Patent ID: 12234072

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

As noted above, stronger shipping boxes may be formed by laminating two or three layers of corrugated fiberboard together to form doubled-walled or triple-walled, respectively, shipping boxes. Double-walled or triple-walled shipping boxes, however, are relatively thick. The thicker material increases cube costs, shipping costs, and storage costs. Thus, a packaging material that creates more strength with less thickness is desired. Such a material could result in enormous savings in these costs. The packaging material discussed herein may be used to form shipping boxes having a higher strength than a single layer of corrugated fiberboard, with a thickness that is less than that of double-walled or triple-walled shipping boxes.

In addition, shipping boxes formed of corrugated fiberboard, particularly those that are double-walled or triple-walled do not readily form alternative shapes and instead are generally limited to rectangular shipping boxes. When round or cylindrical items are shipped in such rectangular shipping boxes, the rectangular boxes thus include void space around the item-to-be-shipped resulting in increased costs for filler material. Further if this void space can be eliminated, more shipping boxes may be included in a shipping container also resulting in enormous savings in these costs. Embodiments of the packaging material discussed herein can also be formed into cylindrical shipping boxes.

Embodiments of the packaging material discussed herein may be used to form shipping boxes. Shipping boxes, as used herein, refers to a container used for shipping (transporting) or otherwise packing an item therein. This item may be referred to herein as an item-to-be-shipped. The term shipping box is not limited to square or rectangular shipping boxes; instead, as used herein, shipping boxes may have other shapes such as the cylindrical shapes discussed below. The term shipping box is used to distinguish from the term shipping container, which is also used herein. Shipping container, as used herein, generally refers to an intermodal freight container. Such intermodal freight containers (shipping containers) are truck size, reusable, typically steel (or other metal) containers that are used to transport goods by ship, train, and truck.

FIG.1shows a packaging material100of an embodiment. The packaging material100may be formed from single-walled corrugated fiberboard102. Corrugated fiberboard is sometimes also referred to as corrugated cardboard. Although not explicitly depicted inFIG.1, the single-walled corrugated fiberboard102may include a top sheet, a bottom sheet, and one corrugated sheet sandwiched between the top sheet and the bottom sheet. The top sheet and the bottom sheet may be flat containerboard or paperboard material formed from cellulosic material (e.g., natural cellulosic fibers). The corrugated sheet includes a plurality of flutes. Any suitable standard flute shape typically used in the construction of cardboard shipping boxes may be used.

The packaging material100shown inFIG.1includes a first surface and a second surface. For ease of reference herein, the first surface will be referred to as a top surface104and the second surface will be referred to as a bottom surface106, but depending upon use the surfaces may have different orientations, such as outer surfaces and inner surfaces, as discussed further below. As will be discussed in more detail below, the single-walled corrugated fiberboard102is folded or otherwise shaped to form a plurality of triangularly shaped cells and, more specifically, a plurality of first triangular cells110and a plurality of second triangular cells120. The first triangular cells110and second triangular cells120are arranged in an alternating pattern with each of the first triangular cells110is adjacent to and, more specifically, between two of the second triangular cells120and, similarly, with the exception of an end cell, each of the second triangular cells120is adjacent to and, more specifically, between two of the first triangular cells110. The end cells, however, are adjacent to only one cell. If one of the first triangular cells110is on the end (an end cell), the end cell of the first triangular cells110is adjacent to one of the second triangular cells120and, similarly, if one of the second triangular cells120is on the end (an end cell), the end cell of the second triangular cells120is adjacent to one of the first triangular cells110. Each of the plurality of triangular cells (i.e., the first triangular cells110and the second triangular cells120) have a longitudinal axis, which in the depicted embodiment, extends in a direction parallel to the top surface104, the bottom surface106, or both.

Each of the first triangular cells110includes a base portion, which is referred to herein as a first base portion112. The first base portion112is a portion of the single-walled corrugated fiberboard102, and collectively, the plurality of first base portions112forms a top wall. The top surface104is an outer surface of the top wall. Similarly, each of the second triangular cells120includes a base portion, which is referred to herein as a second base portion122. The second base portion122is a portion of the single-walled corrugated fiberboard102, and collectively, the plurality of second base portions122forms a bottom wall. The bottom surface106is an outer surface of the bottom wall. The first triangular cells110and the second triangular cells120are thus arranged in an interlocking pattern.

The packaging material100also includes a plurality of transverse walls130. In this embodiment, a transverse wall130is a portion of the single-walled corrugated fiberboard102that extends transversely to the top surface104and the bottom surface106. The packaging material100, or at least a portion thereof, is formed from a continuous sheet (i.e., the single-walled corrugated fiberboard102in this embodiment), and each transverse wall130connects one of the first base portions112with one of the second base portions122, forming a side of one of the triangularly shaped cells. The transverse wall130separates one first triangular cells110from an adjacent second triangular cells120. Two transverse walls130are brought together opposite a base portion to form the apex of the triangular cell. More specifically, two transverse walls130may be brought together opposite the first base portion112to form a first apex114of one of the first triangular cells110, and two transverse walls130may be brought together opposite the second base portion122to form a second apex124of one of the second triangular cells120. The transverse walls130attach to the ends of the first base portion112and the second base portion122. In the depicted embodiment, each end of the first base portion112abuts an end of an adjacent first base portion112at the second apex124, and each end of the second base portion122abuts an end of an adjacent second base portion122at the first apex114. In some embodiments, an adhesive144(FIG.2B) may be at each of the first apexes114and each of the second apexes124. Any suitable adhesive144may be used, but in this embodiment and throughout the embodiments discussed herein, the adhesive144is preferably a biodegradable adhesive.

The transverse walls130of the depicted embodiment have the same length and thus the first triangular cells110and the second triangular cells120may be isosceles triangles or equilateral triangles. In some embodiments, the first base portion112and/or the second base portion122is the same length as each of the transverse walls130, but in other embodiments the first base portion112and/or the second base portion122has a length that is greater or less than each of the transverse walls130. The first triangular cells110and the second triangular cells120are each acute isosceles triangles inFIG.1, but other shapes may be used, such as obtuse triangles, as discussed further below. The numbers, size, and density of the cells may be varied according to the overall crush, burst, and flexibility desired. The angles of the vertices and length of the first base portion112, the second base portion122, and the transverse walls130of the triangular cells may be varied to adjust the properties of the packaging material100. The packaging material100may thus have a total thickness t. In one example, the total thickness t is 5 mm.

A process for forming the packaging material100is shown inFIGS.2A-2D.FIG.2Aillustrates a first step. In the first step, the single-walled corrugated fiberboard102is folded, such as into flutes, forming a folded corrugated-fiberboard sheet142and, more specifically, forming the first base portion112, the second base portion122, and the transverse walls130. In this step, gaps (referred herein to as first-side gaps)116may be present between adjacent first base portions112, and gaps (referred herein to as second-side gaps)126may be present between adjacent second base portions122.

FIG.2Billustrates a second step. In the second step and adhesive144, if used, is applied to ends of the first base portion112and/or ends of the second base portion122. In the depicted embodiment, the adhesive144is applied to each end of the first base portion112and/or the second base portion122.

FIG.2Cillustrates a third step. After or while the adhesive144is applied, the folded corrugated-fiberboard sheet142is cramped and formed into triangular cells (e.g., the first triangular cells110and the second triangular cells120). The first base portions112and the second base portions122are thus positioned relative to each other to form the first triangular cells110and the second triangular cells120with the transverse walls130. A cramping force is applied longitudinally to the folded corrugated-fiberboard sheet142to close the first-side gaps116and the second-side gaps126forming the first triangular cells110and the second triangular cells120. In the depicted embodiment, the cramping force is applied to form fully closed cells (e.g., the first triangular cells110and the second triangular cells120). With the ends of adjacent first base portion112and ends of adjacent second base portion122respectively abutting each other, the first apexes114and the second apexes124are formed and, in the depicted embodiment, the adhesive144holds the first apexes114and the second apexes124. The third step forms a cramped corrugated-fiberboard sheet146, and in some embodiments, the cramped corrugated-fiberboard sheet146is the packaging material100after the adhesive144dries.

FIG.2Dillustrates a fourth step, which is optional. One or more sheets may be applied to the cramped corrugated-fiberboard sheet146. As depicted inFIG.2D, a top sheet152is applied to the top surface104, and a bottom sheet154is applied to the bottom surface106. The top sheet152and/or bottom sheet154may be a cellulosic sheet. In some embodiments, the cellulosic sheet is a flexible, cellulosic sheet, such as paper, but stiffer cellulosic sheets may be used, such as containerboard, fiberboard, or even a corrugated material, such as single-walled corrugated fiberboard. The top sheet152and the bottom sheet154may be laminated to the top surface104and the bottom surface106, respectively, using an adhesive.

FIGS.3A and3Bshow a packaging material212that may be used to form a circumferential wall220(FIG.4) of a cylindrical shipping box200(FIG.4). The packaging material212is similar to the packaging material100discussed above. The same reference numerals will be used for the same and similar components and features, and a detailed description of these features is omitted here. The packaging material212is configurable in a flat configuration, shown inFIG.3A, and a tubular configuration, shown inFIG.3B. The packaging material212of this embodiment provides a “knock-down-flat” (“kdf”) shipping box (cylindrical shipping box200), as will be discussed further below.

In this embodiment, the first surface is an outer surface214similar to the top surface104discussed above, and the second surface is an inner surface216similar to the bottom surface106discussed above. Collectively, the plurality of first base portions112of forms an outer wall (also referred to as an outer wall section), and collectively, the plurality of second base portions122forms an inner wall (also referred to as an inner wall section). The outer surface214is an outer surface of the outer wall, and the inner surface216in an outer surface of the inner wall. In the flat configuration, adjacent second base portions122are spaced apart from each other and a second-side gap126is maintained between adjacent second base portions122. In the flat configuration, the second triangular cells120are thus spaced apart from each other and the first triangular cells110are open triangular cells opposite the first base portion112(i.e., at the first apex114). The second apex124of the second triangular cells120may be adhered to each other in the manner discussed above, such as by the adhesive144applied at the second apex124, a top sheet152being applied to the outer surface214, or both. Although depicted inFIGS.3A and3B, the top sheet152may be optional in this embodiment. To form this spaced-apart arrangement when flat, the first base portion112is longer than a corresponding second base portion122to which it is connected, and the first triangular cells110are free from attachment at the first apex114, such as without the adhesive144applied at the first apex114. Each of the first base portions112may be longer than each of the second base portions122.

The packaging material212can be bent to form an arcuate shape, such as a tubular shape (seeFIG.4), as shown inFIG.3B. As the packaging material212is bent, the second base portions122are brought closer to each other reducing the distance (i.e., size) of the second-side gaps126between adjacent second base portions122. More specifically, adjacent the second base portions122may be brought into contact with each other (i.e., the second base portions122abut each other), closing the second-side gaps126and forming a closed first apex114of each of the first triangular cells110. With the first apex114being free from attachment as discussed above, the packaging material212can move back and forth between the arcuate (or tubular) configuration shown inFIG.3Band the flat configuration shown inFIG.3A.

As noted above, the numbers, size, and density of the cells may be varied and angles of the vertices forming the triangular cells may be varied.FIG.3Cshows a packaging material213that is a variation of the packaging material212shown inFIG.3A.FIG.3Cshows the packaging material213in a flat state. The packaging material213depicted inFIG.3Cis similar to the packaging material212shown inFIG.3A, but includes first triangular cells110and second triangular cells120that have an obtuse triangular shape. More specifically, the angles between the transverse walls130at the first apex114and the second apex124are obtuse, forming an obtuse triangle and, more specifically in the depicted embodiment and obtuse isosceles triangle. With the transverse walls130at this angle, the packaging material213may be less rigid and provide an increased cushioning effect compared to the packaging material212shown inFIG.3A. As depicted inFIG.3C, the length of the base portion (i.e., the first base portion112or the second base portion122) may be longer than each of the transverse walls130.

Although shown and described as a convertible packaging material, with gaps126that allow the packaging material213to be bent into a tubular shape or contoured into other suitable shapes, the obtuse triangular cells depicted inFIG.3C, may be used with the other embodiments discussed herein. For example, the packaging material100shown inFIGS.1to2Dmay include the obtuse isosceles triangular cells depicted inFIG.3Cwith the second base portions122abutting each other. In another example, the first fins412and the second fins422, discussed further below, may be oriented to form the shapes depicted herein. As noted above, the top sheet152may be optional.

FIG.4is an exploded view of a cylindrical shipping box200. The cylindrical shipping box200includes a circumferential wall220, and as noted above, the packaging material212shown inFIGS.3A and3Bmay be used to form the circumferential wall220. The packaging material212is bent from the flat configuration (FIG.3A) to form a tubular shape (FIG.3B). The circumferential wall220includes an axial direction and the longitudinal direction of the plurality of triangular cells of the packaging material212(e.g., the first triangular cells110and the second triangular cells120) extends in the axial direction of the cylindrical shipping box200. The packaging material212may include a first edge222and a second edge224and the packaging material212is bent to bring the first edge222and the second edge224into contact with each other. The first edge222and the second edge224are held in place to hold the packaging material212in the tubular configuration. An adhesive strip218, such as tape, may be used to secure the first edge222and the second edge224and maintain the packaging material212in the tubular shape.

The circumferential wall220includes openings at each end and, more specifically, a top-end opening232and a bottom-end opening234. The cylindrical shipping box200includes a top cap240and a bottom cap250to close the top-end opening232and the bottom-end opening234, respectively. The inner surface216defines an inner cavity226having an inner diameter. The top cap240and the bottom cap250are thus each preferably sized to be larger than the inner diameter. The top cap240and the bottom cap250may each be circular with an overall diameter that is larger than the inner diameter of the inner cavity226. The outer surface214may define an outer diameter of the circumferential wall220and the overall diameter may substantially correspond to the outer diameter of the circumferential wall220.

The circumferential wall220includes a top end236and a bottom end238. In the depicted embodiment, the top cap240is placed to abut the top end236of the circumferential wall220, and the bottom cap250is plate to abut the bottom end238of the circumferential wall220. More specifically, the top cap240includes an inward facing surface242that abuts the top end236, and the bottom cap250includes an inward facing surface252that abuts the bottom end238. The top cap240and the bottom cap250may be attached to the circumferential wall220, such as by using one or more adhesive strips218.

Each of the top cap240and the bottom cap250may be made of the same material as the circumferential wall220, such as single-walled corrugated fiberboard. As depicted inFIG.4, each of the top cap240and the bottom cap250are multi-layer. The top cap240includes an outer layer244and an inner layer246. The overall dimensions of the top cap240discussed above apply to the outer layer244, and the inner layer246is sized and shaped to be inserted into the inner cavity226. As depicted inFIG.4the inner layer246is circular having a diameter that is less than the overall diameter of the outer layer244and is the inner diameter of the inner cavity226or less. This inner layer246may provide a bearing surface248, on which the inner surface216bears or presses against when an inward force is applied to the outer surface214of the circumferential wall220. The bearing surface248may be the outer circumferential surface of the inner layer246. The inner layer246may thus provide structural support for the circumferential wall220and help maintain the shape of the circumferential wall220. The inward facing surface242is formed on the outer layer244and the inner layer246may be attached, such as by an adhesive to the inward facing surface242.

The bottom cap250also includes an outer layer254and an inner layer256with a bearing surface258. The outer layer254of the bottom cap250is similar to the outer layer244of the top cap240, and the inner layer256of the bottom cap250is similar to the inner layer246of the top cap240. The discussion of the features of the top cap240applies to corresponding features of the bottom cap250.

FIGS.5A-5Cillustrate the process of forming the cylindrical shipping box200and packing an item-to-be-shipped10therein.FIG.5Ashows the components of the cylindrical shipping box200including the circumferential wall220in a flat configuration. As noted above, the packaging material212used to form the circumferential wall220provides a “knock-down-flat” (“kdf”) shipping box. As used herein “knock down flat” refers to a shipping box that can be assembled and disassembled into a flat state for storage or shipping of just the packaging material (i.e., the packaging material212, the top cap240, and the bottom cap250) without the item-to-be-shipped10. The cylindrical shipping box200of this embodiment provides a cylindrical box with all the advantages (e.g., strength) of a strong triangular construction of the packaging material212. With the kdf tubes in the flat state, as shown inFIG.5A, the kdf tubes can be shipped and stored flat with cube savings of 80%-90% in comparison with regular tubing.

To form the cylindrical shipping box200, the packaging material212used for the circumferential wall220is bent in the manner discussed above with reference toFIG.3Bto form a tube and, more specifically, the tubular, circumferential wall220. InFIG.5A, the packaging material212includes a tab228, which may be a portion of the top sheet152that extends beyond the first edge222of the packaging material212. A peelable adhesive strip209is applied to an inner surface of the tab228and used as the adhesive strip218. A covering is removed from the peelable adhesive strip and the inner surface of the tab228is attached to the outer surface214and, more specifically, the top sheet152at the second edge224(FIG.4). Then, the bottom cap250is attached to the circumferential wall220, as discussed above.

FIG.5Bshows the cylindrical shipping box200in the assembled condition (after completing the steps above) ready for packing an item-to-be-shipped10therein. The top cap240(not shown inFIG.5B) is removed to provide access to the inner cavity226. The item-to-be-shipped10is then placed into the inner cavity226. As discussed further below, the tubular shape is advantageously used for shipping round or cylindrical objects, such as plates or bowls, for example.FIG.5Bshows a plate12as the item-to-be-shipped10, and after the circumferential wall220is formed and, in some embodiments after the bottom cap250is attached to the circumferential wall220, the item-to-be-shipped10may be placed into the inner cavity226. After all the items-to-be-shipped10are placed in the inner cavity226, along with any packing material14, such as, for example, a corrugated sheet separating the plates12, the top cap240may be attached.FIG.5Cshows the cylindrical shipping box200in the assembled condition with the top cap240installed. After shipping, the process can be reversed and the cylindrical shipping box200“knocked down” to return to components, specifically the circumferential wall220, to its flat configuration.

FIG.6Ais an exploded view of another cylindrical shipping box202. The cylindrical shipping box202is similar to the cylindrical shipping box200discussed above. In the embodiment shown inFIGS.4to5C, an adhesive strip218, such as tape, is used to connect the first edge222and the second edge224of the packaging material212to form the tubular shape. The tubular shape may be held in other ways, however. As shown inFIG.6A, for example, a removeable ring260may be used to maintain the tubular shape in addition or instead of using the adhesive strip218. The ring260may be annular having an opening sized to correspond to the outer diameter of the circumferential wall220. The cylindrical shipping box202shown inFIGS.3A and3Bmay be formed into the tubular shape and then one or more rings260are slid over the tubular shape to maintain the shape. The rings260thus circumscribe the circumferential wall220to maintain the circumferential wall220in the tubular shape. Two rings are shown inFIG.6Aand the rings260are located at each end of the tubular shape (i.e., circumferential wall220), but they may be located at other portions of the tube (i.e., circumferential wall220). These rings260may be a single corrugated layer formed into an annular ring260so that the ring260can be part of the kdf shipping arrangement discussed above. The ring260may be particularly advantageous when the cylindrical shipping box202is used multiple times, as the ring260can be readily removed without damaging the packaging to convert the cylindrical shipping box202from its tubular configuration back to its flat configuration. In some embodiments, the ring260may be integrally formed with the top cap240and/or the bottom cap250.

FIG.6Bis an exploded view of another cylindrical shipping box204. The cylindrical shipping box204is similar to the cylindrical shipping boxes200,202discussed above. InFIG.6A, the rings260are shown as being placed externally to the circumferential wall220. Additionally or alternatively, inner rings262can also be located within the inner cavity226of the circumferential wall220. Like the inner layer246, the outer circumferential surface of the inner ring262forms a bearing surface264, similar to the bearing surface248of the top cap240and the bottom cap250, discussed above. In an assembled configuration, the bearing surface264abuts the inner surface216of the packaging material. The inner rings262thus may help maintain the shape of the tube (i.e., the circumferential wall220) and provide structural support to prevent the circumferential wall220from bending or collapsing. The inner rings262may be annular having a central opening266to allow the item-to-be-shipped10to be placed in the inner cavity226.

As noted above, the cylindrical shipping box200of the embodiments discussed herein can provide for a substantial savings in shipping costs, such as the shipping costs used to transport by shipping container because more of the cylindrical shipping boxes can be fit into a shipping container than a corresponding rectangular shipping box.FIG.7Ashows a comparative example of a rectangular shipping box20for eight plates12(FIG.5B).FIG.7Bshows a cylindrical shipping box206(such as one of the cylindrical shipping boxes discussed above) sized for the same eight plates12.

FIGS.8A and8Bshow the comparative example (the rectangular shipping box20) inFIG.7Apacked into a 40-foot shipping container30.FIG.8Ais a top view of the shipping container30, andFIG.8Bis a side view of the shipping container30. The top and side of the shipping container30are not illustrated, respectively, inFIGS.8A and8Bto show the rectangular shipping box20stacked therein. As illustrated inFIGS.8A and8B, thirteen layers of boxes may be stacked in the shipping container with 328 boxes per layer, resulting in 4,264 boxes and, with eight plates in each box, 34,112 plates.

FIGS.9A and9Bshow the cylindrical shipping box206inFIG.7Bpacked into a 40-foot shipping container30.FIG.9Ais a top view of the shipping container30, andFIG.9Bis a side view of the shipping container30. The top and side of the shipping container30are not illustrated, respectively, inFIGS.9aand9B to show the cylindrical shipping box206stacked therein. As illustrated inFIGS.9A and9B, thirteen layers of boxes may be stacked in the shipping container with383boxes per layer, resulting in 4,979 boxes and, with eight plates in each box, 39,832 plates. As can be seen in these examples, the cylindrical shipping box206of the embodiments discussed herein allows for more shipping boxes and thus more plates12to be shipped in the 40-foot shipping container30, than rectangular shipping box20sized to ship the same number of plates12in each box.

FIGS.10A and10Bshow another packaging material300that may be used to form the cylindrical shipping boxes discussed above, such as the cylindrical shipping box200shown inFIGS.4to5C, for example.FIG.10Ashows the packaging material300in a flat configuration, andFIG.10Bshows the packaging material300in a tubular configuration. The packaging material300is a variation of the packaging material ofFIGS.3A and3Band is similar to the packaging material212discussed above. In the embodiments discussed above, each of the second triangular cells120has the same size. In this embodiment, the second triangular cells120have a plurality of different sizes. For example, the transverse walls130may be of different lengths for different second triangular cells120and the second base portion122may have different lengths for different second triangular cells120. Where an object-to-be-shipped10(FIG.5B) is placed in the cylindrical shipping box200, there may be void space between the object-to-be-shipped10and the inner surface216of the circumferential wall220. In such a case, a void fill material may be added to secure the object-to-be-shipped10within the cylindrical shipping box200. The need to use void fill may particularly be the case where the object-to-be shipped10has an irregular shape. The plurality of sizes of second triangular cells120may be arranged to secure the object-to-be-shipped10in the cylindrical shipping box200eliminating or at least reducing the need for void fill.

FIGS.11A and11Bshow another packaging material400according to another embodiment.FIG.11Ais a perspective view of the packaging material400, andFIG.11Bis an end view of the packaging material400. The packaging material400of this embodiment is similar to the packaging material100discussed above with reference toFIG.1, but instead of being formed from a single sheet of single-walled corrugated fiberboard, the packaging material400shown inFIGS.11A and11Bis formed from two sheets of single-walled corrugated fiberboard to form the plurality of first triangular cells110and the plurality of second triangular cells120. The packaging material400includes a first sheet410and a second sheet420positioned to oppose each other. The first sheet410, which also may be referred to as a top sheet, is shown with solid lines inFIG.11B, and the second sheet420, which also may be referred to as a bottom sheet, is shown with broken lines inFIG.11B. The first sheet410includes the first base portions112, forming the first surface (e.g., the top surface104), and the second sheet420includes the second base portions122, forming the second surface (e.g., the bottom surface106).

Each of the first sheet410and the second sheet420are folded corrugated sheets, and include folded projections, which are pleats or areas of each sheet folded over itself. These folded projections are referred to herein as fins. The first sheet410includes a plurality of fins, which are referred to herein as first fins412, and the second sheet420includes a plurality of fins, which are referred to herein as second fins422. The first fins412are arranged parallel to each other, and the second fins422also are arranged parallel to each other. The first fins412are separated from each other by the first base portion112, and the second fins422are separated from each other by the second base portion122. The first fins412are connected to ends of adjacent first base portions112and, as noted above, may be formed by folding the first sheet410.

The first fins412may thus have a V-shape or a U-shape and include a first leg414extending from one of the first base portions112and a second leg416extending from an adjacent first base portion112. The first leg414connects to the second leg416at a peak418. As will be discussed below, the first leg414and the second leg416collectively form the transverse walls130of one of the first triangular cells110and one of the second triangular cells120. The peak418is thus an end portion of the transverse wall130that is a distal end located away from the base portion, more specifically the first base portion112. The end of each of the first leg414and the second leg416that is connected to the first base portion112is a base end portion or proximal end portion. The first leg414and the second leg416may be continuously connected to each other at the peak418and are a continuation of the same corrugated material at the peak418without being cut or separated.

Other portions of the first leg414and the second leg416(beyond the peak418) may also be connected to each other. For example, an adhesive may be applied between an interior surface of the first leg414and an interior surface of the second leg416. Although the adhesive may be applied to the full length of the interior surface of the first leg414and/or the interior surface of the second leg416, the adhesive144in this embodiment is applied between adjacent first base portions112(depicted once inFIG.11Bfor clarity). In this way, the first leg414and the second leg416is also connected to each other at the base end portion. Connecting the first leg414and the second leg416at the base end portion helps prevent the first sheet410from spreading out when a force is applied to the peak418, for example, and thus provides rigidity to the first sheet410and a protective (cushioning) effect for the packaging material400overall.

The forgoing discussion of the first fins412also applies to the second fins422, and each of the second fins422includes a first leg424, a second leg426, and a peak428, similar to the first leg414, the second leg416, and the peak418, respectively.

The first fins412project from the first base portion112on the same side of the first sheet410, and similarly, the second fins422of the second sheet420project from the second base portion122on the same side of the second sheet420. The first sheet410and the second sheet420are positioned to oppose each other with the first fins412projecting towards the second sheet420and the second fins422projecting towards the first sheet410. The distal end (i.e., the peak418) of the first fins412may be positioned to contact an inner surface429of the second sheet420, and likewise, the distal end (i.e., the peak428) of the second fins422may be positioned to contact an inner surface419of the first sheet410. The inner surface419of the first sheet410may be an inner surface of each first base portion112, and similarly, the inner surface429of the second sheet420may be an inner surface of each second base portion122. At least one of the first fins412or the second fins422may be positioned at an oblique angle with the inner surface419or inner surface429, respectively, to form the plurality of triangular cells of the packaging material400(i.e., the first triangular cells110and the second triangular cells120). As depicted inFIGS.11A and11B, both the first fins412or the second fins422are positioned at an oblique angle with the inner surface419or inner surface429, respectively. More specifically, the peak418of the first fins412is positioned to form the first apex114, such as at one end of the second base portion122, and similarly the peak428of the second fins422is positioned to form the second apex124, such as at one end of the first base portion112.

An adhesive144may be applied at the peaks418of the first fins412and the peaks428of the second fins422to attach the first sheet410to the second sheet420. As noted above, the adhesive144may be applied at other locations. The bonding, using the adhesive144, may however, be selectively applied, and the first fins412and second fins422may be bonded (e.g., glued) or unbonded (e.g., unglued) or a mix of both. For example, cushioning for the strong triangular construction can be created as needed by leaving air spaces between the folds on the vertically oriented parts of the corrugated sheet or by not gluing some of them to the horizontal planes. A top sheet152(paper sheet) and a bottom sheet154(paper sheet) shown and discussed above with reference toFIG.2D, may also be used with the packaging material400shown inFIGS.11A and11B, but as shown in this embodiment, there are a large number of interior gluing surfaces that would obviate the need for the top sheet152and the bottom sheet154.

The packaging material400shown inFIGS.11A and11Bor the packaging material100shown inFIG.1above, may replace the traditional three-layer construction of corrugated material (triple-walled boxes) with two layers of corrugated material. The result is thinner, lower cube packaging which leads to significant savings in transportation and storage costs, as well as less energy consumption. Such savings is shown, for example, in the table below comparing the packaging material of this embodiment with double-wall shipping containers or triple-wall shipping containers.

PackagingDoubleTripleComparisonsMaterial 400WallWallThickness (±0.5 mm)4.5 mm6.5 mm9.5 mmFourth Embodiment savings on a—2.6%6.5%4 cubic foot box (12″ × 24″ × 24″)Fourth Embodiment savings on a—$90$22540′ container (China to NY)

FIGS.12A and12Bshow a packaging material402that may be used to form the circumferential wall220(FIG.4) of a cylindrical shipping box200(FIG.4) discussed above. Like the packaging material100shown inFIG.1, the two-sheet packaging material400discussed above with reference toFIGS.11A and11Bmay also be modified to be used to form the circumferential wall220of a “knock-down-flat” (“kdf”) shipping box (cylindrical shipping box200), and the packaging material402shown inFIGS.12A and12Bdepicts such a modification. The packaging material402is similar to the packaging material400discussed above. The same reference numerals will be used for the same and similar components and features, and a detailed description of these features is omitted here.

The packaging material402is configurable in a flat configuration, shown inFIG.12A, and a tubular configuration, shown inFIG.12B. In the flat configuration, adjacent second base portions122are spaced apart from each other and a second-side gap126is maintained between adjacent second base portions122. Adjacent second base portion122are not bonded to each other and, similarly, the first leg424and the second leg426of the second fins422are not adhered to each other and free from attachment at the base portion. In the flat configuration, the first leg424and the second leg426of the second fins422are thus spaced apart from each other. To form this spaced-apart arrangement when flat, the first base portion112is longer than the second base portion122.

The packaging material402can be bent to form an arcuate shape, such as a tubular shape (seeFIG.4), as shown inFIG.12B. As the packaging material402is bent, the second base portions122are brought closer to each other reducing the length of the second-side gaps126between the first leg424and second leg426. In some embodiments, the second base portion122may be brought into contact with each other (i.e., the second base portions122abut each other), closing the second-side gaps126. With the first leg424and the second leg426being free from attachment as discussed above, the packaging material402can move back and forth between the arcuate (or tubular) configuration shown inFIG.12Band the flat configuration shown inFIG.12A.

Although described using corrugated sheet, the packaging material of this embodiment may use other sheets including relatively thick sheets of paper (e.g., non-corrugated paperboard). In addition, although the packaging materials discussed herein have been described as being formed from cellulosic sheets and, more specifically, corrugated fiberboard, other materials, however, may be used to form the shipping boxes discussed herein. For example, plastic sheets may be used.

Although the described as a packaging material, the embodiments discussed herein may also be used as a packing material to provide additional cushioning or void fill. In such a case, the materials discussed herein are placed inside a shipping box around the item-to-be-shipped 10.

Although this invention has been described with respect to certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art in light of this disclosure. It is, therefore, to be understood that this invention may be practiced otherwise than as specifically described. Thus, the exemplary embodiments of the invention should be considered in all respects to be illustrative and not restrictive, and the scope of the invention to be determined by any claims supportable by this application and the equivalents thereof, rather than by the foregoing description.