Abstract:
A system, method and apparatus for forming a flex-column includes a three-sided column having a triangular cross-sectional shape, an open first end, an open second end, and three corners, each one of the three sides including a flex line dividing each of the three sides into two portions, at least one perforation along an edge of each one of the two portions wherein the edge of each one of the two portions coincides with one of the three corners and at least one non-perforation along an edge of each one of the two portions.

Description:
BACKGROUND 
       [0001]    The present invention relates generally to packing materials, and more particularly, to systems and methods for forming space consuming, shock absorbing packing materials. 
         [0002]    Typical void or space consuming packaging is used to fill space in a packing container around the product being supported and shipped in the container.  FIG. 1  illustrates a typical void packing material  112 ,  112 ′ in a container  110 . The typical void packing material  112  is a polystyrene shape often referred to as “peanut” shapes or “popcorn” shapes. There are many different shapes and sizes of the polystyrene void packing material  112 . A first quantity of the polystyrene void packing material  112 ′ is placed in the container  110  (e.g., shipping box). A product  120  is then placed on top of the first quantity of the polystyrene void packing material  112 ′. A second quantity of the polystyrene void packing material  112  (not shown for clarity purposes) is added to the container  110  around the sides  120 A-D of the product  120 . A third quantity of the polystyrene void packing material  112  (not shown for clarity purposes) is added to the container  110  and between the top  120 E of the product  120  and a top  110 A of the container. 
         [0003]    The container  110  can then be closed. The polystyrene void packing material  112 ,  112 ′ surrounds, supports and separates all sides, top and bottom of the product  120  from the respective sides, top and bottom of the container  110 . As a result the polystyrene void packing material  112 ,  112 ′ protects the product  120  from shocks from impacts during shipment, partial crushing of the container  110  and relatively minor intrusions (e.g., punctures, tears, cuts, etc.) into the container  110 . 
         [0004]    However, the polystyrene void packing material  112 ,  112 ′, like most void packing materials has a fixed volume that also consumes large space such as during a bulk shipment of packing material to a user&#39;s shipping facility where it will be used. This large space requirement increases the cost of shipment and delivery to the user. This large space requirement also requires the user to provide a correspondingly large storage space for storing the large volume of the void packing materials until used, further increasing the costs of most void packing materials. 
         [0005]    Further, most void packing materials are made from virgin materials and are typically used once and disposed of. In the instance of polystyrene void packing material  112 ,  112 ′ the disposed of polystyrene will end up in a dump where it will decompose over the course of many years and even decades. As the polystyrene decomposes toxic and other undesirable chemicals can be produced that can contaminate ground water and air. This use once and disposal cycle of most void packing materials further increases the cost of the void packing materials to the user and to the society at large. 
         [0006]    In view of the foregoing, there is a need for a void packing material that is compact in volume during pre-use shipment and storage and is inexpensive and preferably easily recyclable and reusable and/or can be made from a post consumer waste product. 
       SUMMARY 
       [0007]    Broadly speaking, the present invention fills these needs by providing a flex-column void packing material. It should be appreciated that the present invention can be implemented in numerous ways, including as a process, an apparatus, a system, computer readable media, or a device. Several inventive embodiments of the present invention are described below. 
         [0008]    One embodiment provides a flex-column including a three-sided column having a triangular cross-sectional shape, an open first end, an open second end, and three corners, each one of the three sides including a flex line dividing each of the three sides into two portions, at least one perforation along an edge of each one of the two portions wherein the edge of each one of the two portions coincides with one of the three corners and at least one non-perforation along an edge of each one of the two portions. 
         [0009]    Another embodiment provides a method of making a void packing material including determining a two-dimensional pattern for a desired three-dimensional shaped flex-column, forming the two-dimensional pattern on a selected sheet of material having a selected thickness, separating the two-dimensional pattern from the selected sheet, folding the two-dimensional pattern along fold lines to form the three-dimensional shaped flex-column, and securing the three-dimensional shaped flex-column. 
         [0010]    Yet another embodiment provides a flex-column including a three-sided column having a triangular cross-sectional shape, an open first end, an open second end, and three corners, each one of the three sides including a flex line dividing each of the three sides into two portions, at least one perforation along an edge of each one of the two portions wherein the edge of each one of the two portions coincides with one of the three corners and at least one non-perforation along an edge of each one of the two portions, wherein the at least one non-perforation along an edge of each one of the two portions coincides with an intersection of the flex line and at least one of the three corners, wherein each one of the three sides has a thickness corresponding to a desired flex characteristic, wherein the at least one non-perforated portion along an edge of each one of the two portions has a length corresponding to a desired flex characteristic, wherein the at least one perforated portion along an edge of each one of the two portions has a length corresponding to a desired flex characteristic. 
         [0011]    Other aspects and advantages of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, illustrating by way of example the principles of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]    The present invention will be readily understood by the following detailed description in conjunction with the accompanying drawings. 
           [0013]      FIG. 1  illustrates a typical void packing material in a container. 
           [0014]      FIG. 2  illustrates flex-column, void packing material in a container, in accordance with embodiments of the present invention. 
           [0015]      FIG. 3A  is a perspective side view of a flex column, in accordance with embodiments of the present invention. 
           [0016]      FIG. 3B  is a perspective end view of a flex column, in accordance with embodiments of the present invention. 
           [0017]      FIG. 3C  illustrates the flex-column in two-dimensional form before folding, in accordance with embodiments of the present invention. 
           [0018]      FIG. 3D  is an end view of the flex-column, in accordance with embodiments of the present invention. 
           [0019]      FIG. 3E  illustrates a stack of multiple precut sheets of the flex-columns, in accordance with embodiments of the present invention. 
           [0020]      FIG. 4  is a flowchart diagram that illustrates the method operations performed in forming a flex-column, in accordance with one embodiment of the present invention. 
           [0021]      FIG. 5A  is a perspective side view of a flex column, in accordance with embodiments of the present invention. 
           [0022]      FIG. 5B  is a perspective end view of a flex column, in accordance with embodiments of the present invention. 
           [0023]      FIG. 5C  is an end view of the flex-column, in accordance with embodiments of the present invention. 
           [0024]      FIGS. 5D-5F  illustrate interlocking flex-columns, in various interlocking orientations, in accordance with embodiments of the present invention. 
           [0025]      FIG. 6A  illustrates a flex-column flexing lengthwise to absorb a first force, in accordance with embodiments of the present invention. 
           [0026]      FIG. 6B  illustrates a flex-column flexing lengthwise to absorb a second force, in accordance with embodiments of the present invention. 
           [0027]      FIG. 6C  illustrates a flex-column flexing lengthwise to absorb a third force, in accordance with embodiments of the present invention. 
           [0028]      FIG. 6D  is an end view of flex-column flexing lengthwise to absorb a third force, in accordance with embodiments of the present invention. 
           [0029]      FIG. 7  is a flowchart diagram that illustrates the method operations performed in using a flex-column, in accordance with one embodiment of the present invention. 
           [0030]      FIG. 8A  is a perspective side view of a flex column, in accordance with embodiments of the present invention. 
           [0031]      FIGS. 8B-E  are a detailed views  8 B- 8 D of corresponding portions of the flex column, in accordance with embodiments of the present invention. 
           [0032]      FIG. 9A  is a two-dimensional pattern of the flex-column, in accordance with embodiments of the present invention. 
           [0033]      FIG. 9B  is pre-cut sheet of multiple flex-columns, in accordance with embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0034]    Several exemplary embodiments for a flex-column void packing material will now be described. It will be apparent to those skilled in the art that the present invention may be practiced without some or all of the specific details set forth herein. 
         [0035]    A flex-column void packing material is a space saving expandable loose fill packaging and cushioning material. Flex-columns can be formed from paperboard made from post industrial or consumer waste paper and cardboard. The flex-column void packing material can be shipped a user customer in the form of a compact, pre-cut, pre-perforated sheets. The pre-cut, pre-perforated sheets are fed through a forming machine. The forming machine separates the flex-columns from the pre-cut sheets and folds the separated flex-columns into a corresponding three-dimensional shape. 
         [0036]    Shipping containers can be filled with flex-columns and the product to be protected. The unique shapes of the flex-columns allows the flex-columns to interlock and prevent the product from settling to the bottom of the shipping container, where the product is more susceptible to damage and shock from mishandling. 
         [0037]    The flex-column design allows the void fill material to flex to absorb the impact shocks and other forces sustained during shipment and handling of the shipping container. This flexing ability cushions the product further preventing damage from shock. The flex-column reduces costs created from shipping, storing, and product damage. 
         [0038]    The flex-column can be easily customized as needed by a given product. By way of example, the thickness of the pre-cut, pre-perforated sheets can be varied according to the desired strength of the flex-columns. The number and placement of various cuts and perforations in the flex-column can also be varied according to the desired strength and shock absorbing characteristics of the flex-columns. The size, shape and relative proportions of length and width of the flex-column can be varied according to the desired strength of the flex-columns. 
         [0039]    The flex-column design includes of a series of panels that fold into a flexible, column with a triangular-shaped cross-section. In one embodiment, the flex-column design includes 14 triangular panels and 8 rectangular panels. The flex-column design does not require crease lines, rather perforations are used to assist in the folding of the flat, two-dimensional sheet into the three-dimensional flex column. 
         [0040]    In one exemplary construction the flex-column is formed from paperboard having a basis weight of approximately 65-75 lbs and a thickness ranging from about 0.015 inches to about 0.024 inches, depending on need. The paperboard sheet can be die cut. The flex-column design can be arranged on the paperboard sheet to minimize or even eliminate waste paperboard. Once formed, the flex-column has 12 faces and 15 folds. The edges of the flex-column have a wave or tooth contour to encourage interlocking between individual flex-column Six faces of the flex-column have holes in order to decrease weight and increase opportunities for interlocking between individual flex-columns. The flex-column is held in the folded, three-dimensional form by two tabs and two corresponding slits and/or an adhesive. 
         [0041]      FIG. 2  illustrates flex-column, void packing material  210 ,  210 ′ in a container  110 , in accordance with embodiments of the present invention. There are many different shapes and sizes of the flex-column, void packing material  210 ,  210 ′, the shapes and sizes shown are merely exemplary and not intended to be limited to only the shown shapes and sizes. A first quantity of the flex-columns  210 ,  210 ′ is selected to have support characteristics as may be required by the product, the shipping container, and the foreseeable handling challenges during shipment. The first quantity of the flex-columns  210 ,  210 ′ is placed in the container  110  (e.g., shipping box). A product  120  is then placed on top of the first quantity of the flex-columns  210 ,  210 ′. A second quantity of the flex-columns  210 ,  210 ′ (not shown for clarity purposes) is added to the container  110  around the sides  120 A-D of the product  120 . A third quantity of the flex-columns  210 ,  210 ′ (not shown for clarity purposes) is added to the container  110  and between the top  120 E of the product  120  and a top  110 A of the container. 
         [0042]      FIG. 3A  is a perspective side view of a flex column  210 , in accordance with embodiments of the present invention.  FIG. 3B  is a perspective end view of a flex column  210 , in accordance with embodiments of the present invention.  FIG. 3C  illustrates the flex-column  210  in two-dimensional form before folding, in accordance with embodiments of the present invention.  FIG. 3D  is an end view of the flex-column  210 , in accordance with embodiments of the present invention. 
         [0043]    The flex column  210  has a triangular cross-sectional shape formed by three sides  302 A-C/ 304 A-C. Each of the sides  302 A-C/ 304 A-C has a selected thickness T1. Each of the sides  302 A-C/ 304 A-C is divided by a flex line  320  into two portions  302 A-C and  304 A-C. The sides  302 A-C/ 304 A-C are coupled to the adjacent side by respective folded corners  308 A-D. Tab  318  extends from side  302 A/ 304 A and overlaps a portion of side  302 C/ 304 C. The tab  318  can be secured to the inside surface or the external surface of side  302 C/ 304 C by tabs  312 ,  314  and slits  310 A-B or adhesive  318 A or both or any other suitable means. The tabs  312 ,  314  and slits  310 A-B can be in any suitable, interlocking shapes and sizes. The shapes and sizes of the tabs  312 ,  314  and slits  310 A-B are merely exemplary. 
         [0044]    As will be described in more detail below, each of the folds  308 A-D and flex lines  320  are formed along precisely shaped, sized and placed perforations. The shape, size and location of the perforations in each of the folds  308 A-D and flex lines  320  assists in providing a selected amount of flex in the lengthwise direction of the flex-column  210 . The selected amount of flex in the lengthwise direction of the flex-column  210  is referred to as the flex characteristics of the flex-column. The selectable flex characteristics allows the flex-column  210  to be tuned to allow a selected amount of flex and response for minor shock absorption and to allow a selected activation in response to a selected larger magnitude shocks and impacts. 
         [0045]    The sides  302 A-C/ 304 A-C include multiple holes  306  to reduce weight and provide additional opportunity for the flex-columns  210  to interlock. By way of example, the three corners on each end of the flex-columns  210  can interlock in a hole  306  or an open end of another flex-column. 
         [0046]      FIG. 3E  illustrates a stack  350  of multiple precut sheets of the flex-columns  210 , in accordance with embodiments of the present invention. Each precut sheet includes multiple flex-columns  210 . The stack  350  of multiple precut sheets of the flex-columns  210  minimizes volume and space requirements for shipping and storage prior to use. 
         [0047]      FIG. 4  is a flowchart diagram that illustrates the method operations performed in forming a flex-column  210 , in accordance with one embodiment of the present invention. In an operation  405 , a two-dimensional pattern of the flex-column  210  having the desired flex characteristics is determined. The desired flex characteristics are a determined by a combination of the material type, material thickness T1, flex-column length L, flex-column width W and the shape, size and location of the perforations that define the folds  308 A-D and flex lines  320 . 
         [0048]    In an operation  410 , the selected two-dimensional pattern of the flex-column  210  is formed on a selected sheet of material. As discussed above, the sheet material can be any suitable type of material and combination of materials. By way of example, in a very light weight, delicate, use, the sheet material may be a sheet of paper such as a 20 pound bond weight of paper. Conversely, in a relatively heavy weight, rough use, the sheet material may be a relatively thick paperboard having a thickness T1 of between about 0.05 inches and about 0.25 inches. It should be understood that a corrugated type of cardboard or a plastic material or any other suitable material may be used. 
         [0049]    In an operation  415 , the two-dimensional pattern of the flex-column  210  is separated from the sheet of material and the two-dimensional pattern can be folded into the corresponding three-dimensional shape in an operation  420 . In an operation  425 , the tab  318  is secured to the side  302 C/ 304 C using tabs  312 ,  314  and slits  310 A-B or adhesive  318 A or both or any other suitable means. Operations  415 - 425  can be performed in an automated separation and folding machine. 
         [0050]    Prior to operations  415 - 425 , the flex-columns  210  were in a flat, two-dimensional form and thus consumed minimal volume such as may be desired for pre-use shipping and storage. It should be understood that operations  405  and  410  can be performed at a manufacturing site for the flex-columns  210  and then the sheets of two-dimensional patterns of flex-columns  210  can be shipped to a user&#39;s location. Operations  415 - 425  can be performed immediately prior to use as void filling packing material, thus minimizing the pre-use storage space required by the flex-columns  210  at the user&#39;s facility. 
         [0051]      FIG. 5A  is a perspective side view of a flex column  210 ′, in accordance with embodiments of the present invention.  FIG. 5B  is a perspective end view of a flex column  210 ′, in accordance with embodiments of the present invention.  FIG. 5C  is an end view of the flex-column  210 ′, in accordance with embodiments of the present invention. 
         [0052]    Flex-column  210 ′ is substantially similar in size and construction as the flex-column  210 , described above. However, flex-column  210 ′ has additional features as compared to the flex-column  210 . Flex-column  210 ′ includes different shaped and sized holes  306 ′,  306 ″ in the sides. The illustrated shapes circle/ellipsoid  306 , rectangular/trapezoidal  306 ′, triangular  306 ″ and locations are merely exemplary and any suitable shapes and locations and arrangements can be used. 
         [0053]    The flex-column  210 ′ also includes points  502 A-C and  504 A-C at the respective ends and corners of the flex-column.  FIGS. 5D-5F  illustrate interlocking flex-columns  210 ′A,  210 ′B, in various interlocking orientations, in accordance with embodiments of the present invention. The points  502 A-C and  504 A-C and the holes  306 ,  306 ′,  306 ″ provide additional locations for the flex-columns  210 ′A,  210 ′B,  210 ′  210  to interlock. The points  502 A-C and  504 A-C of a first flex-column  210 ′A can also interlock with a corner fold on one side of a second flex-column  210 ′B as shown in  FIG. 5F . 
         [0054]      FIG. 6A  illustrates a flex-column  210 ′ flexing lengthwise to absorb a first force F1, in accordance with embodiments of the present invention. The first force F1 is sufficient to compress the flex-column  210 ′ from an unloaded height H1 (shown in  FIG. 5A ) to a reduced height of F1 loaded height H2. The first force F1 causes edges  610 A,  610 B of side panels  302 A-C to bow outward. The first force F1 also causes edges  610 C,  610 D of side panels  304 A-C to bow outward. The length of perforations separating edges  610 A,  610 B and separating edges  610 C,  610 D partially determine the lengthwise flexibility characteristics of the flex-column  210 ′. The attached portions  612  help provide a lengthwise resilience of the flex-column  210 ′. The resilience of the flex-column  210 ′ corresponds to a width D1 of the attached portions  612 , as will be described in more detail below. 
         [0055]      FIG. 6B  illustrates a flex-column  210 ″ flexing lengthwise to absorb a second force F2, in accordance with embodiments of the present invention. The second force F2 is greater than the first force F1. The second force F2 is sufficient to compress the flex-column  210 ″ from a F1 loaded height H2 (shown in  FIG. 6A ) to a further reduced height of F2 loaded height H3. The second force F2 causes edges  610 A,  610 B and edges  610 C,  610 D to bow outward with sufficient force to tear the attached portions  612 . When the attached portions  612  are torn, this is referred to activating the flex-column  210 ″. Thus allowing the side panels  302 A-C,  304 A-C to flex or fold along the flex line  320  to form first fold angle θ. The flex line  320  is formed by precisely shaped, sized and located perforations that correspond to a desired resistance to folding or flexing along the flex line  320 . 
         [0056]      FIG. 6C  illustrates a flex-column  210 ′″ flexing lengthwise to absorb a third force F3, in accordance with embodiments of the present invention.  FIG. 6D  is an end view of flex-column  210 ′″ flexing lengthwise to absorb a third force F3, in accordance with embodiments of the present invention. The third force F3 is greater than the second force F2. The third force F3 is sufficient to compress the flex-column  210 ′″ from a F2 loaded height H3 (shown in  FIG. 6B ) to a further reduced height of F3 loaded height H4. The third force F3 causes the side panels  302 A-C,  304 A-C to further flex or fold along the flex line  320  to form second fold angle Ω, where second fold angle Ω is more acute than first fold angle θ. The flex line  320  is formed by precisely shaped, sized and located perforations that correspond to a desired resistance to folding or flexing along the flex line  320 . 
         [0057]      FIG. 7  is a flowchart diagram that illustrates the method operations performed in using a flex-column  210 ,  210 ′, in accordance with one embodiment of the present invention. In an operation  705 , a packing container is partially filled with multiple flex-columns  210 ,  210 ′. The flex-columns  210 ,  210 ′ can be the same shape and size with the same flex characteristics. Alternatively, the flex-columns  210 ,  210 ′ can have multiple different shapes and sizes with multiple different flex characteristics. The flex-columns  210 ,  210 ′ interlock is a variety of substantially random orientations, in an operation  710 . 
         [0058]    In an operation  715 , a cargo/product is placed on the multiple flex-columns  210 ,  210 ′ in the partially filled packing container. The substantially randomly interlocked flex-columns  210 ,  210 ′ flex a selected amount, determined by the design of the flex-columns to support the weight of the cargo/product, in an operation  720 . 
         [0059]    In an operation  725 , the remainder of the packing container is filled with additional multiple flex-columns  210 ,  210 ′ and the packing container can be closed. In an operation  730 , the multiple flex-columns  210 ,  210 ′ absorb shocks and impacts of a force F1 during shipment. In an operation  735 , the at least a portion of the multiple flex-columns  210 ,  210 ′ activate to absorb a force F2 or F3 during shipment. 
         [0060]      FIG. 8A  is a perspective side view of a flex column  810 , in accordance with embodiments of the present invention.  FIGS. 8B-E  are a detailed views  8 B- 8 D of corresponding portions of the flex column  810 , in accordance with embodiments of the present invention. 
         [0061]    Flex-column  810  is substantially similar in size and construction as the flex-column  210 ′, described above. However, flex-column  810  has additional features as compared to the flex-column  210 ′. Flex-column  810  includes different shaped edges and fold lines to increase the opportunity for the interlocking of multiple flex-columns  810 . As shown in detailed views  8 B and  8 C, the edges of the points  802 A-C,  804 A-C are irregular instead of straight as described above. The edges of the points  802 A-C,  804 A-C can be stair stepped  832 ,  832 ′,  832 ″ or saw-toothed  834 ,  836 ,  838  as shown in detailed views  8 B and  8 C respectively. The sizes of each and number of the stair steps or saw teeth can be the same or vary as may be desired. 
         [0062]      FIG. 8D  shows a detailed view of the edges  822 C and  824 C of the respective sides  302 C,  304 C. The edges  822 C and  824 C include multiple scallops  842 ,  846 ,  848 . When folded, the edges  822 C and  824 C cause the multiple scallops  842 ,  846 ,  848  to protrude and thus provide an edge that can interlock on another edge of another flex-column  810 . 
         [0063]      FIG. 8E  shows a detailed view of the fold line  320 ′ of the respective sides  302 A,  304 A. The fold line  320 ′ is formed from multiple curved perforations  852 ,  854 . The curved perforations  852 ,  854  are separated by non-perforated portions  850 . The height and width of each of the curved perforations  852 ,  854 , the number of curved perforations and the width of the non-perforated portions  850  determine how easily (i.e., small force) or how difficult (i.e., larger force) the fold line  320 ′ resists folding. 
         [0064]      FIG. 9A  is a two-dimensional pattern  910  of the flex-column  810 , in accordance with embodiments of the present invention.  FIG. 9B  is pre-cut sheet of multiple flex-columns  810 , in accordance with embodiments of the present invention. The benefit of symmetrically shaped edges is illustrated in  FIG. 9B  as very little of the sheet  920  is wasted material, even though the flex-column  810  is a much greater detailed design as compared to flex-column  210 . 
         [0065]    It will be further appreciated that the instructions represented by the operations in the above figures are not required to be performed in the order illustrated, and that all the processing represented by the operations may not be necessary to practice the invention. 
         [0066]    Although the foregoing invention has been described in some detail for purposes of clarity of understanding, it will be apparent that certain changes and modifications may be practiced within the scope of the appended claims. Accordingly, the present embodiments are to be considered as illustrative and not restrictive, and the invention is not to be limited to the details given herein, but may be modified within the scope and equivalents of the appended claims.