CONTAINER AND DISPENSING SYSTEM FOR EXPANDED SLIT PAPER

A dispensing system includes a container, a roll of slit paper, and a passive tension mechanism. The container includes panels and one of the panels includes a dispensing aperture. The slit paper on the roll is in an unexpanded state. The slit paper can be transformed from the unexpanded state to an expanded state by exerting a longitudinal pulling force on the slit paper. The passive tension mechanism is in the container and arranged such that a path of the slit paper from the roll to the dispensing aperture passes through the passive tension mechanism. The passive tension mechanism is configured to induce tension in the slit paper along the path between the roll of the slit paper and the dispensing aperture such that the slit paper transforms from the unexpanded state to the expanded state along the path between the roll of the slit paper and the dispensing aperture.

BACKGROUND

The present disclosure is in the technical field of dispensers for slit paper. More particularly, the present disclosure is directed to dispensers for slit paper having passive tension mechanisms that induce tension in the slit paper to expand the slit paper as the slit paper is dispensed.

Consumers frequently purchase goods from mail-order or internet retailers, which package and ship the goods to the purchasing consumer via a postal service or other carrier. Millions of such packages are shipped each day. These items are normally packaged in small containers, such as a box or envelope. To protect the items during shipment, they are typically packaged with some form of protective dunnage that may be wrapped around the item or stuffed into the container to prevent movement of the item and to protect it from shock.

Various forms of cushioning and/or void fill material have been developed, including pre-sealed air cellular materials (e.g., BUBBLEWRAP air cellular material sold by Sealed Air Corporation), inflatable air cellular materials (e.g., NEW AIR I.B. air cellular material sold by Sealed Air Corporation), low-density paper cushioning materials (e.g., paper pads formed by PROPAD paper cushioning systems sold by Sealed Air Corporation), and the like. It would be advantageous to provide dispensers of cushioning and/or void fill materials for packers to use when packaging containers for shipping.

SUMMARY

In a first embodiment, a dispensing system includes a container, a roll of slit paper, and a passive tension mechanism. The container has a plurality of panels and a first panel of the plurality of panels includes a dispensing aperture. The slit paper on the roll is in an unexpanded state. The slit paper is capable of being transformed from the unexpanded state to an expanded state by exerting a longitudinal pulling force on the slit paper. The passive tension mechanism is located in the container and arranged such that a path of the slit paper from the roll of the slit paper to the dispensing aperture passes through the passive tension mechanism. The passive tension mechanism is configured to induce tension in the slit paper along the path between the roll of the slit paper and the dispensing aperture such that the slit paper transforms from the unexpanded state to the expanded state along the path between the roll of the slit paper and the dispensing aperture.

In a second embodiment, the passive tension mechanism of the first embodiment is configured to induce a substantially constant amount of tension in the slit paper regardless of the amount of the slit paper remaining on the roll of the slit paper.

In a third embodiment, the passive tension mechanism of any of the previous embodiments is a tortuous path tension mechanism.

In a fourth embodiment, the passive tension mechanism of any of the previous embodiments includes a first rod and a second rod. The first rod is arranged such that the path of the slit paper passes around the first rod in a first direction. The second rod is arranged such that the path of the slit paper passes around the second rod in a second direction that is opposite the first direction after passing around the first rod.

In a fifth embodiment, the first and second rods of the fourth embodiment are static rods that do not rotate with respect to the container.

In a sixth embodiment, the first and second rods of the fourth embodiment are rollers that are configured to rotate with respect to the container.

In a seventh embodiment, the dispensing system of any of the fourth to sixth embodiments is configured such that a distance between an axis of the first rod and the first panel of the container is less than or equal to a distance between an axis of the second rod and the first panel of the container.

In an eighth embodiment, the dispensing system of any of the previous embodiments further includes an insertion assembly configured to be inserted into the container. The insertion assembly is configured to hold the roll of the slit paper in the container.

In a ninth embodiment, the insertion assembly of the eighth embodiment includes first and second roll guides configured to hold sides of a core around which the roll of the slit paper is wound.

In a tenth embodiment, the insertion assembly of the ninth embodiment comprises endcaps inserted through holes in the first and second roll guides and into the sides of the core of the roll of the slit paper.

In an eleventh embodiment, each of the endcaps of the tenth embodiment includes a shaft having a proximal end and a distal end, a collar located at the proximal end of the shaft, and a plurality of slits that are parallel to an axis of the shaft and are spaced apart circumferentially around the distal end of the shaft. The distal end has a larger diameter than the proximal end. The distal end is configured to be inserted into one of the ends of the core of the roll of the slit paper. The collar is configured to abut one of the first and second roll guides.

In a twelfth embodiment, the dispensing system of any of the tenth to eleventh embodiments is configured such that an outer diameter of a shaft of the endcap and an inner diameter of the core of the roll of the slit paper are dimensioned such that the endcap and the core of the roll of the slit paper have an interference fit.

In a thirteenth embodiment, the dispensing system of any of the ninth to eleventh embodiments further includes a roll of interleaf paper located in the container.

In a fourteenth embodiment, the insertion assembly of the thirteenth embodiment includes slots in the first and second roll guides. The slots are configured to configured to receive and hold ends of a core around which the interleaf paper is wound. The slots are further configured to permit the core of the interleaf paper to rotate with respect to the roll guides.

In a fifteenth embodiment, the interleaf paper of any of the thirteenth to fourteenth embodiments is narrower than the slit paper. The insertion assembly further includes at least one spacer located on the roll of the interleaf paper and positioned between the interleaf paper and one of the first and second roll guides.

In a sixteenth embodiment, the at least one spacer of the fifteenth embodiment positions the interleaf paper such that the interleaf paper is substantially centered with respect to the slit paper.

In a seventeenth embodiment, the insertion assembly of the thirteenth embodiment includes slots in the first and second roll guides and a shaft extending between the slots in the first and second roll guides. A core of the roll of the interleaf paper is located around the shaft and the core of the roll of the interleaf paper is configured to rotate with respect to the shaft.

In an eighteenth embodiment, the insertion assembly further includes at least one spacer located on the shaft and positioned between the roll of the interleaf paper and one of the first and second roll guides.

In a nineteenth embodiment, each of the first and second roll guides and the container of any of the ninth to eighteenth embodiments are made from a fiber-based material.

In a twentieth embodiment, the dispensing system of any of the previous embodiments further includes a roll of interleaf paper located in the container. A path of the interleaf paper from the roll of the slit paper to the dispensing aperture passes around the passive tension mechanism.

In a twenty first embodiment, the interleaf paper and the slit paper of the twentieth embodiment are configured to be pulled through the dispensing aperture to simultaneously dispense the slit paper in the expanded state and the interleaf paper.

In a twenty second embodiment, the dispensing system of any of the previous embodiments is configured such that (i) the first panel is a front panel of the container, and (ii) the plurality of panels further comprises a bottom panel, a back panel, two side panels, and a top panel.

In a twenty third embodiment, the front panel of the twenty second embodiment includes a dispensing flap formed by perforated lines along the bottom and sides of the dispensing flap, and wherein the dispensing flap is configured to be pulled out to open the dispensing aperture.

twenty third embodiment, the front panel of the twenty second embodiment includes a dispensing flap formed by perforated lines around a perimeter of the dispensing flap, and wherein the dispensing flap is configured to be removed to open the dispensing aperture.

DETAILED DESCRIPTION

FIG.1depicts an embodiment of slit paper material10in an unexpanded state. The slit paper material10includes a web12of paper or other fiber-based material. In some embodiments, the web12is a web of kraft paper. The slit paper material10includes rows of slits14. The slits14extend generally in a transverse direction (labelled as the direction t in the drawing) and the slits14are arranged in rows that also extend generally in the transverse direction. In the depicted embodiment, each row of slits14is offset from the adjacent rows to form a pattern of the rows that repeats generally in the longitudinal direction (labelled as the direction/in the drawing). In the unexpanded state, the slit paper material10is generally flat and the slit paper material10can be stored in a compact configuration. For example, the slit paper material10can be wound into a roll (e.g., around a core), fanfolded into a fanfolded stack, and the like.

The slit paper material10can also be in an expanded state.FIGS.2A and2Bdepict front and side views, respectively, of an embodiment of the slit paper material10in an expanded state. In some embodiments, the expanded slit paper material10is transformed from the unexpanded state to the expanded state by exerting a longitudinal force16on the slit paper material10. The longitudinal force16causes the slits14to expand to form open cells18. The expansion of the slits14into the open cells18causes the web12to buckle and take a three-dimensional shape, as seen inFIG.2B. The expansion of the slits14into the open cells18also causes the length of the web12to expand in the longitudinal direction and the width of the web12to shrink in the transverse direction.

After the slit paper material10is in the expanded state, the slit paper material10can be wrapped around an object. When wrapped around an object, the slit paper material10tends to remain in the expanded state as the wrapping of the object causes at least some portions of the slit paper material10to interlock and resist retraction of the slit paper material to the unexpanded state. In some embodiments, an interleaf paper material is layered over the slit paper material10and wrapped around the object with the slit paper material10to deter retraction of the slit paper material10. As used herein, an “object” may comprise a single item or a grouping of several distinct items. Further, an object may include any accompanying informational items, such as a packing slip, tracking code, a manifest, an invoice, a machine-readable identifier (e.g., a bar code or a quick response (QR) code) that can be sensed by a reader (e.g., a bar code scanner or a camera), or any other informational item.

The use of expandable slit paper material as a cushioning material is well known. For example, U.S. Pat. No. 5,667,871, issued Sep. 16, 1997, describes the use of slit paper to package objects. In particular, the slit paper is rolled into a roll in its unexpanded state, the roll is placed in a contain, and the slit paper is pulled out of the container. As the slit paper is pulled out of the container, the longitudinal force from pulling the slit paper causes the slit paper to convert from the unexpanded state to the expanded state so that the expanded slit paper can be used as a cushioning material to wrap an object.

When pulling slit paper from a roll in a container, the amount of tension in the slit paper affects the expansion of the slit paper. In one example, too little tension in the slit paper will allow the slit paper to be pulled from the roll in the unexpanded roll. In another example, too much tension in the slit paper will not permit the slit paper to be pulled from the roll without tearing the slit paper. This problem is exacerbated by the use of a roll to hold the slit paper. The amount of resistance needed in the roll to provide the appropriate amount of tension in the slit paper will vary depending on the radius of the roll. However, the radius of the roll varies based on the amount of slit paper remaining on the roll. To address this problem, variable tension devices have been developed to vary the amount of tension in the roll. U.S. Patent Application Publication No. 2019/0193366 A1 provides an example of such a variable tensioning device.

The use of variable tensioning devices in slit paper dispensers can be problematic. First, such variable tensioning devices typically require a user to manually change the level of resistance appropriately based on the amount of slit paper remaining on the roll. This requires training for a user and experience to have the appropriate skill level to properly set the level of resistance, and any such manual operation is subject to user error. Second, variable tensioning can be complex to manufacture and install on a dispenser. Such complexity can be expensive and increase the chances of failure. Third, the materials used in variable tensioning devices are typically not easily recyclable (e.g., curbside recyclable). Having such materials on a dispenser may make the dispenser itself not easily recyclable. It would be advantageous to have a slit paper dispenser that avoids the problems with variable tensioning devices in slit paper dispensers.

FIGS.3and4depict perspective and exploded perspective views, respectively, of an embodiment of a dispensing system100capable of dispensing expanded slit paper. The dispensing system100includes a container110. In the depicted embodiment, the container110is a box that includes a front panel112, a back panel114, left and right panels116and118, a bottom panel119, and a top panel120. In the depicted embodiment, the top panel120includes a flap122such that, when the top panel120is closed, the flap122can be slid behind the front panel112to close the container110. The front panel112also includes a tab124that can be inserted into a slot between the top panel120and the flap122when the top panel120is closed to deter opening of the top panel120. The front panel112also includes a dispensing flap126. In some embodiments, the dispensing flap126is defined by perforated lines in the front panel112and an end user pulls the dispensing flap126open (e.g., to the open position shown inFIGS.3and4) by pulling on the dispensing flap126to break the perforated lines. When the dispensing flap126is in the open position shown inFIGS.3and4, the front panel112has a dispensing aperture128through which webs (e.g., a web of slit paper) can be dispensed from the inside of the container110, through the dispensing aperture128, to the outside of the container110.

The container110is configured to hold a supply of slit paper130in an unexpanded state. In the depicted embodiment, the container110holds a supply of slit paper130in the form of a roll of the slit paper130. In other embodiments, the supply of slit paper130can be in other forms, such as a fanfolded stack of the slit paper130. In some cases, it may be advantageous for the container110to hold another web that can be dispensed with the slit paper130. For example, in the depicted embodiment, the container110is configured to hold a supply of interleaf paper132. As discussed in greater detail below, the container110can be used to simultaneously dispense the slit paper130and the interleaf paper132. In the depicted embodiment, the roll of slit paper130is located on a core134and the roll of interleaf paper132is located on a core136. In some embodiments, the interleaf paper132can have information printed thereon, such as custom-printed information (e.g., advertisements, messages, logos, etc.).

In the depicted embodiment, the dispensing system100includes an insertion assembly140configured to be inserted into the container110. The insertion assembly140is configured to hold the supply of slit paper130. In embodiments where the dispensing system100is also used to dispense the interleaf paper132, as is the case in the depicted embodiment, the insertion assembly140is also configured to hold the supply of interleaf paper132. In some embodiments, the insertion assembly140include roll guides142. The roll guides142are configured to hold the sides of the cores134and136. In the depicted embodiment, the roll guides142each include a hole through which endcaps144are inserted to engage the ends of the core134. The endcaps144are configure either to rotate with respect to the roll guides142and/or to permit the core134to rotate with respect to the endcaps144such that the slit paper130can be withdrawn from the roll by rotating the roll with respect to the roll guides142and the container110. In some embodiments, the endcaps144are configured to provide resistance (e.g., frictional resistance) to the rotation of the core134such that the roll of the slit paper130does not rotate completely freely. Also in the depicted embodiment, the roll guides142include slots146that are configured to receive the ends of the core136. The slots146in the roll guides142are configured to permit the core136to rotate with respect to the roll guides142such that the interleaf paper132can be withdrawn from the roll by rotating the roll with respect to the roll guides142and the container110.

In some embodiments, the interleaf paper132is narrower than the slit paper130. In some embodiments, it may be advantageous for the interleaf paper132to be centered with respect to the slit paper130. In the depicted embodiment, the insertion assembly140includes spacers148located around the core136. Each of the spacers148is located between the roll of the interleaf paper132and one of the roll guides142. In the depicted embodiment, the spacers148have substantially the same width such that the roll of the interleaf paper132is centered with respect to the slit paper130. It will be apparent that the spacers148could have different widths such that the interleaf paper132is not centered with respect to the slit paper130. It will be also understood that only one spacer could be used such that the roll of the interleaf paper132is side-justified with respect to the slit paper130.

FIG.5Adepicts an embodiment of one of the endcaps144that is usable in the dispensing system100. The endcap144includes a collar150and a shaft152extending from the collar150. In use, the shaft152of the endcap144can be pushed through the hole in the roll guide142until the collar abuts the roll guide142and the shaft152of the endcap144can be inserted into the core134of the roll of the slit paper130. In the depicted embodiment, the distal end of the shaft152(i.e., the end opposite the collar150) is larger in diameter than the proximal end of the shaft152(i.e., the end at the collar150). The proximal end of the shaft152includes ridges153configured to engage the hole in the roll guides142to deter rotational movement of the endcap144with respect to the roll guides142after the endcap144is inserted into the hold in the roll guides154. The distal end of the shaft152also has slits154that parallel to an axis of the shaft152and are spaced apart circumferentially around the distal end of the shaft152. The portions of the shaft152between the slits154are tension fingers156. When the tension fingers156engage the inner surface of the core134, the tension fingers156exert a tension force on the core134to deter respective movement of the core134and the endcap144and to increase friction between the core134and the endcap144. In some cases, the outer diameter of the shaft152of the endcap144and the inner diameter of the core134are dimensioned such that the endcap144and the core134have an interference fit.

FIG.5Bdepicts another embodiment of an endcap144′ that is usable in the dispensing system100. The endcap144′ includes a collar150′ and a shaft152′ extending from the collar150′. In use, the shaft152′ of the endcap144′ can be pushed through the hole in the roll guide142until the collar abuts the roll guide142and the shaft152′ of the endcap144′ can be inserted into the core134of the roll of the slit paper130. In the depicted embodiment, the distal end of the shaft152′ (i.e., the end opposite the collar150′) is larger in diameter than the proximal end of the shaft152′ (i.e., the end at the collar150′). The proximal end of the shaft152′ includes ridges153′ configured to engage the hole in the roll guides142′ to deter rotational movement of the endcap144′ with respect to the roll guides142′ after the endcap144′ is inserted into the hold in the roll guides154′. The distal end of the shaft152′ also has slits154′ that parallel to an axis of the shaft152′ and are spaced apart circumferentially around the distal end of the shaft152′. The portions of the shaft152′ between the slits154′ are tension fingers156′. When the tension fingers156′ engage the inner surface of the core134′, the tension fingers156′ exert a tension force on the core134to deter respective movement of the core134and the endcap144′ and to increase friction between the core134and the endcap144′.

In the depicted embodiment, the shaft152′ includes a narrow section158′ configured to increase the tension applied by the tension fingers156′ to the core134. In some cases, the core134into which the endcap144′ is inserted has deformities in shape (e.g., dents). In some cases, having a greater number of tension fingers156′ (e.g., eight tension fingers156′ instead of the six tension fingers156in the endcap144) can allow the endcap144′ to be inserted into the core134while the greater number of tension fingers156′ allows the tension fingers156′ to independently adjust to accommodate the deformities in the core134.

FIGS.6A and7depict front cross-sectional and side cross-sectional views, respectively, of the dispensing system100, including the insertion assembly140after having been inserted into the container110. In the depicted embodiment, the insertion assembly140is arranged such that the roll of the slit paper130and the roll of the interleaf paper132are substantially aligned in the front-to-back direction (i.e., the direction shown from right to left when viewingFIG.7). For example, the axes of the rolls of the slit paper130and the interleaf paper132are the same distances from the front panel112and the axes of the rolls of the slit paper130and the interleaf paper132are the same distances from the back panel114. It will be understood that the axes of the rolls of the slit paper130and the interleaf paper132could be offset from each other in the front-to-back direction. For example, the axis of the roll of the interleaf paper132could be farther away from the back panel114and closer to the front panel112than the axis of the roll of the slit paper130.

FIG.6Bdepicts a partial front cross-sectional view of the insertion assembly140. In the depicted embodiment, the core136is wider than the interleaf paper132and extends into the slots146of the roll guides142. The spacers148are located around the core136of the interleaf paper132. In this embodiment, the interleaf paper132is unwound by pulling on the interleaf paper132to cause the core136to rotate with respect to the slots146and the roll guides.FIG.6Cdepicts a partial front cross-sectional view of another embodiment of an insertion assembly140′. The insertion assembly140′ is similar to the insertion assembly140except that the insertion assembly140′ includes a core136′ of the interleaf paper132that had a similar width to the interleaf paper132itself. The insertion assembly140′ also includes a shaft137that extends into the slots146of the roll guides142. The core136′ of the interleaf paper132is located around the shaft137and the core136′ is configured to rotate with respect to the shaft137. The spacers148are also located around the shaft137. In this embodiment, the interleaf paper132is unwound by pulling on the interleaf paper132to cause the core136′ to rotate with respect to the shaft137. In some cases, the arrangement of the insertion assembly140′ may be preferable because it may be easier to properly align the interleaf paper132on the core136′ because they have substantially similar widths than to align the interleaf paper132on the core136when they have substantially different widths.

An embodiment of the paths of the slit paper130and the interleaf paper132from their respective rolls to the dispensing aperture128is depicted inFIG.7. In the depicted embodiment, the slit paper130is withdrawn from the bottom of the roll and the slit paper130passes through a passive tension mechanism160before the slit paper130passes through the dispensing aperture128. The passive tension mechanism160is arranged to induce tension in the slit paper130as the slit paper130passes through the passive tension mechanism160. In some embodiments, the passive tension mechanism160is configured to induce a substantially constant amount of tension in the slit paper130regardless of the amount of the slit paper130remaining on the roll. In some embodiments, the term “passive” is used to mean one or more of an unpowered tension mechanism, a non-variable tension mechanism, and/or a tension mechanism that is not adjustable by an end user of the dispensing system.

In some embodiments, the passive tension mechanism160is a tortuous path tension mechanism. In the depicted embodiment, the passive tension mechanism160includes a rod162and a rod164. The slit paper130is fed from the bottom of the roll of the slit paper130around the back, top, and front of the rod162in a first direction (e.g., clockwise when viewingFIG.7). The slit paper130is then fed around the back and bottom of the rod164in a second direction that is opposite the first direction (e.g., counterclockwise when viewingFIG.7) before passing to and through the dispensing aperture128. The tortuous path through the passive tension mechanism160causes tension to be induced in the slit paper130such that the slit paper expands from an unexpanded state to an expanded state during and/or after the slit paper130passes through the passive tension mechanism160. In this way, the slit paper130is in the expanded state when the slit paper130passes through the dispensing aperture128. In the depicted embodiment, the profile of the tortuous path is an “S” shape.

In the depicted embodiment, the rods162and164of the passive tension mechanism160are formed as a part of the insertion assembly140. In this way, as the insertion assembly140is inserted into the container110, the passive tension mechanism160is also inserted into the container110. In other embodiments, the rods162and164of the passive tension mechanism160can be formed as a part of the container110such that the passive tension mechanism160is not inserted into or removed from the container110as the insertion assembly140is inserted into and removed from the container110. In some embodiments, the rods162and164can be hollow paper core structures, such as curbside recyclable hollow paper core structures.

In embodiments where the passive tension mechanism160includes the rods162and164, the rods162and164can take a variety of forms. In some embodiments, the rods162and164are static rods that do not rotate with respect to the container110and/or the insertion assembly140. Where the rods162and164are static rods, the movement of the slit paper130over the rods162and164causes friction between the slit paper130and the rods162and164. This friction as the slit paper130is being pulled induces the tension in the slit paper130. In some embodiments, the rods162and164are rollers that rotate with respect to the container110and/or the insertion assembly140. In some examples, the rollers rotate substantially freely with respect to the container110and/or the insertion assembly140. When the rods162and164are rollers, there will be less friction between the slit paper130and the rods162and164as the slit paper130is pulled through the passive tension mechanism160. However, the tortuous path of the passive tension mechanism160still induces tension in the slit paper130as the slit paper130is pulled through the passive tension mechanism160.

In the embodiment shown inFIG.7, the axes of the rods162and164are substantially aligned in the front-to-back direction (the direction from right to left when viewingFIG.7). For example, the axes of the rolls of the rods162and164are the same distances from the front panel112and the axes of the rolls of the rods162and164are the same distances from the back panel114. This arrangement can provide sufficient tension in the slit paper130to cause the slit paper to expand to the expanded state before the slit paper130passes through the dispensing aperture128.

The interleaf paper132is fed to the dispensing aperture128without inducing a significant amount of tension in the interleaf paper132. In the depicted embodiment, the interleaf paper132comes off of the bottom of the roll and proceeds on a path around the roll of the slit paper130and around the passive tension mechanism160before passing through the dispensing aperture128. In the depicted embodiment, the interleaf paper132, on its path from the roll of the interleaf paper132to the dispensing aperture128, contacts both the roll of the slit paper130and the portion of the slit paper130that passes around the rod162. The path of the interleaf paper132allows the slit paper130and the interleaf paper132to be pulled through the dispensing aperture128together while sufficient tension is induced in the slit paper130to expand the slit paper and while the interleaf paper132does not receive enough tension to tear or damage the interleaf paper132.

FIG.8depicts a side cross-sectional view of another embodiment of the dispensing system100. The embodiment shown inFIG.8is similar to the embodiment shown inFIG.7, except for the positioning of the rods162and164and the path of the interleaf paper132from the roll of the interleaf paper132to the dispensing aperture128. In the embodiment shown inFIG.8, the rods162and164are not substantially aligned in the front-to-back direction. In particular, the rod162is located closer to the front panel112than the rod164is located to the front panel. The arrangement of the rods162and164in this embodiment (as compared to the arrangement of the rods162and164in the embodiment shown inFIG.7) provides an even more tortuous path for the slit paper130through the passive tension mechanism160. Such an arrangement can increase the tension induced in the slit paper130and/or provide greater consistency in the tension induced in the slit paper130.

InFIG.8, the interleaf paper132feeds off of the top of the roll of the interleaf paper132. The interleaf paper132is fed around the passive tension mechanism160to the dispensing aperture128. On the path from the roll of the interleaf paper132to the dispensing aperture128, the interleaf paper132contacts the portion of the slit paper130that passes around the rod162, but the interleaf paper132does not contact the roll of slit paper. This path of the interleaf paper132also causes the rolls of the slit paper130and the interleaf paper132to counterrotate as the slit paper130and the interleaf paper132are withdrawn from the rolls.

FIGS.9and10show perspective and partially-hidden perspective views, respectively, of the dispensing system100while the slit paper130and the interleaf paper132are being dispensed through the dispensing aperture128. The slit paper130and the interleaf paper132are being dispensed through the dispensing aperture128as shown inFIGS.9and10using both the embodiment of the passive tension mechanism160shown inFIG.7and the embodiment of the passive tension mechanism160shown inFIG.8. To dispense the slit paper130and the interleaf paper132, a user can grasp the ends of the slit paper130and the interleaf paper132and pull them through the dispensing aperture128. As this pulling force is applied, the combination of the pulling force and the tension induced by the passive tension mechanism160causes the slit paper130exiting the container110through the dispensing aperture128to be in the expanded state. The pulling force can also pull the interleaf paper132without ripping or tearing the interleaf paper132. When the user determines that sufficient amounts of the slit paper130and the interleaf paper132have been pulled out for packaging an object, the user can tear or cut both the slit paper130and the interleaf paper132to break off the slit paper130and the interleaf paper132from the webs of the slit paper130and the interleaf paper132.

The embodiments of dispensing systems depicted herein include both a roll of slit paper and a roll of interleaf paper. It will be understood that, while the inclusion of the interleaf paper may be advantageous in certain circumstances, slit paper can be used without interleaf paper. Thus, the interleaf paper in all of the embodiments depicted and discussed herein will be understood to be an optional feature of the dispensing system. It will also be understood that any of the dispensing systems described herein could be modified such that the only roll held within the dispensing system is a roll of slit paper.

One of the advantages of using slit paper130as a cushioning material is that the slit paper130is easily recyclable for end consumers. In many jurisdictions (e.g., municipalities, counties, etc.), slit paper can be recycled by an end user by simply placing the slit paper in curbside recycling bins. This ease of recyclability is appealing to suppliers and consumers alike who want to lessen the impact of their packaging materials on the environment. In some cases, it would also appealing not only for the slit paper itself to be easily recyclable but also for the dispenser itself to be made from easily-recyclable materials. For example, in the embodiment of the dispensing system100, each of the container110, the cores134and136, the roll guides142, and the spacers148can be made from fiber-based materials, such as cardboard, paperboard, kraft paper, cardstock, and the like. Cardboard materials may comprise corrugated cardboard, such as any of single-wall B-flute, C-flute, and/or E-flute corrugated cardboard, B/C double-wall corrugated cardboard, EB double-wall corrugated cardboard, or any combination thereof. In this way, when the rolls of the slit paper130and the interleaf paper132are exhausted, most parts of the dispensing system100can be recycled in the same way that paper products are recycled. While most parts of the dispensing system100can be made from fiber-based materials, some of the part can be made from other materials. For example, one or more parts (e.g., the endcaps144) can be formed from another materials. In some embodiments, the endcaps144are made from plastic. In some embodiments, the rods162and164are made from one of a fiber-based material, a wood material, and/or a metal material. In some embodiments, not all components of the dispensing system100can be made from fiber-based materials. For example, the endcaps144may not work as desired if they are made from fiber-based materials. In those cases, it may be advantageous to use a polymer material that is easily recyclable and/or formed from recycled materials, such as polypropylene. In other cases, the endcaps144can be omitted, such as in the case where the core134of the slit paper130extends beyond the ends of the slit paper130to directly engage the roll guides142(e.g., similar to how the core136of the interleaf paper132directly engages the roll guides142).

In some embodiments, it may also reduce waste for the container110to be used to ship and/or distribute the slit paper130and, when included, the interleaf paper132. For example, the container110can be made from cardboard and form a cardboard box. The container can be closed for shipping and/or distributing the dispensing system100. The dispensing flap126can be formed in the front panel by perforated lines along the bottom and sides of the dispensing flap126. When an end user receives the dispensing system, the user can break the perforated lines of the dispensing flap126and pull the dispensing slot to the position shown inFIGS.9and10in order to open the dispensing aperture128. In some embodiments, it may be advantageous for the end of the slit paper130(and the end of the interleaf paper132, when included) to be releasably connected (e.g., taped) to the inside of the dispensing flap126. In this way, when the user opens the dispensing aperture128, the end of the slit paper130and/or the end of the interleaf paper132can easily be released and pulled through the dispensing aperture128to begin dispensing the slit paper130and/or the interleaf paper132. The user can then dispense the slit paper130until the roll is exhausted, at which point any of the recyclable materials of the dispensing system100can be recycled.

FIGS.11and12depict perspective of an embodiment of a dispensing system100′ capable of dispensing expanded slit paper in closed and open conditions, respectively. The dispensing system100′ includes a container110′, which is a variation of the container110. In the depicted embodiment, the container110′ is a box that includes the front panel112, the back panel114, the left and right panels116and118, the bottom panel119, the top panel120, and the flap122. InFIG.11, the container110′ is in a closed condition with the top panel120closed. InFIG.12, the container110′ is in an open condition with the top panel120open. The front panel112also includes tabs124′ that are inserted into slots between the top panel120and the flap122when the top panel120is closed to deter opening of the top panel120. It will be apparent that any number of tabs124′ can be used in any of the embodiments described herein.

The front panel112also includes a dispensing flap126′. In some embodiments, the dispensing flap126′ is defined by perforated lines in the front panel112and an end user removes the dispensing flap126′ from the front panel112by tearing the perforated lines.FIG.11shows the dispensing flap126′ with perforated lines around the perimeter of the dispensing flap126′.FIG.12shows the dispensing flap126′ in the process of being removed from the front panel112. When the dispensing flap126′ is full removed from the front panel112, the front panel112has a dispensing aperture128′ through which a web of slit paper and/or a web of interleaf paper can be dispensed from the inside of the container110′, through the dispensing aperture128′, to the outside of the container110′. In the depicted embodiment, the dispensing system100′ includes the supply of slit paper130, the supply of interleaf paper132, and the insertion assembly140.

For purposes of this disclosure, terminology such as “upper,” “lower,” “vertical,” “horizontal,” “inwardly,” “outwardly,” “inner,” “outer,” “front,” “rear,” and the like, should be construed as descriptive and not limiting the scope of the claimed subject matter. Further, the use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless limited otherwise, the terms “connected,” “coupled,” and “mounted” and variations thereof herein are used broadly and encompass direct and indirect connections, couplings, and mountings. Unless stated otherwise, the terms “substantially,” “approximately,” and the like are used to mean within 5% of a target value.