Patent Publication Number: US-2022219878-A1

Title: Packing Material, Use, and Methods of Manufacture

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This U.S. non-provisional patent application claims the benefit of and/or priority under 35 U.S.C. § 119(e) to U.S. provisional patent application Ser. No. 63/135,820 filed Jan. 11, 2021 titled Packing Material and Method of Manufacture, the entire contents of which is specifically incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to packing materials for storing, shipping, and/or protecting packaged items and, more particularly, to sustainable packing material for storing, shipping, and/or protecting packaged items. 
     BACKGROUND OF THE INVENTION 
     A significant number of goods are shipped throughout the United States every day. The growth of on-line purchasing has created a boon in shipping. However, merchandise damaged during transit creates lost revenue and frustration for the recipient. It is thus beneficial to the shipper, the merchant, and the recipient for the shipped goods to arrive undamaged. In order to try and ensure undamaged delivery, dunnage or packing material(s) are used to wrap or otherwise envelope the goods for shipping. 
     Heretofore, various types of packing material(s) have been used. Plastic peanuts, plastic balls and the like, plastic bubble-wrap, plastic air-filled “pillows,” form-fitting foam, and straw and straw-like material are used as packing material. All of these packing materials have drawbacks. Particularly, plastic is bad for the environment since it is not biodegradable. Because of this, paper packing material is preferable over plastic packing material since paper is biodegradable and easily recyclable. While single crumpled paper sheets are not practical for large-scale packaging, paper sheets, or simply paper, converted into a low density packing or cushioning product is practical. 
     Assorted patents have been granted for converting paper into a low density packing or cushioning product. For example, U.S. Pat. No. 6,626,813 discloses a cushioning conversion system and method for making a coil of cushioning product from a sheet of paper. FIG. 6 of U.S. Pat. No. 6,626,813 shows the produced coil of cushioning product (the &#39;813 coil), the &#39;813 coil having a width the size of the sheet of paper. The size of the &#39;813 coil makes it impractical to form the coils into adequate packing material that can cushion around variously-shaped items without much manipulating of the &#39;813 coil or cutting them. This adds an additional packing step. U.S. Patent Publication 2008/0153685 discloses a method of making a dunnage (packing) product from a continuous length of stock material having a cohesive on at least one surface. The dunnage product is a large coil of crumpled paper (the &#39;685 coil) that uses its cohesiveness to keep its crumpled and coiled shape. Like the &#39;813 coil, the &#39;685 coil makes it impractical to form the coils into adequate packing material that can cushion around variously-shaped items without much manipulating of the &#39;685 coil—adding an additional packing step. Moreover, the &#39;813 and &#39;685 coils are not able to form a generally cohesive packing mass around an item or items for packing, creating only a loose assemblage of coils that can shift and move during transit. 
     In view of the above, it would therefore be desirous to have a paper-based packing product that alleviates the shortcomings of the prior art. It would be further desirous to have a paper-based packing product formed by a curl or spiral of cohesive paper wherein the cohesive portion of the paper is on the outside of the curl/spiral (i.e., faces radially outward). It would therefore be even further desirous to have a paper-based packing product of individual curls/spirals that forms a generally cohesive mass about an item or items for packing. The present invention addresses the above issues. 
     SUMMARY OF THE INVENTION 
     The present invention is a paper-based dunnage, packing, and/or cushioning product or the like (collectively, packing product), its use, methods of manufacture, and manufacturing machines. The packing product is fashioned as a curl or spiral (collectively, curl) from a dimension controlled, spiraled/wound strip of cohesive paper having a cohesive side and a non-cohesive side and formed with a leading end that is bent upon itself such that a cohesive side of the leading end contacts the cohesive side of the dimension controlled strip of cohesive paper, and a trailing end opposite the leading end that is bent upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, wherein the dimensioned strip of cohesive paper is spiraled or wound into a curl or spiral with the cohesive side of the dimensioned strip of cohesive paper on the outside of the curl/spiral. 
     A plurality of the present curls provides a generally cohesive mass or clump around an item or items in packing due to the curls loosely adhering to one another. The curls may also loosely adhere to the item or items. A method of packing an item or items includes placing a plurality of the present packing curls into a package with the item or items. The method may include providing a plurality of curls dimensioned and sized according to the item or items being packed. Smaller items may use smaller curls while large items may use larger curls, or vice versa. A mix of curl sizes may be used. 
     In one form, a curl is formed from roll of cohesive paper that is dimensioned into a strip of cohesive paper having a width that is preferably, but not necessarily, one quarter inch (¼″) to three quarters inch (¾″), with one half inch (½″) being most preferable, and preferably, but not necessarily, two inches (2″) to six inches (6″) long. Other sizes are contemplated and may depend on the size of the item or items being packed. The cohesive paper has a weight that is preferably, but not necessarily, from the teens to the fifties. The width or vertical side of a curl provides blocking/stack strength for the packaged item, while the size of the curl (length or horizontal side) provides cushioning for the packaged item. When a plurality of curls are clumped together in random directions, a protectant mass is formed around an item or items by interaction of the cohesive nature of the cohesive paper of each curl with respect to other curls. A mass of curls can assume any size and shape, especially around a packaged item, such as in a corrugated box. 
     The curls can be used for single or multiple, light or heavy items. The curls may also be used in conjunction with an item or items wrapped in cohesive paper. With the cohesive side of the paper placed on the outside of the item or items, the curls surround the item or items to stabilize as well as protect the item(s). Such packing also keeps the item(s) free from abrasion. Other types of cohesive wrapping such as, but not limited to, foam may be used in place of cohesive paper wrapping. 
     The curl producing machine may be sized according to application need. For instance, a small desktop curl producing machine may be used for packing small boxes, while a larger, free-standing curl producing machine may be used for packing larger boxes. Curl producing machines may be fashioned for low volume curl production or high volume curl production. 
     A method and machine of producing a curl includes providing a roll of a cohesive paper sheet having a cohesive side and a non-cohesive side, cutting the cohesive paper sheet into a dimensioned strip, creating a folded leading end on the dimensioned strip that is bent upon itself such that a cohesive side of the leading end adheres to the cohesive side of the dimensioned strip of cohesive paper, creating a trailing end on the dimensioned strip opposite the leading end that is bent upon itself such that a non-cohesive side of the trailing end contacts the non-cohesive side of the dimensioned strip of cohesive paper, and winding/spiraling and cutting the dimensioned and end folded strip of cohesive paper into a curl or spiral with the cohesive side of the dimensioned and end folded strip of cohesive paper on the outside. Cutting of the strips may occur before winding, after winding, or in conjunction with winding. 
     A method of and machine for packing or cushioning one or more items includes providing a plurality of the present curls or spirals around or about the one or more items, with or without the item(s) first being swathed in a cohesive wrapper. The plurality of curls are preferably, but not necessarily, dimensioned and sized according to the item or items being packed. Smaller items may use smaller curls while large items may use larger curls, or vice versa. A mix of curl sizes may be used. The present machines for producing the curls are adjustable to provide different lengths of curls, width, etc. for different packing needs. 
     Different cohesive papers may be used for the curls. The cohesive paper may be have a color, be different weights, or have texturing. 
     Further aspects of the present invention will become apparent from consideration of the drawings and the following description of forms of the present invention. A person skilled in the art will realize that other forms of the invention are possible and that the details of the invention can be modified in a number of respects without departing from the inventive concept. The following drawings and description are to be regarded as illustrative in nature and not restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The present invention and its features will be better understood by reference to the accompanying illustrations/drawings, wherein: 
         FIG. 1  is diagrammatic view of an exemplary machine for producing packing curls (curls) from a supply of cohesive paper in accordance with the principles of the present invention; 
         FIG. 2  is a view of an individual packing curl that can be made by the machine of  FIG. 1  and a method of manufacture as described herein; 
         FIG. 3  is a view of a packaged item surrounded by a mass (plurality) of packing curls (curls) made by the exemplary machine of  FIG. 1 , the mass of packing curls creating a void filler that cushions and protects the packaged item; 
         FIG. 4  is a view of a roll of cohesive paper used for the present packing curls; 
         FIG. 5  is a schematic view of another exemplary machine for producing packing curls (curls) from a supply of cohesive paper in accordance with the principles of the present invention; 
         FIG. 6  is a side view of an exemplary cut and folded strip of cohesive paper ready for curling; 
         FIGS. 7A-E  depict a sequence of curling of the exemplary cut and folded strip of cohesive paper of  FIG. 6  into a packing curl in accordance with the principles of the present invention; 
         FIG. 8  is a perspective view of a packing curl produced by the principles of the present invention; 
         FIG. 9  is a diagrammatic view of the exemplary folding section of the exemplary machine of  FIG. 5 ; 
         FIG. 10  is an enlarged view illustrating the flow of cohesive paper through the exemplary folding section of  FIG. 9 ; and 
         FIG. 11  is a top view of an exemplary roller for curling and cutting the curls. 
     
    
    
     For the purposes of promoting an understanding of the principles of this invention, reference will now be made to the embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described embodiments, and any further applications of the principles of the invention as described herein are contemplated as would normally occur to one skilled in the art to which the invention relates. 
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring to  FIG. 1 , there is shown a diagrammatic view of an exemplary machine, mechanism, apparatus or the like (collectively, machine)  10  for producing one form of curls  30  in accordance with the present principles. It should be understood that the machine  10  of  FIG. 1  depicts only basic components and/or features for producing the curls  30 . The machine  10  has a housing  12  to which is connected a paper holder  16 . A roll of cohesive paper  14  (cohesive paper being paper with a cohesive on one side only) is held by the paper holder  16  such that the roll of cohesive paper  14  may freely rotate about an axle  17  of the paper holder  16 . The paper holder  16  is configured to allow various sizes (length and width) of rolls of cohesive paper to be retained. The paper holder  16  is also configured to allow replacement of cohesive paper rolls. 
     Cohesive paper (a continuous cohesive paper sheet), collectively cohesive paper P, from the cohesive paper roll  14  is received by/into a paper feed/feeder/feed mechanism (collectively, feed)  18  which directs the cohesive paper P into the housing  12  and to a paper guide  19 . The paper guide  19  includes first and second feed rollers R 1 , R 2  disposed opposite one another such that the cohesive paper P is properly received and aligned for curling and cutting. The first and second rollers R 1 , R 2  lead the cohesive paper P over a third roller R 3  such that the cohesive paper P is received onto a shaft  20 . A rotation mechanism  21 , here shown as a first motive roller  22  and a second motive roller  23  connected by a belt or belt drive  25 , rotates the shaft  20  and cohesive paper to provide wound cohesive paper  24  about the shaft  20 . 
     The wound cohesive paper  24  travels about the shaft  20  where it encounters a cutter  26 , here shown as two cutting blades C1 and C2, that cuts the wound cohesive paper  24  into cohesive paper packing curls (curls)  30 , one of which is shown in  FIG. 2 . Preferably, but not necessarily, each curl has a width of one quarter inch (¼″) to three quarters inch (¾″) with one half inch (½″) being most preferable, and a length of two inches (2″) to six inches (6″) long. The curls  30  are released into a director  28  which dispenses the curls  30  into a hopper (not shown) or directly into a box as shown in  FIG. 3  which contains an item  60 .  FIG. 3  shows a mass  50  of curls  30  about and/or around the item  60  for product/item packing, cushioning, blocking, bracing, and/or void fill. 
     While the machine  10  cuts the wound cohesive paper  24  into curls  30  after winding on the shaft  24 , it should be appreciated that a machine may produce the present curls by first cutting the cohesive paper into the desired size (width and length) of strips before curling. Moreover, the roll of cohesive paper may already have a width of one quarter inch (¼″) to three quarters inch (¾″), which is then cut to a length of two inches (2″) to six inches (6″) long for curling. 
     Variations in the curl producing machine  10  are contemplated such as, but not limited to, placement and numbers of cohesive paper guide/feed rollers, the manner of rotating the curling shaft, the manner of feeding the cohesive paper into the curling and cutting mechanisms, and the like. Other variations are contemplated, the end result of which is to make/produce curls  30 . 
     Referring now to  FIG. 4 , there is depicted an illustrative roll of cohesive paper  100  such as can be used in the curl producing machine  10  of  FIG. 1  and the exemplary curl producing machine  101  of  FIG. 5  that produces curls  150  from cut and end-folded strips  200  (see, e.g.,  FIG. 6 ) of cohesive paper. The roll of cohesive paper  100  is formed by a wound continuous sheet  102  of cohesive paper of a given width. The machine  101  can accommodate rolls of various widths. As shown in  FIG. 5 , the sheet of cohesive paper  102  has a cohesive side  104  and a non-cohesive side  105 . The exemplary curl producing machine  101  feeds the sheet of cohesive paper  102  through various drive rollers (D.R.) to a cutter or cutting section  110  (labeled Sheet Cut in  FIG. 5 ). The cutting section  110  cuts the sheet of cohesive paper  102  into individual sheets of a given length, the given length of which will be (is) the total length of a curl  150 . The cutting section  110  is configured to adjust length size of each individual sheet. Same length individual sheets may be produced in succession or variations in individual sheet length. 
     The individual length-cut sheets are conveyed to a folder or folding section  120  via drive rollers (D.R.). The folding section  120  is designed to create a folded leading end or edge  202  and a folded trailing end or edge  204  opposite to the folded leading end  202  to each individual length-cut sheet of cohesive paper  200  (see, e.g.,  FIG. 6 ). The leading end  202  is folded back onto itself such that the cohesive side  104  of the folded leading end  202  contacts and adheres to the cohesive side  104  of the sheet of cohesive paper  200 , while the trailing end  204  is folded back onto itself such that the non-cohesive side  105  of the folded trailing end  204  contacts to the non-cohesive side  105  of the sheet of cohesive paper  200 . An individual end folded length of cohesive sheet  200  is depicted in  FIG. 6 . At this point, the sheet  200  is ready to be cut and curled, although not necessarily in that order. Cutting and curling can also be performed simultaneously such as with a cutting/curling roller  320  of  FIG. 11 . 
     In  FIGS. 7A-7E , the formation of a curl  150  is illustrated. It should be appreciated that this illustration does not show the mechanism (e.g. rollers, cutters, etc.) for curling, but rather illustrates the manner in which the sheet of cohesive paper  200  is curled. In  FIG. 7A  the individual sheet of cohesive paper  200  is shown before its ends/edges have been folded. In  FIG. 7B , the leading end/edge  202  has been folded such that its cohesive side adheres to the cohesive side  104  of the sheet of cohesive paper  200 , while the trailing end/edge  204  of the sheet of cohesive paper  200  has been folded such that its non-cohesive side abuts the non-cohesive side  105  of the sheet of cohesive paper  200 . In  FIG. 7C , the end-folded sheet of cohesive paper  200  is beginning to be coiled, wound, spiraled, twisted, curled, or the like into a curl  150 . The leading end  202  is being curled under itself such that the cohesive side  104  faces outward (is radially outward with respect to the curl  150 ) and the non-cohesive side  105  faces inward (is radially inward with respect to the curl  150 ).  FIG. 7D  illustrates further curling of the end-folded sheet of cohesive paper  200  from that of  FIG. 7C .  FIG. 7E  illustrates a final or near final curling of the sheet of cohesive paper  200 .  FIG. 8  depicts a final curl  150  cut in a desired strip width. It should be appreciated that the end-folded strip of cohesive paper  200  may be wound or spiraled opposite, or differently, to that shown in  FIGS. 7A-E  while achieving the same result of having the cohesive side of the curls  150  facing outward. 
       FIGS. 9 and 10  provide a more detailed depiction of a manner in which the length-cut sheets of cohesive paper gets folded. Drive rollers direct or feed the length-cut sheets of cohesive paper into the folder. Initially, the nomenclature first and second are arbitrary and interchangeable here and throughout. A first end of the sheet  200  is directed by meshing of folding roller 1 (FR1) and folding roller 2 (FR2) into a first stop  300  which bends the first end onto itself such that the non-cohesive side  105  of the first end is adjacent to the non-cohesive side  105  of the sheet  200 . As the first end is folded by the first stop  300 , a crease is formed in the sheet  200 , the crease of which is then fed/conveyed into meshing folding roller 2 (FR2) and folding roller 3 (FR3). The crease of the sheet  200  then becomes the crease of a folded trailing end  204 . The folded trailing end  204  is fed into a second stop  310 . The second end of the sheet  200  that is now opposite the trailing end  204  will be folded upon itself by meshing folding roller 3 (FR3) and folding roller 4 (FR4) when the trailing end  204  bottoms out in the second stop  310  to form a folded leading end  202 . The leading end is folded such that a cohesive side of the second end contacts and adheres to the cohesive side  104  of the sheet  200 . The length of the second stop  310  is adjustable. Direction of sheet travel is depicted in  FIG. 10 . The cohesive paper is fed into the machine  101  with the cohesive side in one direction, with the folded sheets of cohesive paper flipped for cutting. The end-folded sheet of cohesive paper  200  is then sent to the curler and cutter  130 . 
       FIG. 11  depicts an exemplary curling and cutting roller  320  of the curl and cut section  130 . A curling and cutting roller  320  is characterized by a cylinder  322  having a plurality of radial blades  323  spaced to provide a given strip width. Different rollers can provide a difference strip width. The curling and cutting section  130  may use more cutting rollers, and/or different manners of curling and cutting the sheets  200 . The process of selecting strip width may also be automatic. As the sheets  200  are wound onto the roller  322 , the blades  323  cut the width. Other manners may be used. 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only a preferred embodiment has been shown and described, and that all changes and modifications that come within the spirit of the invention are desired to be protected. It should be understood that while the use of words such as preferable, preferably, preferred or more preferred utilized in the description above indicate that the feature so described may be more desirable, it nonetheless may not be necessary and embodiments lacking the same may be contemplated as within the scope of the invention.