Abstract:
A corrugated paper structure is described for providing improved impact resistant packaging products. The corrugated paper structure comprises a plurality of structural members attached to base pads for forming a packaging product. The structural members are formed from a tube of corrugated paper with a rectangular cross-section and a truss member disposed therein.

Description:
BACKGROUND 
       [0001]    The present invention described herein relates to structures formed from corrugated paper. The corrugated paper structures may be used for packaging items for storage or transportation. The corrugated paper structures are relatively inexpensive to produce, and provide superior protection from damage for items stored using the corrugated paper structure. 
         [0002]    Corrugated paper has been used to create a wide variety of structures for storing and transporting items. The strength and protective capability of a corrugated paper structure varies depending on the specific design of the structure. For example, simple corrugated paper boxes are well known but, without additional packing structures inside the box, they provide little protection to their contents from damage from dropping or other impact or crushing forces. 
         [0003]    Often corrugated paper structures that are designed to provide higher levels of damage protection for their contents are complex in design or require components designed to protect a specific item. The corrugated paper structure described has a structure that may be utilized to encase and protect a variety of items. 
       SUMMARY OF THE INVENTION 
       [0004]    The corrugated paper structure comprises a first and second base pad of corrugated paper; at least one structural member comprising a corrugated paper tube with a rectangular cross-section and a corrugated paper truss member disposed diagonally within the corrugated paper tube; wherein each of the structural members is disposed between and attached to the first and second base pads. 
         [0005]    In an embodiment of the corrugated paper structure, the structural members are disposed adjacent to the edges of the first and second base pads defining an interior volume for containing an item. In a preferred embodiment of the corrugated paper structure the structural members are attached to the first and second base pads by a cohesive composition applied to the members and the pads. 
         [0006]    The invention also includes a method for packing an item comprising the steps of providing a first and second base pad of corrugated paper; providing a plurality of structural members of corrugated paper; attaching each of the plurality of structural members to the first base pad; placing the item on the first base pad between the plurality of structural members; and attaching the second base bad to the plurality of structural members. 
         [0007]    In a preferred embodiment, the step of providing a plurality of structural members of corrugated paper further comprises the steps of providing a tube of corrugated paper with a rectangular cross-section; and providing a truss member of corrugated paper; and disposing the truss member diagonally within the tube and attaching the truss member to the interior surface of the tube. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is an exploded perspective view of an embodiment of the corrugated paper structure. 
           [0009]      FIG. 2  is a perspective cross-sectional view of an embodiment of the corrugated paper structure. 
           [0010]      FIG. 3  is a top plan view of a component of an embodiment of the corrugated paper structure. 
           [0011]      FIG. 4  is a top plan view of a component of an embodiment of the corrugated paper structure. 
           [0012]      FIG. 5  is a perspective cross-sectional view of an alternative embodiment of the corrugated paper structure. 
           [0013]      FIG. 6  is a top plan view of an alternative embodiment of the corrugated paper structure. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    The corrugated paper structure as described in reference to the embodiment depicted in the figures provides an improved structural design for use in corrugated paper packs, boxes, pallets and other corrugated paper structures. The corrugated paper structure has improved resistance to failure resulting from crushing, bending, breaking or other external forces. 
         [0015]    Referring now to  FIG. 1 , an exploded perspective view of an embodiment of the corrugated paper structure is depicted in use in a corrugated paper pack. The corrugated paper pack depicted in the figure comprises four structural members  100 . Two pads  102  are provided for joining to the members  100  to form a pack for protecting and shipping an item. The bases  102  are attached to opposing sides of the members  100  defining an interior volume of the pack for containing the item to be protected. 
         [0016]    The members  100  and pads  102  are formed from corrugated paper. The internal structure of members  100  is described in relation to later figures. Pads  102  are sheets of corrugated paper of appropriate size and thickness for the application. 
         [0017]    The top and bottom surfaces  104  of members  100  are coated with a material to attach the members  100  to the pads  102 . Similarly, areas  106  adjacent to the edges of pads  102  are coated with a material to attach to members  100 . The materials may be glues, adhesives or other materials suitable for attaching two corrugated paper components together. 
         [0018]    In a preferred embodiment of the corrugated paper structure, a cohesive material is utilized to coat the top and bottom surfaces  104  and areas  106 . The cohesive materials may be applied to the areas, and once dried will cohere to each other when placed in contact, forming a permanent connection between the components. Cohesive materials used in a preferred embodiment do not adhere to other materials when dried, but instantly adhere to other coatings of the same material. 
         [0019]    The cohesive materials are typically applied by rolling them onto a surface of a component and allowing them to cure or dry if necessary, though different materials may be sprayed on or applied as appropriate for a specific cohesive material. Once the cohesive materials have properly cured, become tacky or dried they are placed in contact with a coating of the same material on the surface of the other component, at which time the two coatings cohere and securely attach the two components together. 
         [0020]    The corrugated paper structure members  100  may alternatively be attached to each other near the ends of each member, though in a preferred embodiment they are not attached to each other directly. In a preferred embodiment, the attachment to pads  102  described above is sufficient to secure the members  100  together in the desired configuration. 
         [0021]    The specific size, shape and number of components shown in  FIG. 1  is not limiting of the present invention. Other sizes and shapes of pad  102  may be utilized, such as triangular, hexagonal or other polygonal shapes. Similarly embodiments of the invention may utilize more or fewer members  100  than shown in  FIG. 1 , and the members  100  may be arranged in different configurations. Structures may be formed by attaching members  100  to other members to form taller sides to a structure, or structures may include multiple layers of members  100  and pads  102  to form structures as desired. 
         [0022]    In some embodiments pads  102  may have holes, openings, or other perforations. Similarly, structures created according to the present invention may have multiple separate interior volumes defined by the pads  102  and the members  100 . In other embodiments of the present invention, not all the edges, or portions of edges, of the pads  102  are attached to a member  100 . 
         [0023]    Referring now to  FIG. 2 , a perspective cross-sectional view of an embodiment of the corrugated paper member  100  is depicted. The corrugated paper structure comprises a tube member  200  and a truss member  202 . The tube member  200  is a tube with a rectangular cross-section formed from corrugated paper. In various embodiments of the corrugated paper structure the dimensions and cross-section of the tube member  200  vary as necessary for specific applications. 
         [0024]    The tube member  200  is formed from a single sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the tube member  200  is depicted in  FIG. 3 . The flat sheet of corrugated paper may be of any size necessary to form a member  100  of the size necessary for a given application. In one embodiment of the present invention, the sheet of corrugated paper is 16 ½ inches by 96 ⅜ inches. In other embodiments the sheet may be of varying length and width. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application. 
         [0025]    The flat sheet is scored or otherwise prepared for folding along its length to create sides  300 ,  302 ,  304 ,  306  and a glue tab  308 , each running the length of the flat sheet. The sides are folded into a tube and secured by gluing the glue tab  308  to side  300  using standard techniques for processing corrugated paper. In a preferred embodiment of the present invention, the corrugation will be oriented across the width of the sheet from which the tube  200  is formed, perpendicular to the scoring for the sides and glue tab. 
         [0026]    In an embodiment of the tube member  200 , side  300  is 2 ⅞ inches wide, side  302  is 4 ⅜ inches wide, side  304  is 2 15/16 inches wide, side  306  is 4 5/16 inches wide and glue tab  308  is 2 inches wide. A tube formed from the described sheet has inside dimensions of 4 3/16 by 2 ¾ by 96 ⅜. In other embodiments, the sheet and resulting tube may have other dimensions as necessary for a given application. 
         [0027]    The truss member  202  is formed from a second sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the truss member  202  is depicted in  FIG. 4 . The sheet of corrugated paper may be of varying size so long as it is appropriately sized to be folded into a configuration that will fit inside the tube member  200 . In one embodiment of the present invention the truss member  202 , sized to fit the preferred embodiment of tube member  200  described in relation to  FIG. 3 , the sheet of corrugated paper for the truss member  202  is 10 ¼ inches by 96 ⅜. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application. 
         [0028]    The truss member comprises a panel  400  that extends diagonally across the interior of truss member  200 , from one corner thereof to the opposing corner. In the embodiment of the truss member  202  designed to be inserted into the embodiment of the tube member  200  described above, the truss member panel  400  is 4 ¾ inches wide. At each end of panel  400 , a glue tab  402  is provided for attaching the truss member  402  to the tube member  200 . In the depicted embodiment, glue tabs  402  are 2 ¾ inches wide. In other embodiments, the sheet and resulting truss may have other dimensions as necessary for a given application. 
         [0029]    The truss member  202  is prepared by folding the flat sheet along the depicted lines into a Z shape. The folding of truss member  202  may be accomplished using typical methods known for processing corrugated paper. As part of the folding process or as a subsequent process, glue or adhesive is applied to the outer surfaces of glue tabs  402 . The truss member  202  is then inserted into tube member  200  and the glue tabs  402  contact and bond with the inner surfaces of tube member  200 . 
         [0030]    In a preferred embodiment of the process, after applying the glue to the glue tabs  402 , the glue tabs  402  are folded against or nearly against panel  400  of the truss member  202 . The truss member  202  is inserted into the tube member  200 . Once the truss member  202  is fully inserted into tube member  200 , glue tabs  402  are released and expand to contact the interior of tube member  200 . After curing the adhesive attachment between glue tabs  402  and the interior surfaces of tube member  200 , the structural members  100  may be attached to pads  102  to form a corrugated paper structure. 
         [0031]    Referring now to  FIG. 5 , a perspective cross-sectional view of an alternative embodiment of the corrugated paper member  100  is depicted. The corrugated paper structure comprises a scored tube member  500  formed from a single sheet of corrugated paper. The tube member  500  is a tube with a rectangular cross-section and an internal truss  502  formed when folding the tube. In various embodiments of the corrugated paper structure the dimensions and cross-section of the tube member  500  vary as necessary for specific applications. 
         [0032]    In the alternative embodiment depicted in  FIG. 5 , the tube member  500  and the truss member  502  are formed from a single sheet of corrugated paper. A top plan view of the corrugated paper sheet for an embodiment of the tube member  500  is depicted in  FIG. 6 . The flat sheet of corrugated paper may be of any size necessary to form a member  100  of the size necessary for a given application. In one embodiment of the present invention, the sheet of corrugated paper is 24 ⅝ inches by 96 ⅜ inches. In other embodiments the sheet may be of varying length and width. The sheet may be formed from varying weights and thicknesses of corrugated paper as necessary for a given application. 
         [0033]    The flat sheet is scored or otherwise prepared for folding along its length and formed with side  600 , and truss area  602  and sides  604 ,  606 ,  608 , and  610  and a glue tab  312 , each running the length of the flat sheet. The side  600  is folded back and truss area  602  and sides  604 ,  606 ,  608  and  610  are folded into a tube and secured by gluing the glue tab  612  to side  604  using standard techniques for processing corrugated paper. In a preferred embodiment of the present invention, the corrugation will be oriented across the width of the sheet from which the tube  500  and cross support  502  is formed, perpendicular to the scoring for the sides and glue tab. 
         [0034]    In an embodiment of the tube member  500 , side  600  is 2 ⅞ inches wide, side  602  is 4 ⅜ inches wide, side  604  is 2 15/16 inches wide, side  606  is 4 ¼ inches wide,  608  is 2 ¾ inches wide,  610  is 4 ¾ wide and glue tab  612  is 2 11/16 inches wide. In other embodiments, the sheet and resulting tube may have other dimensions as necessary for a given application. 
         [0035]    Many different arrangements of the various components depicted, as well as components not shown, are possible without departing from the spirit and scope of the present invention. Embodiments of the present invention have been described with the intent to be illustrative rather than restrictive. Alternative embodiments will become apparent to those skilled in the art that do not depart from its scope. A skilled artisan may develop alternative means of implementing the aforementioned improvements without departing from the scope of the present invention. 
         [0036]    It will be understood that certain features and subcombinations are of utility and may be employed without reference to other features and subcombinations and are contemplated within the scope of the claims. Not all steps listed in the various figures need be carried out in the specific order described.