Shipping and dispensing box for slit sheet material

Exemplary embodiments pertain to a combined shipping and expansion device for shipping a roll of unexpanded slit sheet material and for expanding the slit sheet material. In some examples, the device includes: a container made with recyclable paper or board; a roll of slit sheet material wound around a core member and positioned within the container; the roll of slit sheet material having a slit pattern that forms open cells upon expansion; the core member being made with recyclable paper or board and having a length greater than a width of the roll of slit sheet wound around the core member and having protrusions that extend beyond each side of the roll of slit sheet material; a plurality of yoke members within the container, including at least one yoke member that rotatably receives a first of the protrusions and at least one yoke member that rotatably receives a second of the protrusions; and the container having a dispensing opening through which the slit sheet material wound around the core member can be extended and pulled, causing the core member to rotate relative to the yoke members via rotation of the roll of slit sheet material. The combined shipping and expansion device is made from substantially entirely recyclable paper or board materials, whereby after complete dispensing of the slit sheet material from the shipping and expansion device, the combined shipping and expansion device can be recycled in a paper recycling facility.

The present application is a non-provisional of prior U.S. provisional application No. 62/571,382, filed Oct. 12, 2017, and prior U.S. provisional application No. 62/633,630, file Feb. 22, 2018, the entire disclosures of which are both incorporated herein by reference.

BACKGROUND

Technical Field

The preferred embodiments relate to, e.g., the use of a corrugated box and tensioning device made from paper able to be completely recycled when discarded.

The Background Art

There have been a number of devices to dispense expanded slit sheet material. Each device has plastics or metals or wood to provide the tensioning required to simultaneously feed and expand the expandable slit sheet material.

SUMMARY

The preferred embodiments advantageously overcome shortcomings of the above and other background art.

In accordance with some embodiments of the invention, the use of a shipping box and tensioning device, made completely of paper, enables them both to be completely recycled when the expanded slit sheet material has been fully dispensed.

According to some embodiments of the invention, a combined shipping and expansion device for shipping a roll of unexpanded slit sheet material and for expanding the slit sheet material is provided that includes: a) a container having: a first pair of side wall members; a second pair of side wall members; a bottom panel; and a top cover panel; b) a roll of slit sheet material wound around a core member and positioned within the container; c) the roll of slit sheet material having a slit pattern that forms open cells upon expansion; d) the core member having a length greater than a width of the roll of slit sheet wound around the core member and having protrusions that extend beyond each side of the roll of slit sheet material; e) a plurality of yoke members within the container, including at least one yoke member that rotatably receives a first of the protrusions and at least one yoke member that rotatably receives a second of the protrusions; and f) a friction member arranged to apply frictional pressure against at least one of the protrusions for regulating force required to rotate the roll with respect to the yoke members during unwinding of the roll of slit sheet material from the core member.

In some examples, the core member is a hollow paper tube end the container is formed from corrugated board. In some examples, the yoke members each have an arcuate opening with a radius of curvature that is substantially equal to a radius of the core member. In some examples, the at least one yoke member that rotatably receives the first of the protrusions and the at least one yoke member that rotatably receives the second of the protrusions each include two adjacent yoke members for increased support of each of the protrusions.

In some examples, the adjacent yoke members are separate yoke panel that are placed adjacent one another, with a first of the adjacent yoke panels folded downward over a second of the adjacent yoke panels. In some examples, the first of the adjacent yoke panels includes an extension tab that is received within a receiving slot formed in or proximate the bottom panel, locking the first of the adjacent yoke panels folded downward over the second of the adjacent yoke panels.

In some examples, each of the yoke members being formed on respective contiguous panels connected to the first pair of panels, each of the contiguous panels including a respective one of the arcuate openings, and each of the contiguous panels being folded to a position overlying a respective panel of the first pair of panels such that its respective the arcuate opening is arranged to receive a respective one of the protrusions of the core member.

In some examples, the roll of slit sheet material is positioning within the combined shipping and expansion device and with each of the cylinder protrusions in contact with a respective one of the arcuate openings. In some examples, a first of the second pair of side wall members has an elongated tear-away region extending from a position proximate a first of the second pair of side wall members to a position proximate a second of the second pair of side wall members.

In some examples, the top cover panel being movably mounted above the roll of slit sheet material within the container and being movable to apply pressure to the friction member, and releasable affixing means for releasably affixing the top cover panel with respect to the friction member to regulate the force required to rotate the roll with respect to the yoke members during unwinding of the roll of slit sheet material from the core member. In some examples, the releasable affixing means includes a releasable attachment mechanism that includes at least a portion substantially directly above the core. In some examples, the releasable affixing means includes two releasable attachment mechanisms located proximate opposite sides of the container.

In some examples, the friction member is a tensioning panel having an arcuate surface configured to be pressed against an upper surface of the core. In some examples, the tensioning panel has a through-hole opening that receives one of the protrusions of the core, and wherein the through-hole opening completely surrounds a perimeter of the core such as to be retained by the core. In some examples, the tensioning panel has an elongated slot that extends through a side edge of the tensioning panel such that the tensioning panel is laterally slidable with respect to a protrusion of the core with the protrusion received within the elongated slot. In some examples, the releasable affixing means is a releasable adhesive, and, in some examples, the releasable affixing means is hook and loop fasteners. In some examples, the friction member arranged to apply frictional pressure against at least one of the protrusions includes a tensioning member configured to slidingly move within the container, the tensioning member having an arcuate surface configured to be positioned against the at least one of the protrusions for applying pressure against the at least one of the protrusions. In some examples, the top cover panel is variably movable against a pressing surface of the tensioning member that is opposite to the arcuate surface, whereby the top cover can be moved to increase a force against the pressing surface and increase the pressure applied by the arcuate surface against the at least one of the protrusions.

In some examples, the top cover panel has at least one depending tab member positioned to contact the pressing surface of the tensioning member when the top cover panel is in a closed position. In some examples, the tensioning device having a height that is less than an interior height of the container such that the tensioning device applies pressure to the at least one of the protrusions without contacting the bottom panel. In some examples, the invention further includes at least one removable spacer, the at least one removable spacer being positioned between ends of the roll of slit material and the first pair of panels of the container to stabilize the roll of slit material during shipping of the combined shipping and expansion device. In some examples, the at least one removable spacer includes an elongated slot that extends from an open first end to an arcuate shaped end, thereby forming an elongated channel having an arcuate end, the arcuate end being positioned around the at least one of the protrusions. In some examples, the at least one spacer includes a packing member having downwardly extending panels placed at each end of the roll. In some examples, the at least one spacer includes two spacers, with a respective one of the spacers placed at each end of the roll.

In some examples, the slit sheet paper is extensible and has an extensible range from 1-9% in a machine direction and 1-5% in a cross direction. In some examples, the extensible paper has an extensible range from 1-6% in the machine direction and 1-4% in the cross direction. In some examples, the extensible paper has an extensible range from 1-4% in the machine direction and 1-3% in the cross direction. In some examples, the slit sheet is expandable by applying an expansion force in a range from 0.15 to 0.22 pounds per inch, to form at least one expanded sheet having an array of hexagonal cells. In some examples, the slit sheet paper is a paper having a weight in a range from about 30 to 40 pounds per 3,000 square feet.

According to some other embodiments, a combined shipping and expansion device for shipping a roll of unexpended slit sheet material and for expanding the slit sheet material is provided that includes: a) a container made with recyclable paper or board; b) a roll of slit sheet material wound around a core member and positioned within the container; c) the roll of slit sheet material having a slit pattern that forms open cells upon expansion; d) the core member being made with recyclable paper or board and having a length greater than a width of the roll of slit sheet wound around the core member and having protrusions that extend beyond each side of the roll of slit sheet material; e) a plurality of yoke members within the container, including at least one yoke member that rotatably receives a first of the protrusions and at least one yoke member that rotatably receives a second of the protrusions; and f) the container having a dispensing opening through which the slit sheet material wound around the core member can be extended and pulled, causing the core member to rotate relative to the yoke members via rotation of the roll of slit sheet material; wherein the combined shipping and expansion device is made from substantially entirely recyclable paper or board materials, whereby after complete dispensing of the slit sheet material from the shipping and expansion device, the combined shipping and expansion device can be recycled in a paper recycling facility.

According to some further embodiments, a method of using the combined shipping and expansion device according to the present invention includes: a) shipping the combined shipping and expansion device to a location of a user; and b) at the location of the user, manually pulling the slit sheet material outward through the dispensing opening and expanding the slit sheet material.

In some examples, the method further includes after fully dispensing the slit sheet material from the container delivering the combined shipping and expansion device to a paper recycling facility. In some examples, the method further includes after fully dispensing the slit sheet material from the container disposing of the combined shipping and expansion device, whereby the combined shipping and expansion device is used as a single-use shipping and expansion device. In some examples, the method further includes that the disposing of the combined shipping and expansion device includes delivering the combined shipping and expansion device to a paper recycling facility for recycling. In some examples, the method further includes providing the container with an elongated tear-away region that covers the dispensing opening during the shipping, and further including removing the tear-away region prior to the manually pulling and expanding.

In some examples, the method further includes applying pressure on the core member during the manually pulling and expanding with a tensioning device that frictionally contacts at least one of the protrusions of the core member.

In some examples, the method further includes adjustably increasing pressure upon the core member via the tensioning device by adjustably positioning of an adjustable panel of the container.

In some examples, the adjustable panel of the container is a cover of the container and adjustably positioning the cover using a releasable affixing means.

In some examples, the method further includes stabilizing the roll of slit material during the shipping with respect to the core member with at least one spacer located proximate opposite ends of the roll of slit material, and removing the at least one spacer prior to the manually pulling and expanding.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

While the present invention may be embodied in many different forms, the illustrative embodiments are described herein with the understanding that the present disclosure is to be considered as providing examples of the principles of the invention and that such examples are not intended to limit the invention to preferred embodiments described herein and/or illustrated herein.

Definitions

In this application, the following terminology should be interpreted based on the definitions set forth below.

For the purposes of the present application, the term “Hexacomb” (employed in light of the product trademark Hexacomb®) means a panel constructed of two paper sheet housing vertical hexagonal cells that can be manufactured in various thicknesses to fill gaps.

For the purposes of the present application, the descriptions and terminology in relation to the paper and slit patterns within the embodiments set forth in U.S. Pat. No. 5,667,871, are applicable to some preferred embodiments in this present application.

For the purposes of the present application, the term “telescope” means a lateral movement of a roll of paper along an axis of the core member, including minimal lateral movement at the region of the roll having the smallest diameter (i.e., closer to the core member) and larger lateral movement at the region of the roll having the largest diameter (i.e., further from the core member). The tendency to telescope is due, in part, to the unexpended slit sheet paper having a narrower width than the paper core around which the slit sheet paper is wound.

For the purposes of the present application, the term “paper core” means a round paper tube around which an expanded slit sheet paper is wound.

For the purposes of the present application, the term “cylinder” as employed herein, means an elongated member or tube having a solid or hollow circular cross-section.

For the purposes of the present application, the term “contiguous” means that two parts are connected in a continuing sequence, such as, e.g., by a solid or perforated fold line.

For the purposes of the present application, the term “expandable” as applied to paper sheets, means a paper having a slit pattern that enables the paper to be expanded by opening of the slits upon applying a force in a longitudinal direction of the paper sheet.

Further information relating to the paper, slit patterns, and the expansion process which can be used in some embodiments of the present invention is found in: a) the following U.S. Pat. Nos. 5,538,778; 5,667,871; 5,688,578; 5,782,735; 3,908,071; 3,104,197; 3,220,116; 3,266,972; 3,269,393; 3,908,071; 6,024,832; 6,458,447; and 6,712,930; b) the following international PCT application(s): WO 1984002936A1; and c) the following U.S. published applications: 2014/901977; 2002/0060034; and 2007/0240841, the entire disclosures of which patents and applications are all incorporated by reference herein, as though recited herein in full.

In addition, the entire disclosures of U.S. Publication 2018/0127197-A1 (U.S. application Ser. No. 15/820,514), U.S. Publication 2018/0222665 A1 (U.S. application Ser. No. 15/428,144) and U.S. Provisional Application 62/524,905 (filed as U.S. Non-Provisional application Ser. No. 16/018,702, and internationally published as PCT/US2018/039416) are incorporated by reference herein in their entireties as if recited herein in full as part of the description of the present invention.

Application PCT/US2018/039416 describes a use of extensible paper to greatly reduce the tension required to stretch the slit sheet material. It is particularly useful for the new art shipping box and tensioning device of this application to utilize the extensible paper of the PCT/US2018/039416 application in some preferred embodiments. Although such extensible paper is employed in some preferred embodiments, as described herein other papers can be employed in other embodiments.

For the purposes of the present application, the term “extensible” as applied to paper sheets means a paper sheet that is able to stretch in a longitudinal direction of the paper sheet upon applying a force In the longitudinal direction of the paper sheet. Illustrative extensible sheets are disclosed in U.S. Pat. No. 3,908,071, U.S. patent application Ser. No. 14/901,977 (U.S. Pat. No. 9,945,077), International Application No. WO 1984002936, U.S. Publication Nos. 2002/0060034, 2007/0240841 (U.S. Pat. No. 7,918,966), and U.S. Pat. Nos. 3,104,197, 3,220,116, 3,266,972, 3,269,393, 3,908,071, 6,024,832, 6,458,447, and 6,712,930, the entire disclosures of which are incorporated by reference herein, as though recited herein in full. It should be understood that the stretching of an extensible paper must be measured in an unslit sheet of paper. As disclosed in U.S. Pat. No. 3,266,972, the test and characterization procedures employed in measuring elongation (extensibility) properties can be in accordance with standard TAPPI test Elongation T457. In addition, as disclosed in U.S. Pat. No. 3,266,972, the expression “extensible papers” means a paper having an increasable elongation in the machine direction as compared to standard, non-extensible Kraft paper.

For the purposes of the present invention the term extensible slit sheet papery means a paper that is both extensible and expandable. In accordance with another embodiment of the invention, the use of extensible paper reduces the tendency of the slit paper to tear during the expanding of the expandable slit sheet paper without negating the ability to tear the expanded slit sheet paper from the roll of expandable slit sheet paper at the end of the wrapping step.

DETAILED DESCRIPTION

In accordance with some preferred embodiments of the invention, an expanded slit sheet paper is employed that is made with an extensible paper that, e.g., advantageously substantially reduces a pulling force necessary to expand the expanded slit sheet material. Among other benefits, this reduced pulling force leads to a variety of very substantial benefits, including that it avoids previously required complex resistant devices that were previously necessary and opens the market to smaller manual expansion devices that can be made to be almost completely recyclable.

In some preferred embodiments, machine direction extensibility ranges of the extendible slit sheet paper can have ranges of:a) from 1.5%-9%, or more preferably from 1.5% to 6%, or even more preferably from 1.5% to 4%; orb) from 2%-9%, or more preferably from 2% to 6%, or even more preferably from 2% to 4%; orc) from 3%-9%, or more preferably from 3% to 6%, or even more preferably from 3% to 4%.

In some preferred embodiments of the present invention, the extensible paper that is employed has low extensible properties as compared to other types of extensible papers. In this regard, an optimal extensible paper enables a smooth transition from an unexpanded to the expanded slit sheet by providing a small amount of stretching at the very start of expansion of the extensible slit sheet paper material.

In accordance with a broad embodiment of the invention, the use of extensible paper reduces the pulling force necessary to stretch the expanded slit sheet material and thereby expands the market to include, e.g., void fill usage and lighter weight papers for greater cushioning effect for very fragile items.

In accordance with another embodiment of the present invention, an extensible slit sheet paper product is produced having a slit pattern that forms open cells upon expansion of the paper product. In some preferred embodiments, the paper product is an extensible paper having an extensibility in the range from 1-9% in the machine direction and 1-5% in the cross direction. Preferably, the extensible paper has an extensible range from 1-6% in the machine direction and 1-4% in the cross direction. Most preferably, the extensible paper has an extensible range from 1-4% in the machine direction and 1-3% in the cross direction.

In accordance with some preferred embodiments of the present invention, an extensible slit sheet paper product is produced having a slit pattern that forms open cells upon expansion of said paper product, wherein said slit sheet is expandable by applying an expansion force in the range from 0.15 to 0.22 pounds per inch, to form at least one expanded sheet having an array of hexagonal cells and where the extensible paper has an extensible range from 1-6% in the machine direction and 1-4% in the cross direction.

For the purposes of expanding the slit sheet paper for use as a packaging wrap, it has been found that cross direction extensible ranges from 1%-5% provides an adequate extensibility, with ranges of 1% to 4% being more preferred, and with ranges of 1% to 3% being most highly preferred.

In some alternative embodiments, cross direction extensibility ranges of the extendible slit sheet paper can have ranges of:a) from 1.5%-5%, or more preferably from 1.5% to 4%, or even more preferably from 1.5% to 3%; orb) from 2%-5%, or more preferably from 2% to 4%, or even more preferably from 2% to 3%.

In some preferred embodiments, a shipping box with an integrated dispenser is provided. In preferred embodiments, a shipping box with such an integrated dispenser has particular utility and advantages when combined with an extensible paper because of, e.g., the ease of expansion of the extensible paper. Among other things, this can expand the market to customers that use a very small amount of wrap as compared to the industrial market.

Additionally, employment of extensible paper in preferred embodiments also enhances the ease of use by the packer by providing for less ripping during the wrapping process that occurs when the tension is not properly set. As the roll of expanded slit sheet becomes smaller and lighter, there is an increased requirement to increase the tension. With the use of the extensible paper, the tension required is significantly decreased and the strength of the paper is increased. Both benefit the person wrapping by making the tensioning required much less precise, even to the point at which a single tension setting can be used with little or no adjustment. If the tension is set higher than necessary, the increase in strength from the extensible paper keeps the product from tearing and, therefore, makes it easier for the packer to use. Therefore, the packer can make fewer adjustments as the slit sheet roll becomes smaller and smaller as the paper is unwound from the roll, reducing the diameter of the remaining paper on the roll).

In some preferred embodiments, a shipping box (“box”) and tensioning device is made from paper and, most preferably, made from corrugated paper.

In the preferred embodiments, the shipping box is also the dispenser/expander of the slit sheet material with tensioning adjustments made using the top flap in combination with two hook and loop strips that hold the tension adjustment in place that presses on the tensioning devices.

In some preferred embodiments, a method by which a shipping box is prepared to be used includes the following steps:(1) The top cover104ofFIG. 7is opened and spacers601and double-sided adhesive strips603, as found inFIG. 6, are removed.(2) Tensioning devices are placed between yokes106ofFIG. 1and slit paper roll402ofFIG. 4, on both sides.(3) Double-sided adhesive strips801are attached to the bottom of the shipping box as shown inFIG. 8.(4) Tear-away strip110ofFIGS. 1 and 2is removed from the front panel101ofFIG. 1.(5) Expanded slit sheet material602shown inFIG. 6(i.e., which is optionally used as a protective padding around at least portion of the roll402during shipping) is removed. In some examples, it is removed from under the open top cover104. In some embodiments, it can be removed by unwinding the slit sheet roll402shown inFIG. 5and feeding the expanded slit sheet material602through the tear-away opening110shown inFIG. 2until the expanded material602shown inFIG. 6is fully exits the opening110and is clear and the unexpanded slit sheet404ofFIG. 5appears.(6) The top cover104ofFIGS. 5 and 6can then be gently closed for the expansion of the full roll of slit sheet material404ofFIGS. 4 and 5that requires no tension.(7) As the slit sheet roll402ofFIG. 4becomes smaller, tension will eventually be required and is done so by closing the top cover104ofFIG. 2more firmly in a downward manor and using the hook and loop strips112and113ofFIG. 2to maintain the top cover104position.(8) As more tension is required the top cover104ofFIG. 2would be adjusted further downward by un-attaching the hook and loop strips112and113ofFIG. 2and reattaching them in the new optimum position.

While the use of hook and loop strips is preferred, in other embodiments, other forms of releasable attachment mechanisms can be employed. For example, in some embodiments, a releasable adhesive can be employed, wherein an adhesively attached closure can be repeatedly opened and resealed. In some examples, a number of appropriate release coatings may be used in some embodiments of the present invention. In some examples, resealable closures can employ features as shown in the following references, which are all incorporated herein by reference in their entireties: G.B. 2147564A; U.S. Pat. No. 2,822,290 (Webber); U.S. Pat. No. 2,880,862 (Sermattei); U.S. Pat. No. 2,985,554 (Dickard); U.S. Pat. No. 4,902,141A (Linnewiel); and U.S. Pub. No. 2002/0164477 (Lonc, et al.).

Other exemplary resealable closures that can be employed in embodiments of the present invention are shown in the U.S. Patents discussed below in this paragraph, the entire disclosures of which are incorporated herein by reference. A first example is shown in U.S. Pat. No. 6,726,054 which is designed for containing breath films or other oral care strips in which the package includes a blister pack having a hinged flap which is resealable against the top surface of the blister pack. The package has a top surface which forms a flange around the perimeter opening of the tray compartment. A second example is shown in U.S. Pat. No. 6,691,886 which includes a plastic tray with a lid film that includes a sealing area around its perimeter which seals to a flange surface of the tray. A third example is shown in U.S. Pat. No. 5,647,506 which shows another resealable container that includes a dispenser for moisture-impregnated articles such as moist tissues using a rigid plastic container with an opening formed in its top surface, wherein a resealable label reseals the top opening.

In preferred embodiments, the hook and loop strips do not interfere with the recyclability of the paper. In some preferred embodiments, the tensioning devices are shipped loose on top of the roll of slit paper within the package and are put in place by the user at the required time—that is, the user preferably installs the tensioning devices when the dispensing is to be commenced.

In some embodiments, when first dispensing the slit sheet paper roll, no tension is necessary. That is, in some embodiments, the initial weight of the roll achieves sufficient frictional resistance to enable expansion of the paper upon pulling by a user without providing additional tension. However, as the roll reduces in weight and diameter during use, the roll will spin more freely due to the decreased weight and require an increasing amount of tension. Thus, in preferred embodiments, a tensioning device is provided.

In some preferred embodiments, the shipping box, tensioning device and the paper core upon which the slit sheet material was wound are recyclable, such that, after use, they can be together discarded by placing in a recycling bin or the like for recycling paper.

In some preferred embodiments, based on the various diameters and weight weights of the slit sheet roll size, the corrugated material can be single or double wall walled material. In some preferred embodiments, the shipping box and tensioning device are made from single wall material. In some embodiments, the two yokes106ofFIG. 1that support the paper core483ofFIG. 4, that enables the slit sheet roll402ofFIG. 4to rotate, are also be made with single wall material; for example, such a single wall material can be employed in embodiments having an 8-inch diameter paper roll that weighs 10 pounds. On the other hand, in some embodiments having a 10-inch diameter 20-pound roll, double wall walled corrugated yokes can be employed.

With reference toFIG. 1,FIG. 1is a planar view of a shipping box100according to some illustrative embodiments after completion of a die-cut manufacturing process. In particular, in some embodiments, a flat sheet is die-cut to the form shown inFIG. 1. Then, the sheet is folded to create the shipping box100. In some embodiments, the specific order employed to setup the box for use includes that the shipping box bottom101is oriented such that side panels105are to the left and right of the person setting up the box. Then, the front panel102and back panel103are lifted so that they are oriented upright (e.g., 90 degrees) from the bottom of panel101. Then, the vertical interlocking panels107and108are turned inward towards panel101(e.g., by 90 degrees). Then, the side panels105are rotated upward to rest against vertically oriented interlocking panels107and108. This leaves yoke panels106that are attached to side panels105in the vertical position, but that are immediately folded inward and around vertical interlocking panels107and108with spacer panels111becoming the horizontal spacer that rests on top of the interlocking panels107and108. The yoke panels106are then locked in place with locking tabs115that are placed into receiving holes114. After the shipping box100is setup, the slit paper roll402and paper core403assembly ofFIG. 4is placed into the box as shown inFIG. 5. For reference,FIG. 16shows an illustrative paper roll402supported on a paper core403(i.e., in a similar manner to that shown in FIG. 9 of U.S. 2018/0222665). As illustrated, the paper core403is longer in an axial direction (i.e., in a direction transverse to the pulling direction of the paper from the roll (i.e., the widthwise direction) than the paper roll wound on the core, such that opposite ends of the core protrude outwardly from the paper roll402wound around the core.

Then, the top cover tabs109are folded inward and adhered onto the inner side of top cap104as shown inFIG. 2. Preferably, the tear-away flap110(shown inFIG. 2) is not removed until the shipping box100is used as a dispensing box as shown inFIG. 5. Then, the pads113are adhered to the exterior of front panel113and loop pads112are adhered to the interior of the top folding panel116.

FIG. 2is a perspective view of a partially constructed shipping box100showing shipping box sides102,103and the left lateral side105having been first put in the upright position. Then, the left yoke106, on the left as shown inFIG. 2, is folded over and around the inwardly-folded interlocking panels107and108with spacer section111(i.e., between the side105and yoke106) resting on top. Then, the same process is performed on the right-hand side. The folding flap116is then folded inward (e.g., 90 degrees) in relation to the top cover104. In this manner, the hook and loop pads112and113, respectively, can now be positioned to make contact and connect together when top flap104is folded downward and top folding panel116is pressed towards and against the front panel102. Side panels105have an additional relief area119that enables top cover tabs109which, have been folded completely inward, and which are adhered to an underside of the top cover104, to apply pressure to the tensioning devices300as shown inFIG. 3without interference from side panel105. In this manner, when the slit sheet roll402becomes smaller as it is used (i.e., as paper is dispensed from the roll402), the tensioning device300is pressed downwards to apply a pressure against the core403to increase resistance in order to compensate for the smaller (i.e., lighter) slit sheet roll402, as it is being used up. In the configuration shown inFIG. 2, the tear-away flap110is still in its shipping configuration and is still attached to front panel102.

FIG. 3is a front view of the tensioning device300according to some preferred embodiments. As shown, the tensioning device300has a yoke area302that is configured to be placed so as to straddle over an extending portion of the paper core403as shown inFIG. 4. The side areas301of the tensioning device300are configured to slide or rub against front panel101and back panel103, respectively, for guidance. This helps to maintain a straight downward pressure. The recess region302of the tension device300is configured to have a similar radius of curvature to the core403and to press against an upper surface of the core member403such as to apply a variable frictional resistance to the rotation of the core member403. That is, the amount of frictional resistance can be adjusted by adjusting the amount of downward pressure that is applied against the tensioning device.

FIG. 4is a perspective view of the tensioning device300as it sits vertically on paper core403adjacent to the slit sheet roll402. In the figure,401shows an open area underneath tensioning device300. This is created by making tensioning device300shorter than the total interior height of shipping box100to enable constant tension without it hitting the bottom of the box. It should also be appreciated that the bottom surface of the core403at ends of the core that extend from the roll402are supported within the box100upon the respective cut-out openings of the yokes106. In this manner, the core403is supported at a fixed height within the box100, while the tensioning device300can be positionally adjusted with respect to the height of the core403to vary the pressure applied by the tensioning device300against the core403.

FIG. 5is a perspective view of the packaging assembly500set up to dispense and provide tension to the slit sheet roll402. To apply tensioning via the tensioning device300, the top cover104is moved downward from the position illustrated and the folding tabs109are pressed against tensioning device300. The top folding panel116is used to lock the tensioning device300into position by guiding the hook and loop material112and113to make contact and lock in place. Notably, in the preferred embodiments, the pads112and113are sized to enable the vertical positions of the pads112with respect to the pads113to be variably selected by a user to manually vary the amount of pressure applied via the tensioning device300. Then, the tear-away sheet110is rotated upward or completely removed to enable the slit sheet paper404to exit the dispenser system500. The paper can be unwound from the roll402and dispensed through the opening at404as shown. Although in some embodiments the paper roll can be dispensed with a clockwise or counterclockwise rotation, in the arrangement as shown inFIG. 5the paper roll is preferably dispensed with a counterclockwise rotation of the roll402. More particularly, in the preferred embodiments, the roll402is rotated so that the paper is separated from the roll402at a lower position of the roll (i.e., proximate to the height of the opening at the tear-away sheet).

With reference toFIG. 6,FIG. 6shows an illustrative assembly process for preparing the shipping box100for shipping. As shown, a roll402of expanded slit sheet material is wrapped around a core (not shown inFIG. 6) with the slit sheet material in the roll402in an unexpanded state. As shown inFIG. 6, in order to help further protect the roll402during shipping. In some preferred embodiments, a padding602is inserted within the container during shipping. In some embodiments, the padding602can be formed of expanded slit sheet material in an expanded state, and in some embodiments, the padding602can be formed of a plurality of layers of such expanded slit sheet material in such expanded state. In the illustrated example, the padding602is formed so as to surround the roll and can have a substantially rectangular shape that is bent around the roll402as shown. In some embodiments, the padding is sized to substantially entirely surround the circumference of the roll402. In some embodiments, the padding602can surround only a portion of the roll, such as, e.g., an upper surface of the roll. Moreover, in some embodiments, the padding can include a plurality of padding portions, with, e.g., a first padding portion over an upper portion of the roll (e.g., as shown inFIG. 6) and, e.g., a second padding portion under a lower portion of the roll. In the illustrated example, ends of the roll402are exposed below the padding. The padding is preferably employed to help fill any gaps around the periphery of the roll402and the walls of the container. As shown inFIG. 6, the roll402is also preferably sized to substantially fill the container, while the padding602helps fill remaining gaps around the roll402and the four sides of the shipping box100. In addition, in the preferred embodiments, thick spacers601are preferably provided to fill spaces at the ends of the roll corresponding to the extended portions of the core403extending from the roll. In the preferred embodiments, the spacers are made from multiple layers of corrugated paper or Hexacomb® or the like and are placed adjacent to the slit sheet roll402and straddling the core403in order to prevent telescoping movement of the roll402with respect to the core403during shipment. In some preferred embodiments, the spacers601are made one quarter of an inch shorter than the tensioning device300so that the folding tabs109do not make contact during shipment. In preferred embodiments, tensioning devices300can be placed on top of the expanded slit sheet material or the like padding602for storage during shipment, such as schematically depicted inFIG. 6. In some preferred embodiments, double sided adhesive strips603can also be placed on top of tensioning devices300for later use, such as shown inFIG. 8.

With respect toFIG. 7,FIG. 7shows an illustrative packing system700in a closed state. As shown, the closed slit roll packing system700is ready for shipment with the top cover104in its closed position.

With respect toFIG. 8,FIG. 8is a perspective view according to some illustrative embodiments in which the bottom of the shipping box is provided with double-sided adhesive or tape attached to bottom shipping box panel101. In some preferred embodiments, during use the double-sided adhesive or tape can be used to help stabilize the dispenser on a surface during use. In some implementations, this embodiment can also be used to facilitate stacking and/or stabilizing of a plurality of shipping boxes during shipping or the like. However, in some preferred embodiments, the adhesive or tape would be covered during shipping and only exposed prior to use to provide stability during use.

With respect toFIG. 9,FIG. 9is a perspective view showing another optional mechanism to facilitate stabilizing of the box during use. As shown, in some embodiments, the back panel of the shipping box100and include a clamping tab that is configured to facilitate stabilizing the box on a table during use upon a packing table900. As shown, in some embodiments, a releasable clamping tab opening901is created by folding the releasable clamping tab902from an upright position and downward in an arc204to a horizontal state resting in a flat position203on the table900.

FIG. 10is a perspective view of the shipping box100resting on a table900with the releasable clamping tab203resting flat on the table, andFIG. 11is a perspective view of the releasable clamping tab203firmly in place with a clamping device1100clamping the tab203against a packing table201.

FIGS. 12-16show an alternate embodiment of the invention. With reference toFIG. 12,FIG. 12shows a plan view of a blank1420for forming an alternate embodiment of the shipping and dispensing box. In particular,FIG. 12is a planar view of a shipping box1420according to some illustrative embodiments after completion of a die-cut manufacturing process. In some embodiments, a flat sheet is die-cut to the form shown inFIG. 12. Then, the sheet is folded to create the shipping box1420. In the illustrated example shown inFIG. 12, the dashed lines between contiguous sections depict “folding” areas in which the sections are connected but fold around the illustrated dashed lines. On the other hand, the solid lines depict complete cut edges, such that, e.g., the adjacent panels1416and1401discussed below are completely separated along the solid lines between the panels and not contiguously connected at such solid lines. In some illustrative embodiments, the blank1420can be folded to create the shipping box by initially orienting the blank1420such that side panels1405are to the left and right of the person setting up the box. Then, the front, panel1422and back panel1403are lifted so that they are oriented upright (e.g., 90 degrees) from the bottom of panel1401. Then, the interlocking panels1416are turned upwards to approach the contiguous panels1405and then rotated inwards so as to extend over the bottom panel1401(e.g., by rotating the panels1405with respect to the panel1403by 90 degrees around the dashed line connecting region shown inFIG. 12). At this point, the rear panel1403and the side panels1405have been rotated to substantially vertical positions, and the interlocking panels1416lie flat against the bottom panel1401.

In this alternative embodiment, the box is configured to include two cooperating yoke portions at each end of the box. In this manner, each extension portion of the core member can be securely supported by two cooperating yoke portions. In this illustrative example, first and second yoke portions are respectively folded to align with one another to form a double-walled yoke at each side of the box. Towards this end, as shown, the yoke panels1407are rotated toward the front panel1422(e.g., 90 degrees) around the dashed-line region shown. Then, the front panels1422and the yoke panels1407are rotated upward with the yoke panels resting against the vertically oriented side panels1405. The yoke panels1406are rotated downward to a position overlying the yoke panels1407, thus forming two cooperating yoke portions formed by a pair of adjacent yoke panels. To further secure the positions of the panels, tabs1415are inserted into tab receiving notches1414, thus locking the shipping/dispenser box1420in a secure configuration. As shown inFIG. 12, the adjacent pair of spaced fold lines1446and1448provide for space to receive the yoke panels1407in between the yoke panels1406and the side panels1405.

As shown inFIG. 13, after the shipping box1420is setup as discussed above, a tensioning panel1300(shown inFIG. 15) is fitted over a protrusion portion of the paper core403extending outward from the slit paper roll402and, in that state, the combined tensioning panel1300, core403and roll402, are lowered into the box1420as schematically shown inFIG. 13. In some preferred embodiments, in order to stabilize the roll402within the box1420during shipment, an upper packing member1402is placed over the slit paper roll402and extends in between the tensioning panels1300and the slit paper roll402in order to serve as a space filler to enhance stability (e.g., similar to the spacer601described in relation to the embodiments shown inFIGS. 1-11).

FIG. 13also shows a perspective view of an illustrative paper roll402supported on a paper core403(i.e., in a similar manner to that shown in FIG. 9 of U.S. 2018/0222665). As shown, the core protrudes from the roll402at both ends, with protrusion portions extending through corresponding tensioning panels1300. Although some embodiments could employ a single tensioning panel1300at one of the protrusion portions, some preferred embodiments will include two tensioning panels as shown, e.g., inFIG. 16. The at least one tensioning panel(s)1300is preferably positioned on the paper core projection403as shown inFIG. 16prior to placing the slit paper roll402in the box, and is then lowered into the box and positioned adjacent the yoke panels1407and1406as shown inFIG. 14.

The assembly of the shipping and dispensing box shown inFIG. 14illustrates the upper packing member generally as element1402. In the assembled configuration, the side panels1442of the upper packing member1402are preferably inserted between the tensioning panel1300and the roll402of slit paper, thereby restricting lateral movement of the slit paper on the core403. The opposing side panels1444(only one of which is shown inFIG. 14) also preferably are configured to fill the space between the roll of slit paper402and the interior walls of the box.

In some preferred implementations, the pressure yolk1300shown inFIG. 15has an oblong shaped opening, preferably an elongated oval shape as shown in FIG.15. At least the edge1304of the oblong1302that contacts the core and applies pressure thereto is preferably arcuate, and preferably has an arcuate shape corresponding to the shape of the core403. The opposing end1306of the oblong can also be arcuate but can any desired configuration since it is not in contact with the core403during the dispensing operation. The closed configuration of the oblong opening1302of the tensioning yoke1300prevents the tensioning yoke1300from accidentally being removed from the shipping box when the corrugated shipping padding1402is removed from the shipping box and discarded with the bottom padding1422.

The optional bottom padding1422and the corrugated shipping padding1402are removed when the user is ready to draw and expand the slit sheet paper for wrapping around an object.

When the box is being used as a dispenser/expander of the slit sheet paper402, variable pressure can be applied to the tensioning panel1300through the use of a releasable attachment system that pulls the cover member1404downward as needed. In some embodiments, the releasable attachment system can employ a strip with a releasable and resealable coating similar to that described above. As shown inFIG. 14, the releasable attachment system is preferably a hook and loop system such as sold under the trademark VELCRO™. In some examples, a strip of hook fabric1412is attached at one end to the top1404and a strip of loop fabric1408is attached to the side panel1416. It should be understood that this arrangement can be reversed, as for example, the strip1412can be attached to the side panel1416, and the strip1408can be attached to the top cover1404. Either1408or1412can be a hook member and the loop member can be on the other of1408or1412. Most preferably, the attachment system is positioned so that pressure is applied directly above the core member403. Towards that end, in the illustrated embodiment, it is, thus, most preferable that the downward pressure on the tensioning panel1300is applied at substantially the midpoint of the edge1310of tension panel1300. For example, in some embodiments, when the box is supported on a horizontal surface, in some embodiments, the releasable attachment system is at least partly located vertically above a region within a diameter of the core (i.e., such as to be directly above at least a portion of the core), and, in some preferred embodiments, the releasable attachment system includes at least a portion directly above substantially the central axis of the core.

Similar to the embodiment described above in relation toFIG. 11, during use of the box1420as an expander, to increase stability the box can optionally be clamped to a table or support structure as shown inFIG. 14.

In the preferred embodiments, to facilitate application of downward pressure at least one pressure tab1409(only one shown inFIG. 14) can be provided on the top cover panel1404. In some preferred embodiments, the top cover tab(s) are equivalent to the top cover pad(s)109described above and shown inFIGS. 2, 5, and 6, and can be formed of similar materials. Moreover, althoughFIGS. 12-16depict a releasable and resealable mechanism at one side of the box, in some embodiments, a similar mechanism can be employed at both sides of the box, in a like manner to that employed in the embodiment shown in, e.g.,FIG. 5.

In the present application, it should be understood that the use of any and all individual numerical values are stated as approximations as though the values were preceded by the word “about”, “substantially”, or “approximately.” Similarly, the numerical values in the various ranges specified in this application, unless expressly indicated otherwise, are stated as approximations as though the minimum and maximum values within the stated ranges were both preceded by the word “about”, “substantially”, or “approximately.” In this manner, variations above and below the stated ranges can be used to achieve substantially the same results as values within the ranges. As used herein, the terms “about”, “substantially”, and “approximately” when referring to a numerical value shall have their plain and ordinary meanings to a person of ordinary skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue.

The amount of broadening from the strict numerical boundary depends upon many factors. For example, some of the factors which may be considered include the criticality of the element and/or the effect of a given amount of variation will have on the performance of the claimed subject matter, as well as other considerations known to those skilled in the art. As used herein, the use of differing amounts of significant digits for different numerical values is not meant to limit how the use of the words “about”, “substantially”, or “approximately” will serve to broaden a particular numerical value or range. Thus, as a general matter, “about”, “substantially”, or “approximately” broaden the numerical value. Also, the disclosure of ranges is intended as a continuous range including every value between the minimum and maximum values plus the broadening of the range afforded by the use of the term “about”, “substantially”, or “approximately”. Thus, recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. To the extent that determining a given amount of variation of some the factors such as the criticality of the slit patterns, paper width differential pre- and post-expansion, paper weights and type, as well as other considerations known to those skilled in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue will have on the performance of the claimed subject matter, is not considered to be within the ability of one of ordinary skill in the art, or is not explicitly stated in the claims, then the terms “about”, “substantially”, and “approximately” should be understood to mean the numerical value, plus or minus 15%.

It is to be understood that any ranges, ratios and ranges of ratios that can be formed by, or derived from, any of the data disclosed herein represent further embodiments of the present disclosure and are included as part of the disclosure as though they were explicitly set forth. This includes ranges that can be formed that do or do not include a finite upper and/or lower boundary.

Furthermore, it should be noted that in this application, all theories related to functioning of the invention are provided to facilitate appreciation of concepts of the invention, rather than by way of limitation.

Accordingly, a person of ordinary skill in the corresponding art related to a particular range, ratio or range of ratios will appreciate that such values are unambiguously derivable from the data presented herein.