Patent Publication Number: US-6660366-B1

Title: Interlocking fastening and packing material

Description:
FIELD OF THE INVENTION 
     The present invention is an interlocking fastening or packing material. More particularly, the present invention is a fastening and packing material having interlocking corrugations which can be utilized for fastening and/or for providing protection to an object stored therein. 
     BACKGROUND OF THE INVENTION 
     The fastening of articles often requires the use of fastening mechanisms such as adhesives, strings, ropes, or adherent textured fabrics, for example, Velcro, which may be difficult to adjust, reposition and/or remove. For example, Velcro may be utilized instead of, for example, buttons, shoe laces, strings, buckles and any other suitable elements on apparel to provide an easily manipulated and easily adjustable fastening mechanism. However, the use of Velcro may cause damage to the article to be fastened due to the amount of force needed to unfasten the Velcro for removal or repositioning. Adhesives may also cause damage to the article to be fastened and it may be difficult to unfasten the articles held together by adhesives. Thus, it is desirable to provide a mechanism for fastening which is easily manipulated, repositionable, adjustable, removable and which does not cause damage to the articles to be fastened. 
     Further, such conventional fastening mechanisms are not designed to simultaneously protect the articles during storage, handling and/or shipping. Packaging of articles for storage, handling and shipping often relies upon the use of a box filled with various types of filler materials such as Styrofoam “peanuts,” popcorn, foam rubber and expanded starch packing material. However, these packing materials are inconvenient and/or undesirable in that they create debris which preferably is recycled but often is not. Storage of the packing material prior to use also consumes a large amount of storage space. Thus, it is desirable to provide a mechanism for the simultaneous fastening and protection of articles. 
     SUMMARY OF THE INVENTION 
     The present invention is an interlocking fastening and packing material generally comprising a backing having two opposing surfaces and having corrugations attached to one or both of the backing surfaces. The corrugations include alternating concave and convex portions which are shaped such that each concave portion can receive and interlock with a convex portion therein. The corrugations may be elongate or may comprise a matrix of bulbous nodules. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1A shows a perspective view of an interlocking fastening and packing material of the present invention having elongate corrugations; 
     FIG. 1B shows a perspective view of the interlocking fastening and packing material of FIG. 1A having a backing material attached to the corrugations; 
     FIG. 2 shows a cross-sectional view of the interlocking fastening and packing material of FIG. 1; 
     FIGS. 3A,  3 B and  3 C show variations of the cross-sectional shape of the corrugations; 
     FIG. 4A shows a cross-sectional view of an interlocked single piece of the interlocking fastening of FIG. 1B containing an object therein; 
     FIG. 4B shows an enlarged view of the cross-sectional portion  4 B of FIG. 4A; 
     FIG. 4C shows a cross-sectional view of two interlocked pieces of the interlocking fastening of FIG. 1B containing an object therein; 
     FIG. 4D shows an enlarged view of the cross-sectional portion  4 D of FIG. 4C; 
     FIG. 4E shows a cross-sectional view of an interlocked single piece of the interlocking fastening of FIG. 1A containing an object therein; 
     FIG. 5A shows a cross-sectional view of the interlocking fastening and packing material of the present invention having corrugations on both surfaces of the backing material and containing a plurality of objects therein; 
     FIG. 5B shows an enlarged view of the cross-sectional portion  5 B of FIG. 5A; 
     FIG. 6A shows a partial perspective view of another interlocking fastening and packing material of the present invention having corrugations formed of an array or matrix of bulbous nodules; 
     FIG. 6B shows a top view of the interlocking fastening and packing material of FIG. 6A; and 
     FIG. 6C shows a perspective view of the two pieces of the interlocking fastening and packing material of FIG. 6A containing a plurality of objects therein. 
    
    
     DESCRIPTION OF THE INVENTION 
     The present invention comprises an interlocking fastening and packing material for protecting objects, particularly during shipping. The following description is presented to enable any person skilled in the art to make and use the invention. Descriptions of specific applications are provided only as examples. Various modifications to the preferred embodiment will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. 
     A perspective view of a single piece of the interlocking fastening and packing material  10 A of the present invention is shown in FIG.  1 A. The interlocking material  10 A generally comprises interlocking corrugations  14 . Preferably, each of corrugations  14  is elongated. Corrugations  14  may be attached to one or both surfaces or sides of the backing  12 . For example, FIG. 1B shows a perspective view of the interlocking fastening and packing material  10  having corrugations  14  on only one side or surface of the backing  12 . The backing  12  may provide increased stiffness and/or stability to the interlocking material  10 . As is evident, where material  10  is provided without a backing, corrugations  14  of interlocking material  10 A is preferably relatively stiff and rigid such that corrugations  14  can maintain their shapes. For example, corrugations  14  of interlocking material  10 A can be made of a relatively stiff and rigid material and/or can have a thin plastic coating or other types of coatings and/or additives for increased stiffness and rigidity. 
     One variation of the corrugations  14  of the interlocking fastening and packing material  10  or  10 ′ is shown in cross-section in more detail in FIG.  2 . The corrugations  14  comprise alternating convex portions or protrusions  16  and concave portions or spaces  18  which are preferably defined by two adjacent convex portions  16 . Each of convex and concave portions  16 ,  18  defines a free end portion  16   a ,  18   a  and a surface portion  16   b ,  18   b  respectively. Preferably, the cross-sectional shape and size of the free end convex portions  16   a  are generally the same as or similar to those of the surface concave portions  18   b . Similarly, the cross-sectional shape and size of the surface convex portions  16   b  are generally the same as or similar to those of the free end concave portions  18   a.    
     The upper diameter  17   a  of free end convex portion  16   a  is preferably approximately equal to the lower diameter  19   b  of surface concave portion  18   b . Similarly, the upper diameter  19   a  of surface concave portion  18   a  is preferably approximately equal to the lower diameter  17   b  of surface convex portion  16   b . Further, diameters  17   a ,  19   b , are preferably greater than diameters  19   a ,  17   b.    
     Such configuration of the convex and concave portions  16 ,  18  of interlocking corrugations  14  ensures that the each free end convex portion  16   a  can be received in and interlocked with a surface concave portion  18   b  and that each surface convex portions  16   b  can be received in and interlocked with a free end concave portion  18   a . In other words, one portion of the corrugations  14  of material  10  can be interlocked with another portion thereof or with the corrugations of another piece of the interlocking material. 
     As shown in FIG. 2, corrugations  14  preferably is shaped such that the cross-sectional shape of each of the free end convex portions  16   a  and the surface concave portions  18   b  is generally semi-circular. As is evident, corrugations  14  may have any shape suitable for each surface concave portion  18   b  to receive and interlock with a free end convex portion  16   a . Preferably, each of free end portions  16   a ,  18   a  and surface portions  16   b ,  18   b  is preferably rounded to facilitate the insertion of a convex portion  16  into a concave portion  18  as well as to facilitate the removal of the convex portion  16  from the concave portion  18 . 
     Examples of alternative shapes of corrugations  14   a ,  14   b , and  14   c , are shown in FIGS. 3A,  3 B and  3 C, respectively. Specifically, free end convex portions of corrugations  14   a ,  14   b , and  14 c may have a generally rectangular, hexagonal and rhombus cross-sectional shape, respectively. 
     A single or multiple pieces of the interlocking material  10  of the present invention may be utilized as a packing material to protect one or more objects contained therein. Additionally or alternatively, the single or multiple pieces of the interlocking material  10  may be utilized as a fastening material for fastening a plurality of objects contained therein. 
     FIG. 4A shows a cross-sectional view of a single piece of interlocking material  10  containing an object  30  therein by interlocking portions of the interlocking material  10 . In addition, FIG. 4B shows an enlarged view of the cross-sectional portion  4 B of FIG.  4 A. As shown, a plurality of convex portions  16  are received in and interlocked with a plurality of concave portions  18 . The interlocking position, i.e. the specific convex portion  16  to be received in and interlocked with a particular concave portion  18 , is determined by the size and the positioning of the object  30  within the interlocking material  10 . 
     Alternatively, the object  30  may be contained by two or more pieces of interlocking material  10 ,  10 ′, portions of which are interlocked to each other as shown in cross-section in FIG.  4 C. In addition, FIG. 4D shows an enlarged view of the cross-sectional portion  4 D of FIG.  4 C. As shown, a plurality of convex portions  16  of interlocking material  10  are received in and interlocked with a plurality of concave portions  18 ′ of interlocking material  10 ′. Similarly, a plurality of convex portions  16 ′ of interlocking material  10 ′ are received in and interlocked with a plurality of concave portions  18  of interlocking material  10 . The interlocking position, i.e. the specific convex portion  16 ,  16 ′ to be received in and interlocked with a particular concave portion  18 ,  18 ′, respectively, is determined by the size and the positioning of the object  30  within the interlocking material  10 ,  10 ′. Clearly, the one or more pieces of the interlocking material provide several discrete interlocking positions for containing one or more objects  30  therein. 
     FIG. 4E shows a cross-sectional view of a single piece of interlocking material  10 A of FIG. 1A containing an object  30  therein by interlocking portions of the interlocking material  10 A. Because interlocking material  10 A does not include a backing, each convex portion  16  is a concave portion  18  when viewed from the opposing side. Thus, as shown, when the interlocking material  10 A is wrapped around object  30  and overlaps with itself, one or more convex portions  16  are overlapped and interlocked with one or more convex portions  16  in another part of the interlocking material  10 A. Similarly, one or more concave portions  18  are overlapped and interlocked with one or more concave portions  18  in another part of the interlocking material  10 A. Further, the interlocking position, i.e. the specific convex portion  16  to be overlapped and interlocked with a particular other convex portion  16 , is determined by the size and positioning of the object  30  within the interlocking material  10 . The interlocking position is also determined by the amount that the interlocking material  10 A stretches due to the lack of a backing, which in part depends upon the rigidity of the corrugations  14 . 
     FIGS. 5A and 5B show a single piece of interlocking material  20  having corrugations  24 ,  34  on both surfaces of backing  22  and containing a plurality of objects  30  therein. Corrugations  24  attached to a first surface of the backing  22  comprises alternating convex portions  26  and concave portions  28 . Similarly, corrugations  34  attached to a second surface of the backing  22  comprises alternating convex portions  36  and concave portions  38 . Providing corrugations on both surfaces of backing also provides additional protection to the objects contained in the interlocking material. 
     To contain the objects  30  within the interlocking material  20 , the user may simply wrap the interlocking material  20  around the objects  30  until a portion thereof overlaps with another portion thereof to allow for interlocking of the two portions. The interlocking mechanism is similar to that described above wherein a plurality of convex portions are received in and interlocked with a plurality of concave portions. Specifically, a plurality of convex portions  26  on the first surface of backing  22  are received in and interlocked with a plurality of concave portions  38  on the second surface of backing  22 . Similarly, a plurality of convex portions  36  on the second surface of backing  22  are received in and interlocked with a plurality of concave portions  28  on the first surface of backing  22 . The interlocking position, i.e. the specific convex portion  26 ,  36  to be received in and interlocked with a particular concave portion  38 ,  28 , respectively, is determined by the size and the positioning of the objects  30  within the interlocking material  20 . Clearly, interlocking material  20  provides several discrete interlocking positions for containing objects  30  therein. 
     FIGS. 6A and 6B show another interlocking fastening and packing material  40  having a backing  42  and corrugations  44  on one side of the backing  42 , although corrugations may be provided on both sides thereof. The corrugations  44  of material  40 , rather than being elongate, comprise an array or matrix of bulbous nodules  46  with corresponding concave portions or spaces  48  therearound. The cross-sectional shape of each of bulbous nodule  46  is similar to that of convex portions of the corrugations  14 ,  14   a ,  14   b  or  14   c  as shown in FIGS. 2,  3 A-C. As is evident, bulbous nodules  46  may have any suitable cross-sectional shape such that each concave portion  48  can receive and interlock with a nodule  46 . Although not shown, material  40  may be provided without a backing. Where material  40  is provided without a backing, corrugations  44  is preferably relatively stiff and rigid such that corrugations  44  can maintain their shapes without the support of a backing. 
     FIG. 6C illustrates an example of interlocking materials  40 A,  40 B, each interlocked to itself as well as to each other to secure and/or protect one or more objects  30 ′. Each of materials  40 A and  40 B comprises bulbous nodules  46 A,  46 B and spaces  48 A,  48 B on both sides of backing  42 A,  42 B, respectively, although only one surface of each of backing  42 A,  42 B is visible in FIG.  6 C. 
     Material  40 B may be first wrapped around objects  30 ′ and secured onto itself by overlapping and interlocking one or more bulbous nodules  46 B disposed on the surface of backing  42 B hidden in FIG. 6C with one or more spaces  48 B on the surface of backing  42 B visible in FIG. 6C, although the overlapped portion is not shown. Material  40 A may then be placed over a portion of material  40 B and interlocked therewith at, for example, an approximately 90° angle relative to material  40 B. Material  40 A may then be partially wrapped around objects  30 ′ until it overlaps with material  40 B, such as the overlapped portion  50 . The material  40 A is then interlocked with material  40 B at, for example, an approximately 90° angle relative to material  40 B. Finally, material  40 A is completely wrapped around objects  30 ′ and secured onto itself in a manner similar to that described above. 
     As is evident, depending upon the specific arrangement and spacing of the array or matrix of bulbous nodules  46 , interlocking fastening and packing material  40  can be interlocked with itself or with another material at a plurality of angles relative to itself or material  40 . Further, providing interlocking fastening and packing material  40  with a matrix of bulbous nodules  46  rather than elongate corrugations may also increase the interlocking strength. 
     Any suitable material or combinations of materials may be utilized for the interlocking material of the present invention, depending on the intended use of the interlocking material, such as the objects to be contained, the desired level of protection to the objects, and other factors. Preferably, the corrugations comprise a material sufficiently rigid to facilitate interlocking of and maintaining the interlocked state of the corrugations. The corrugations may comprise the same or similar materials as the backing and may further comprise a coating or an additive to further provide rigidity to and further strengthen the corrugations. 
     For example, the backing and the corrugations may be made of cardboard similar to that of corrugated cardboard such as kraft paper or other similar paper stock. Alternatively, materials such as fabric, cloth, polyethylene terephthalate (Mylar), polyethylene sheet, polypropylene (clear or fibrous paper product), or the like may also be suitable. Further, the backing of the interlocking material may be creased and/or partially scored to facilitate forming the interlocking material into a desired shape. 
     The interlocking material of the present invention may be supplied to the user in the form of a roll. The user may simply cut off a desired length of the interlocking material for use in any of numerous applications. As described above, the interlocking material may provide protection to the objects contained therein during storage, handling and/or shipping. Additionally or alternatively, the interlocking material may be utilized as a fastening material for applications similar but not limited to those of, for example, VELCRO, adhesive tape, ropes and any other fastening mechanisms. 
     While specific embodiments of the invention have been described and illustrated, it will be appreciated that modifications can be made to these embodiments without departing from the spirit of the invention. Thus, the invention is intended to be defined in terms of the following claims.