     
     
         4 . The packaging material of  claim 1 , wherein the starch-based padding comprises lignin. 
     
     
         5 . The packaging material of  claim 1 , wherein the first surface of the first web is moistened prior to contact with the starch-based padding. 
     
     
         6 . The packaging material of  claim 1 , wherein the second layer of heat seal coating is moistened prior to contact with the starch-based padding. 
     
     
         7 . The packaging material of  claim 1 , wherein the starch-based padding comprises starch, a plasticizer, and a foaming aid. 
     
     
         8 . The packaging material of  claim 1 , wherein the starch-based padding is a plurality of starch-based particles. 
     
     
         9 . The packaging material of  claim 8 , wherein each of the plurality of starch-based particles define a particle diameter, wherein the particle diameter is between about 0.2 in to about 0.4 in. 
     
     
         10 . The packaging material of  claim 8 , wherein each of the plurality of starch-based particles define a particle thickness, and wherein the particle thickness is between about in to about 0.25 in. 
     
     
         11 . The packaging material of  claim 1 , wherein the starch-based padding is a sheet. 
     
     
         12 . A method of forming a packaging material for use in an automated packaging machine, the method comprising:
 providing a first web of paper-based material, wherein the first web defines a first surface and a second surface;   applying a first layer of heat seal coating to the second surface of the first web;   providing a second web of paper-based material, wherein the second web defines a first surface and a second surface;   applying a second layer of heat seal coating to the second surface of the second web;   applying a starch-based padding onto the first surface of the first web; and   causing the first web and the second web to come together such that the starch-based padding is sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.   
     
     
         13 . The method of  claim 12 , wherein the starch-based padding is a plurality of starch-based particles. 
     
     
         14 . The method of  claim 13 , further comprising:
 transferring the plurality of starch-based particles from a hopper to a vacuum wheel, wherein the vacuum wheel comprises a plurality of openings in a determined pattern.   
     
     
         15 . The method  claim 14 , wherein the plurality of starch-based particles are secured within the plurality of openings via vacuum suction. 
     
     
         16 . A mailer formed from a padded material, the padded material comprising:
 a first web of paper-based material defining a first surface and a second surface opposite the first surface;   a first layer of heat seal coating disposed on the second surface of the first web;   a second web of paper-based material defining a first surface and a second surface opposite the first surface;   a second layer of heat seal coating disposed on the second surface of the second web; and   a starch-based padding sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.   
     
     
         17 . The mailer of  claim 16 , wherein the starch-based padding covers between about 20% to about 40% of the first surface of the first web. 
     
     
         18 . The mailer of  claim 16 , wherein the starch-based padding defines a final density between about 1.5 lbs/ft 3  to about 2.25 lbs/ft 3 . 
     
     
         19 . The mailer of  claim 16 , wherein the starch-based padding comprises lignin. 
     
     
         20 . The mailer of  claim 16 , wherein the first surface of the first web is moistened prior to contact with the starch-based padding. 
     
     
         21 . The mailer of  claim 16 , wherein the second layer of heat seal coating is moistened prior to contact with the starch-based padding. 
     
     
         22 . The mailer of  claim 16 , wherein the starch-based padding comprises starch, a plasticizer, and a foaming aid. 
     
     
         23 . The mailer of  claim 16 , wherein the starch-based padding is a plurality of starch-based particles. 
     
     
         24 . The mailer of  claim 23 , wherein each of the plurality of starch-based particles define a particle diameter, wherein the particle diameter is between about 0.2 in to about 0.4 in. 
     
     
         25 . The mailer of  claim 23 , wherein each of the plurality of starch-based particles define a particle thickness, and wherein the particle thickness is between about 0.1 in to about 0.25 in. 
     
     
         26 . The mailer of  claim 16 , wherein the starch-based padding is a sheet. 
     
     
         27 . A mailer produced by the process of:
 providing a first web of paper-based material, wherein the first web defines a first surface and a second surface;   applying a first layer of heat seal coating to the second surface of the first web;   providing a second web of paper-based material, wherein the second web defines a first surface and a second surface;   applying a second layer of heat seal coating to the second surface of the second web;   applying a starch-based padding onto the first surface of the first web; and causing the first web and the second web to come together such that the starch-based padding is sandwiched between the first web and the second web, wherein the starch-based padding is positioned between the first surface of the first web and the second layer of heat seal coating disposed on the second surface of the second web.   
     
     
         28 - 34 . (canceled)