EXPANDABLE POLYLACTIC ACID-BASED THERMAL AND PROTECTIVE PACKAGING AND METHODS THEREOF
Molded foam articles are provided. The molded foam articles have at least one surface having at least a portion that has been skin-formed for improving the thermal and mechanical properties of the molded foam articles without the need for material, density, or foam particle size changes.
1 . A molded bead foam article comprising polylactic acid, wherein the molded bead foam article comprises at least one surface, wherein at least a portion of the at least one surface has been skin-formed.
2 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface has a greater compressive resistance than a conventional EPS-based foam article having the same density.
3 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface has a lower density than a conventional EPS-based foam article having the same compressive resistance.
4 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface has a compressive resistance that is 30%-50% greater than a surface of a PLA-based molded bead foam article that has not been skin-formed.
5 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface comprises a skin-formed corner or skin-formed edge of the molded bead foam article, and wherein the skin-formed corner or skin-formed edge is effective to increase a drop resistance of the molded bead foam article without changing the density.
6 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface has a density of between about 1.0 pcf and about 6.0 pcf.
7 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface is leak-proof.
8 . The molded bead foam article of claim 1 , wherein the skin-formed portion of the at least one surface has an R-value that is unchanged in at least 1 year when exposed to water.
9 . The molded bead foam article of claim 1 , further comprising identifying information printed directly on the skin-formed portion of the at least one surface.
10 . The molded bead foam article of claim 9 , wherein the identifying information is printed with ink comprising ethanol, methyl ethyl ketone, water, or a combination thereof.
11 . The molded bead foam article of claim 1 , wherein the molded bead foam article has an anisotropic compressive modulus and/or an anisotropic flexural modulus.
12 . The molded bead foam article of claim 1 , further comprising a label with product information printed directly on the skin-formed surface.
13 . The molded bead foam article of claim 1 , wherein the molded bead foam article is in the form of a box having a plurality of sides.
14 . The molded bead foam article of claim 13 , wherein fewer than all sides of the box have a skin-formed portion of a surface.
15 . The molded bead foam article of claim 1 , wherein the molded bead foam article is in the form of an automobile headrest.
16 . The molded bead foam article of claim 1 , wherein the molded bead foam article is in the form of a spare wheel cover.
18 . (canceled)
17 . The molded bead foam article of claim 1 , wherein the molded bead foam article comprises blends or copolymers of polylactic acid.
18 . A method for producing a molded bead foam article comprising:
molding a plurality of foam beads comprising polylactic acid in a mold to produce the molded bead foam article, and
skin-forming at least a portion of at least one surface of the molded bead foam article.
19 . The method of claim 18 , wherein the skin-formed portion of the at least one surface is skin-formed while the molded bead foam article is in the mold.
20 . The method of claim 18 , wherein the skin-formed portion of the at least one surface is skin-formed after the molded bead foam article has been removed from the mold.
21 . The method of claim 18 , further comprising printing identifying information on the skin-formed portion of the at least one surface.
22 . The method of claim 18 , wherein the method is performed in-line.
23 . The method of claim 18 , wherein the method is performed proximal to a packaging facility.
24 . The method of claim 18 , wherein the method is performed by automated apparatus.
25 . The molded bead foam article of claim 1 , wherein the at least one surface with the skin-formed portion is curved.