Biodegradable packaging for shipping

Abstract

A biodegradable, thermally insulated mailer and cooler, and method of making them, are disclosed. The thermally insulated packaging material are made from laminated starch foam and bio-plastic film. The lamination can be performed by heat bonding, without the use of an adhesive bonding agent, to produce biodegradable packaging materials that can pass ASTM and other certifications for home compostability and marine environment safety.

1 . A biodegradable mailer, made from a composite consisting essentially of:
 a corn starch foam paper made from high-amylose content foam having at least about 90% corn starch, by weight;   a bio-plastic film that is heat-bonded to the corn starch foam paper; and   compostable ink;   wherein the compostable ink is used to present information about biodegradability of the mailer.   
     
     
         2 . The biodegradable mailer of  claim 1 , wherein the bio-plastic film is a bio-polymer resin film, and wherein the biodegradable mailer satisfies ASTM 6400. 
     
     
         3 . The biodegradable mailer of  claim 1 , wherein the corn starch foam paper is made by compressing the high-amylose content foam into a flexible sheet. 
     
     
         4 . The biodegradable mailer of  claim 3 , wherein the bio-plastic film is a bio-polymer resin film, and wherein the biodegradable mailer satisfies ASTM 6400. 
     
     
         5 . (canceled) 
     
     
         6 . (canceled) 
     
     
         7 . A composite paper comprising:
 a compressed, flexible corn starch foam sheet;   a bio-plastic film that is heat bonded to the corn starch paper,   wherein no adhesive is used to bond the corn starch film and the bio-plastic film.   
     
     
         8 . A method of making a biodegradable composite paper comprising:
 providing a compressed, flexible corn starch foam sheet;   providing a bio-plastic film;   adhering the corn starch foam sheet and the bio-plastic film by running them through a laminator, without an adhesive.   
     
     
         9 . The method of  claim 8 , wherein a fine water mist is applied in place of an adhesive to assist in achieving a consistent lamination between the foam and the film. 
     
     
         10 . The method of  claim 8 , wherein the foam is Green Cell Foam™. 
     
     
         11 . The method of  claim 8 , wherein the film is Danimer 12291. 
     
     
         12 . A biodegradable cooler, comprising:
 corn starch foam panels;   a bio-plastic film that is heat-bonded to the corn starch foam panels;   wherein the bio-plastic film encloses the corn starch foam panels, and   wherein no adhesive is used to bond the bio-plastic film.   
     
     
         13 . The biodegradable cooler of  claim 12 , wherein the corn starch film is Green Cell Foam™. 
     
     
         14 . The biodegradable cooler of  claim 12 , wherein the bio-plastic film is Danimer 12291. 
     
     
         15 . The biodegradable cooler of  claim 12 , wherein the bioplastic film flexibly connects at least two of the corn starch panels to one another to form a hinge. 
     
     
         16 . The biodegradable cooler of  claim 15 , wherein the bioplastic film flexibly connects exactly three of the corn starch panels, whereby the cooler can be assembled for use by inserting two 3-panel pieces into a standard box to form two interlocking “C” forms. 
     
     
         17 . The biodegradable cooler of  claim 13 , wherein the corn start foam panels are formed by laminating multiple layers of Green Cell Foam™ to one another to form at least 2″ thick sheets. 
     
     
         18 . A method of making biodegradable packaging comprising heat bonding corn starch foam and bio-plastic film without an adhesive bonding agent. 
     
     
         19 . The method of  claim 18 , wherein at least some of the corn starch foam has been made into corn starch paper. 
     
     
         20 . The method of  claim 19 , wherein the heat bonding is performed by a lamination at a temperature between about 253° F. and about 258° F. and a speed of about 31 ft/s and about 36 ft/s.