Patent ID: 12202226

DETAILED DESCRIPTION

In the following detailed description, reference may be made to the accompanying set of drawings that form a part hereof and in which are shown by way of illustration several specific embodiments. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure.

Various embodiments of the present disclosure relate to single slit patterns and to articles including single slit patterns. A “slit” is defined herein as a narrow cut through the article forming at least one line, which may be straight or curved, having at least two terminal ends. Slits described herein are discrete, meaning that individuals slits do not intersect other slits. A slit is generally not a cut-out, where a “cut-out” is defined as a surface area of the sheet that is removed from the sheet when a slit intersects itself. However, in practice, many forming techniques result in the removal of some surface area of the sheet that is not considered a “cut-out” for the purposes of the present application. In particular, many cutting technologies produce a “kerf”, or a cut having some physical width. For example, a laser cutter will ablate some surface area of the sheet to create the slit, a router will cut away some surface area of the material to create the slit, and even crush cutting creates some deformation on the edges of the material that forms a physical gap across the surface area of the material. Furthermore, molding techniques require material between opposing faces of the slit, creating a gap or kerf at the slit. In various embodiments, the gap or kerf of the slit will be less than or equal to the thickness of the material. For example, a slit pattern cut into paper that is 0.007″ thick might have slits with a gap that is approximately 0.007″ or less. However, it is understood that the width of the slit could be increased to a factor that is many times larger than the thickness of the material and be consistent with the technology disclosed herein.

As used herein, the term “single slit pattern” refers to a pattern of individual slits that form individual rows each extending across the sheet transversely, where the rows form a repeating pattern of individual rows along the axial length of the sheet, and the pattern of slits in each row is different than the pattern of slits in the directly adjacent rows. For example, the slits in one row may be axially offset or out of phase with the slits in the directly adjacent rows. In some embodiments, the slit, flap and/or folding wall shapes described herein amplify the out-of-plane motion of the materials or articles as compared to the prior art slit shapes ofFIGS.1A and1B.

The enhanced rotation of the material out of the plane of the sheet of material compared to the prior art slit/flap shapes ofFIGS.1A and1Badvantageously creates interlocking features. Whether a material is interlocking can be determined by the following test method.

A sample measuring 36-inches (0.91 m) long and 7.5-inches (19 cm) wide was obtained. The sample was fully deployed without tearing, and was then placed directly adjacent to a smooth PVC pipe having an outer diameter (OD) of 3.15 inches (8 cm) and a length of 23 inches (58.4 cm), ensuring that the sample remained fully deployed during rolling. The sample was wrapped over the pipe ensuring that each successive layer was placed directly over the previous layer and that the sample was placed at the center (along the length) of the pipe. The sample was wrapped around the pipe a minimum of two times. After the sample was wrapped around the pipe, the sample was released and whether the sample unfolded/unwrapped was observed. If the sample did not unfold/unwrap after a 1-minute wait, the sample was slid off the pipe onto a smooth surface such as a table top. The sample was then lifted by the trailing edge to see if it unrolled/unwrapped or held its shape.

If the sample opened/unwrapped within a minute of being released, during sliding it off the pipe, or when lifted by the trailing edge, the sample was deemed “not interlocking”. If the sample held its tubular shape during and after sliding it off the pipe and when lifted by the trailing edge, then it was deemed interlocking. The test was repeated 10 times for each sample.

An exemplary embodiment of a single slit pattern in a material400is shown schematically inFIG.4A. The material400is a sheet defining a plane having an axial direction x (which is the vertical direction relative to the figure) that is parallel to a tension axis T and a transverse direction y (which is the horizontal direction relative to the figure) that is orthogonal to the axial direction x. The material400defines the x-y plane in a pretensioned state; that is to say, prior to application of tension along the tension axis T. The single-slit pattern ofFIG.4Aincludes a first set of rows412athat include a first plurality of slits410aextending across the sheet in the transverse direction y, where the first plurality of slits410ahave a first shape and position. The first plurality of slits410ais a repeating pattern of slits. The first set of rows412aalternate with a second set of rows412balong the axial length of the sheet. Each of the second set of rows412bis defined by a second plurality of slits410bextending across the sheet in the transverse direction y. The second plurality of slits410bis a repeating pattern of slits. The second set of rows412bincludes slits having the same slit shape but the slits410are positioned differently (in this case, inverted and axially offset). Slits410each include a first terminal end414, a second terminal end416, and a midpoint418.

The first terminal end414aof each slit in the first plurality of slits410ais defined by a first terminal end segment421(that is a first axial portion421, in the current example). The first terminal end segment421of each slit in the first plurality of slits410aintersects an imaginary line i connecting the terminal ends414b,416bof a first slit in the second plurality of slits410b. The first terminal end414aof each slit in the first plurality of slits410ais between the terminal ends414b,416bof a first slit in the second plurality of slits410bin each of the axial and transverse directions. In this particular example, the first terminal end414aof each slit in the first plurality of slits410ais aligned with the imaginary line i. Stated differently, the first terminal end414aof each slit in the first plurality of slits410ais aligned with the terminal ends414b,416bof the first slit in the second plurality of slits410balong an axis (overlapping with imaginary line i) extending in the transverse direction y.

The second terminal end416aof each slit in the first plurality of slits410ais defined by a second terminal end segment423(that is a second axial portion423, in the current example). The second terminal end segment423of each of the slits in the first plurality of slits410ais aligned with an imaginary line i connecting the terminal ends414b,416bof a second slit in the second plurality of slits410b. In this example, the second terminal end416aof each of the slits in the first plurality of slits410ais between the terminal ends414b,416bof a slit in the second plurality of slits410bin each of the axial and transverse directions. In particular, the second terminal end416aof each slit in the first plurality of slits410ais aligned with the terminal ends414b,416bof a slit in the second plurality of slits410bin each of the axial and transverse directions. In various embodiments, the first slit and the second slit in the second plurality of slits410bare adjacent slits.

A plurality of individual slits410are aligned to form rows412that are generally perpendicular to the tension axis T. “Generally perpendicular” is defined herein as encompassing angles within a 5-degree margin of error or within a 3-degree margin of error. Material420is present between adjacent slits410in a row412forming beams420that extend generally axially. The material between directly adjacent rows412of slits410forms transverse beams430aand folding wall regions430b. Each axial beam420extends axially through each transverse beam430athat intersects the axial beam420. Slits410are not straight lines (like slits110of the slit pattern ofFIGS.1A and2A) but instead include two generally axial portions421,423that are generally parallel to the tension axis T and are connected to a generally transverse portion425that is generally perpendicular to the tension axis T. The first terminal end414is along a first axial portion421and the second terminal end416is along a second axial portion423. Slits410are generally u-shaped with a generally perpendicular intersection angle between the two generally axial portions421,423and the generally transverse portion425. A folding wall450is generally the area enclosed by the path of slit410and the imaginary line i between the terminal ends414and416. While in the current example, each of the axial portions421,423and the transverse portion425are straight line segments, in various embodiments one or more of such portions can be curved lines, zig-zagged, and the like.

When the slits410are inverted relative to one another in directly adjacent rows, this creates the opportunity for them to align with one another such that one or more of the terminal ends414,416of a slit410align along a transverse axis i (which is colinear with the imaginary line i) with the terminal ends414,416of a slit410in a directly adjacent row. These unique patterns create unique beam widths, sizes, and shapes. Because the terminal ends414,416of slits410in directly adjacent rows412aand412balign to approximate an imaginary, essentially straight, single line perpendicular to the tension axis T, the size and shape of beams varies from the embodiments previously described herein. The continuous transverse region between the generally transverse portions (which are substantially perpendicular to the tension axis) forms a first beam430a. This beam only occurs once between every two sets of transversely aligned, directly adjacent rows412aand412b. Transversely aligned, directly adjacent rows412aand412bare arranged such that there is no continuous transverse region between the terminal ends414,416of slits410in the directly adjacent, transversely aligned row. The area of material400into which the slits410with transversely aligned terminal ends414,416extend define a folding wall region430bthat has a plurality of folding walls450extending across the sheet to form a row in the transverse direction y. The folding wall region430bcan be further described as having two generally rectangular regions431that are each bound by (1) a directly adjacent generally transverse portions425of opposing slits410which is perpendicular to the tension axis T and (2) adjacent axial portions421and423on directly adjacent, opposing slits410. Material forming axially extending beams420is present between adjacent slits410in a single row412. Directly adjacent the beam420is a region433which is the remaining material in the folding wall region430bbounded in the axial direction by the beam420and the generally transverse portion425, and bounded in the transverse direction by the two generally rectangular regions431.

The plurality of slits410through the sheet400define a plurality of axially extending beams420arranged in columns across the axial length of the sheet. Due to having an extension parallel to the tension axis T of the material, the axially extending beams420are generally configured to transmit tension upon application of tension to the sheet of material400along the tension axis T. While each of the plurality of beams420are depicted in the current examples as generally rectangular in shape, in various embodiments some or all of the plurality of beams can have an alternate shape. In some embodiments, each of a plurality of beams have an irregular shape.

The plurality of slits410form a first plurality of axial beams420aforming a first column402a. Between each beam420ain the axial direction x is a transverse portion425of a slit of the plurality of slits410. Such a configuration advantageously allows axial expansion of the material400when tension is applied along the tension axis T. Tension is transmitted through the axial beams420and around each slit410between adjacent axial beams420, causing axial expansion of each of the slits410.

In various embodiments, the plurality of slits has a first group of slits440a, each having a transverse portion425athat is axially between each beam in the first plurality of beams420a. The plurality of slits410define a second plurality of beams420bextending in the axial direction x. The second plurality of beams420bform a second column402bextending across the sheet400in the axial direction x. The second plurality of beams420bare spaced from the first plurality of beams420ain the transverse direction y. Between each beam420bin the axial direction x is a transverse portion425of a slit in a second group of slits440bof the plurality of slits410. The plurality of slits410can similarly define a third plurality of beams420c, a fourth plurality of beams, and so on.

In the current example, the first plurality of beams420aand the second plurality of beams420bare staggered in the axial and transverse directions. However, each beam of the first plurality of beams420ahas a terminus424athat is aligned along a transverse axis i with a terminus424bof a beam of the second plurality of beams420b. The “terminus” of a beam is the end of the beam defined by terminal ends of the adjacent slits that define the beam. In some alternate embodiments, each beam of the first plurality of beams420aextends through an axis defined by a terminus424bof a beam of the second plurality of beams420b. In the current example, each slit in the first group of slits440ahas an axial portion421(the second axial portion423) that defines a beam in the second plurality of beams420b. Each slit in the second group of slits440bof the plurality of slits410has an axial portion423(the first axial portion421) that defines a beam in the first plurality of beams420a.

In the current example, the first plurality of slits410aforms a beam420a/cin the first plurality of beams420a. In particular, the beam420a/cis defined by the material between adjacent slits in the first row. Indeed, the first plurality of slits410adefines a plurality of beams across the first row412a, which can be referred to as a third plurality of beams420c. Each of the third plurality of beams420cextend in the axial direction x. Each beam in the third plurality of beams420cis defined by material between adjacent slits410ain the first row.

Also, in the current example, the second plurality of slits410bforms a beam420b/din the second plurality of beams420b. In particular, the beam420b/dis defined by the material between adjacent slits410bin the second row412b. Furthermore, the second plurality of slits define a fourth plurality of beams420dacross the second row412b, where each of the beams extend in the axial direction x. Each beam in the fourth plurality of beams420dis defined by material between adjacent slits410bin the second row412b.

In this exemplary embodiment, the slits have two terminal ends. A straight, imaginary line extends between and connects these terminal ends. In this embodiment, the straight, imaginary line extending between and connecting the terminal ends of a first slit is substantially colinear with the straight, imaginary line extending between and connecting the terminal ends of a directly adjacent slit. In this exemplary embodiment, all of the straight, imaginary lines extending between and connecting the slit terminal ends in a row are approximately colinear.

Those of skill in the art will appreciate that many changes may be made to the pattern while still falling within the scope of the present disclosure. Those of skill in the art will appreciate that the shape and slit length can vary. Alternatively, the slit length, row size or shape, and beam size or shape can vary. Further, the pattern can alternate in 2 rows, 3 rows, 4 rows, etc. Alternatively, the row size or shape, and beam size or shape can vary. Further, the degrees of offset or phase offset can vary from what is shown. Even further, many of the examples herein depict and describe slits that have axial portions intersecting a transverse portion at about a 90° angle to form a corner. In various embodiments, however the axial portions of slits may intersect a transverse portion to form a rounded corner. In some other embodiments, there is no discernible transition between the axial portions and the transverse portion, such as where the slit defines a semi-circle.

FIGS.4B-4Dshow the pattern ofFIG.4Aformed in a sheet of paper and exposed to tension along the tension axis T. When material400is tension activated or deployed along tension axis T, portions of material400experiences tension and/or compression that causes the material to move out of the original plane of material400in its non-tensioned format. When exposed to tension along the tension axis, two things to happen to the transverse beams430aand folding wall regions430b. The transverse beam430abends into a shape that undulates to bring the beam420between adjacent slits closer in the transverse direction y to the adjacent beam420in the same row, while keeping the terminal ends414and416approximately in a single plane that is parallel to the original plane of material400in its pretensioned state. The folding wall region430brotates and folds into an accordion-like shape such that all of the two generally rectangular regions431and region433are nominally flat, have folds between all adjacent generally rectangular regions431and regions433, and all flat surfaces are nominally orthogonal to the original plane of material400in its pretensioned state. Axial beams420between adjacent slits410in a row412primarily experiences tension aligned with tension axis T, so this region or area tends to bend with first beam430a. These movements in material400form two distinct regions, the folded wall region430bwhich is orthogonal to the tension axis and the original plane of material400in its pretensioned state, as seen inFIG.4D. The other region is the transverse beam430awhich undulates and is tilted at an angle relative to the original plane of material400in its pretensioned state, as show inFIG.4D.

Embodiments like the specific implementation ofFIGS.4A-4Dhave unique benefits. For example,FIGS.4A-4Dexemplify one set of embodiments in which portions of the material rotate to the normal axis (substantially 90° or orthogonal to the original plane of material400in its pretensioned state) when deployed or tension-activated. Additionally, some of these embodiments can withstand exposure to greater loads applied in the normal axis relative to other single slit patterned structures without being crushed. This means that they can provide increased or enhanced protection for things like packages being shipped and other applications. Another advantage to single slit patterns like the specific implementation shown inFIGS.4A-4Dis that, in some embodiments, once the construction is in its deployed (via application of tension) position, the construction substantially remains in its extended/tensioned position even once the tension is no longer applied. This feature can provide a more stable construction. Some of these benefits are a result of the increased strength of the folded wall geometry. The folded wall, or accordion shaped wall, or rotating/folding beam has a large area moment of inertia (also called moment of area or second moment of inertia) in the deployed article (deployed via the application of tension or force) where the area moment of inertia is in the plane of the original sheet. The area moment of inertia is increased relative to a straight vertical wall without folds.

When the tension-activated material400is wrapped around an article or placed directly adjacent to itself, the accordion folded folding wall regions430bor the undulating first beams430acan interlock with one another and/or opening portions422, to create an interlocking structure. Interlocking can be measured as stated in the interlocking test articulated above.

Another exemplary embodiment of a single slit pattern in a sheet of material500is shown schematically inFIG.5A. The pattern ofFIG.5Ais similar to the pattern ofFIGS.4A-4Dand, as such, the description ofFIGS.4A-4Dgenerally apply to the current description, except that inFIG.4Adirectly adjacent rows align with one another such that one or more of the terminal ends of a slit align with the terminal ends of a slit in a directly adjacent row along a transverse axis i. In contrast, inFIG.5A, the slits in adjacent rows nest together or overlap, meaning that a first terminal end segment of a slit in one row extends through an imaginary line connecting the terminal ends of a first slit in a second, adjacent row. Similarly, a second terminal end segment of the slit extends through an imaginary line connecting the terminal ends of a second slit in the second, adjacent row. This configuration affects the beam width, size, and shape of the material upon application of a threshold amount of tension along the tension axis T.

More specifically, the single-slit pattern ofFIG.5Aincludes a first set of rows512athat include a first plurality of slits510ahaving a first shape and position and a second set of rows512bwith a second plurality of slits510bthat include the same slit shape but the slits are positioned differently (in this case, inverted). The first plurality of slits510adefine a first plurality of axial beams520athat is the material between the slits510a. The second plurality of slits510bdefine a second plurality of axial beams520bbetween the slits510b. The slit shape, general configurations, and possible alternatives in both the first set of rows512aand the second set of rows512bis similar to that ofFIG.4A, whose description above is repeated herein.

In the current example, however, the second plurality of slits510bnest or overlap with another slit510in a directly adjacent row, specifically with the first plurality of slits510ain the current example. Each of the slits in the second plurality of slits510bextend through a first imaginary line i1that connects the terminal ends of a slit in the first plurality of slits510a. Similarly, each of the slits in the first plurality of slits510aextend through a second imaginary line i2that connects the terminal ends of a slit in the second plurality of slits510b. Furthermore, each beam520in the first plurality of beams520ahas a terminus524athat extends through a transverse axis (overlapping with the second imaginary line i2) defined by a terminus524bof a beam of the second plurality of beams520b. Similarly, each beam520in the second plurality of beams520bhas a terminus524bthat extends through a transverse axis (overlapping with the first imaginary line i1) defined by a terminus524aof a beam of the first plurality of beams520a. This nesting or overlap creates the opportunity to create unique beam width, size, and shape.

Because the terminal ends514,516of slits510in directly adjacent rows512aand512boverlap, such that a single line (nominally transverse) will pass through a portion of all of the axial portions521and523of all slits510in the overlapped rows512aand512b, the size and shape of beams varies from the embodiments previously described herein. The continuous transverse region between the generally transverse portions (which are substantially perpendicular to the tension axis T) forms a first beam530a. This beam only occurs once between every two sets of overlapped rows512aand512b. Overlapped rows512aand512bare arranged such that there is no continuous transverse region between the terminal ends514,516of slits510in the directly adjacent, overlapped, row. The overlapped row of slits512aand512bcomprises a folding wall region530b. The folding wall region can be further described as having two generally rectangular regions531that are bounded in the axial direction by adjacent generally transverse portions525on opposing sides of the folding wall region530band bounded in the transverse direction by adjacent axial portions521and523on opposing sides of the folding wall region530b. The axial beam520(for example axial beam520aand520b) is present between adjacent slits510in a single row512. Directly adjacent the beam520is a region533which is the remaining material in the folding wall region530bbounded in the axial direction by the beam520and the generally transverse portion525and bounded in the transverse direction by the two adjacent generally rectangular regions531, more specifically by the axial extensions of the adjacent axial portions521and523.

Similar to the discussion ofFIGS.4A-4D, above, in the current example the axial beams520are arranged in columns extending the axial length of the sheet of material500. The axial beams520extend axially through an adjacent portion of each transverse beam530athat intersects the axial beam520. Transverse portions525of slits510are generally arranged between each of the axial beams520in each respective column such that the axial beams520within a column are separated from each other by a transverse portion525of a slit.

Those of skill in the art will appreciate that many changes may be made to the pattern while still falling within the scope of the present disclosure. Those of skill in the art will appreciate that the shape and slit length can vary. For example, in some embodiments, the shape is u-shaped with more rounded edges than is shown inFIG.5A. Alternatively, the slit length, row size or shape, and beam size or shape can vary. Further, the pattern can alternate in 2 rows, 3 rows, 4 rows, etc. Alternatively, the row size or shape, and beam size or shape can vary. Further, the degrees of offset or phase offset can vary from what is shown.

FIGS.5B-5Dshow the pattern ofFIG.5Aformed in a sheet of paper and exposed to tension along the tension axis T. When material500is tension activated or deployed along tension axis T, portions of material500experiences tension and/or compression that causes the material to move out of the original plane of material500in its non-tensioned format. When exposed to tension along the tension axis, two things to happen to the two different types of beams530aand530b. The first beam530abends into a shape that undulates to bring the axial beam520between adjacent slits510closer to the adjacent beam520in the same row, while keeping the terminal ends514and516approximately in a single plane that is parallel to the original plane of material500in its pretensioned state. The folding wall region530brotates and folds into an accordion-like shape such that all of the generally rectangular regions531and regions533are nominally flat, have folds between two generally rectangular regions531and regions533, and have a single common axis (that in the flat state was the axial axis) that rotates at least 90 degrees from the original plane of the material500in its pretensioned state. The rotation of the common axis can also be understood and even calculated when it is considered as an additional consequence of all the terminal ends514and516being pulled into the same plane. These movements in material500form a series of two distinct folded beams one of which rotated at least orthogonal to the tension axis and the original plane of material500in its pretensioned state, as seen inFIG.5D.

Embodiments like the specific implementation ofFIGS.5A-5Dhave unique benefits. For example,FIGS.5A-5Dexemplify one set of embodiments in which portions of the material rotate to or beyond the normal axis, or substantially 90° or orthogonal to the original plane of material500in its pretensioned state when deployed or tension-activated. Additionally, some of these embodiments can withstand exposure to greater loads applied in the normal axis relative to other single slit patterned structures without being crushed. This means that they can provide increased or enhanced protection for things like packages being shipped and other applications. Another advantage to single slit patterns like the specific implementation shown inFIGS.5A-5Dis that, in various embodiments, once the construction is in its deployed (via application of tension) position, the construction substantially remains in its deployed/extended/tensioned position even once the tension is no longer applied. This feature can provide a more stable construction.

Because the implementation ofFIGS.5A-5Drotates beyond 90 degrees, it creates additional stress in some of the folds that tends to plastically deform (or crease) the material making it even more likely to stay in its deployed position even once the tension is no longer applied than the implementation ofFIGS.4A-4D. Some of these benefits are a result of the increased strength of the folded wall geometry. The folded wall, or accordion shaped wall, or rotating/folding beam has a large area moment of inertia (also called moment of area or second moment of inertia) in the deployed article (deployed via the application of tension or force) where the area moment of inertia is in the plane of the original sheet. The area moment of inertia is increased relative to a straight vertical wall without folds.

When the tension-activated material500is wrapped around an article or placed directly adjacent to itself, the accordion folded folding wall regions530b, or the undulating first beams530acan interlock with one another and/or opening portions522, to create an interlocking structure. Interlocking can be measured by the “interlocking test method” described below.

Additional single slit patterns are shown in, for example, U.S. Patent Application No. 62/952,789, assigned to the present assignee, the entirety of which is incorporated herein.

Multi-Slit Patterns

Various embodiments of the present disclosure relate to multi-slit patterns and to articles including these multi-slit patterns. The term “multi-slit pattern” is defined herein as a pattern of individual slits that form a first set of adjacent rows across the transverse direction y of the sheet, where the individual slits within the first set of adjacent rows are aligned in the transverse direction y. In a multi-slit pattern, the first set of adjacent rows form a repeating pattern with at least a second row along the axial length of the sheet, where the slits in the first set of adjacent identical rows are offset from the slits in the second row in the transverse direction y. The term “multi-slit pattern” includes double slit patterns, triple slit patterns, quadruple slit patterns, etc. A double slit pattern is where the slits form a set of two identical rows that are repeated in the pattern of rows along the axial length of the sheet, a triple slit pattern is where the slits form three identical rows that are repeated in the pattern of rows, and so on. Substantial alignment of the terminal ends of aligned multi-slits means that if you draw an imaginary line between two terminal ends of slits in adjacent rows, the angle of that imaginary line relative to the alignment axis (the axis that is perpendicular to the row(s) in the plane of the sheet) is no greater than +/−20 degrees. In some embodiments, the length of each slit that forms a multi-slit differs by no more than +/−20% of the total length of the longest or shortest slit. In some embodiments, where the slits are linear, they are substantially parallel to one another. In some embodiments where the slits are not linear, the aligned multi-slits are all substantially aligned parallel to the tension axis within +/−20 degrees.

As used herein, the term “double slit pattern” refers to a pattern of a plurality of individual slits. Each slit in the plurality can be formed by a single continuous cut that does not crossover or intersect itself. The pattern includes a plurality of rows of slits and the individual slits in a first row are substantially aligned with the individual slits in a directly adjacent, second row. A double slit is comprised of a slit in a first row that is substantially aligned with a slit in a second row. Together, these two substantially aligned slits form a double slit.

Double, triple, quadruple, or multi-slit patterns create significantly more out of plane undulation than single slit patterns when exposed to tension along a tension axis. This out of plane undulation of the material has great value for many applications. For example, these out of plane undulation areas create out of plane material or loops that can interlock with other areas of out of plane material or loops when portions of the material are placed adjacent to one another or wrapped together. As such, multi-slit patterns inherently interlock and/or include interlocking features. Once tension-activated, these features and patterns interlock and hold the material substantially in place. Interlocking can be measured as described above.

The undulations also create structures that can absorb energy in a spring-like fashion without significant plastic deformation. When double slit patterns are cut into a two-dimensional article (such as, for example, paper) and tension is applied to the article along the tension axis T, portions of the two-dimensional article undulate or move into the z-axis (the axis perpendicular to the original pretensioned plane of the two dimensional article), resulting in the formation of a three-dimensional article. In some embodiments, the slit or folding wall shapes described herein amplify the out-of-plane motion of the materials or articles as compared to the prior art slits or flap shapes and/or orientations ofFIGS.1A-2B. In some embodiments, the materials into which the double slit patterns are formed are substantially non-extensible. In some embodiments, the double slit patterns continue through and are truncated by at least one edge of the material without stopping or changing. The resulting materials and/or articles offer a wide variety of advantages.

FIG.6Ais a schematic drawing of an exemplary double slit pattern. The pattern600includes a plurality of slits610in rows of slits612. Each slit610includes a midpoint618between a first terminal end614and a second terminal end616. A first row612aof slits610and a second row612bof slits610each include a plurality of slits610that are spaced from one another. The space between directly adjacent slits610in a row612can be referred to as the material620between adjacent slits610in a row612. A straight, imaginary line extends between and connects terminal ends614,616. In this exemplary embodiment, the straight, imaginary line extending between and connecting the terminal ends of a first slit is substantially colinear with the straight, imaginary line extending between and connecting the terminal ends of a directly adjacent second slit in the same row. In this exemplary embodiment, all of the straight, imaginary lines extending between and connecting the slit terminal ends in a single row are approximately colinear.

Together, rows612a,612bof slits610form a transverse beam630. Transverse beam630is bound transversely by slits610. An overlap beam636is directly adjacent to and, in this embodiment, on both sides of each transverse beam630a,630b. Overlap beam636is bound by non-aligned slits. The slits in each directly adjacent row612a,612bthat forms an edge or side of transverse beam630are substantially aligned with one another such that they are substantially parallel and their terminal ends614,616are substantially aligned perpendicular to the axis of the row and equidistant to one another. In some embodiments, the slits that are aligned have substantially the same slit length and pitch (pitch being relative to the tension axis).

More specifically, material600includes slits610a,610b,610c,610d. Together, slits610aand610bform a double slit. Also, together, slits610cand610dform another double slit. Slits610aand610bform sides or edges of a portion of a first transverse beam630a. Slits610band610cform sides or edges of a portion of overlap beam636Slits610cand610dform sides or edges of a portion of a second transverse beam630b. Transverse beam630ais directly adjacent to overlap beam636. Overlap beam636is directly adjacent to transverse beam630b. Slits610aand610bare substantially aligned with one another. Slits610cand610dsubstantially aligned with one another. Slits610band610care not aligned with one another. Instead, slits610band610care phase separated or spaced from one another. In the embodiment ofFIG.6A, slits610are substantially perpendicular to the tension axis T.

Each section of transverse beam630bordered by two parallel and substantially aligned slits610includes a midpoint632that is (1) at the midpoint (transversely) between first terminal end614and a second terminal end616of the slits610that form the sides of transverse beam630and (2) at the midpoint (axially) between the two slits610that form the sides of transverse beam630. A midpoint632aof a first section of transverse beam630ais out of phase with a midpoint632bof the directly adjacent section of the directly adjacent transverse beam630b. In the embodiment ofFIG.6A, the midpoint632aof a first section of transverse beam630asubstantially aligns axially with midpoint632cof a first section of transverse beam630c, which is the second directly adjacent transverse beam from transverse beam630a.

FIG.6Aalso shows the tension axis (T) which is substantially parallel to the axial direction x and substantially perpendicular to the transverse direction y, and the direction of the rows of slits, in the embodiment ofFIG.6A. The tension axis (T) is an axis along which tension can be provided to deploy the material into which the pattern600has been formed, which creates the upward and downward movement of transverse beams630and rotation of overlap beams636.

FIGS.6B and6Cshow a material including the slit pattern ofFIG.6Awhen exposed to tension along tension axis T. When material600is tension activated or deployed along tension axis T, portions of material600experience tension and/or compression that causes material600to move out of the original plane of material600in its non-tensioned format. When exposed to tension along the tension axis, terminal ends614,616experience compression and are drawn toward one another, causing a flap region650of the material600to move or buckle upward relative to the horizontal plane of the material600in its pretensioned state (FIG.6A), creating a flap624. Portions of transverse beams630undulate out of the original plane of the material600in its pretensioned state (FIG.6A) forming loops, while staying nominally parallel to the tension axis. The material620between adjacent slits610in a row612stays substantially parallel to the original plane of material600in its pretensioned state (FIG.6A). Overlap beams636buckle and rotate out of the plane of the original material or sheet. The motion of the flap region650in combination with the undulation of the transverse beams630creates open portions622.

Those of skill in the art will appreciate that many changes may be made to the pattern and material while still falling within the scope of the present disclosure. For example, in some embodiments, multi-slit pattern will be a triple slit, quadruple slit, or other multi-slit instead of a double slit pattern. Alternatively, the slit length, slit size, slit thickness, slit shape, row size or shape, transverse beam size or shape, and/or overlap beam size or shape can vary. Further, the degrees of offset or phase offset can vary from what is shown. The slit, row, or beam pitch can vary. The angle between the tension axis and slits can vary. Many of these changes could change the deployment pattern.

When the tension-activated material600is wrapped around an article or placed directly adjacent to itself, the transverse beams630and/or flaps624interlock with one another and/or opening portions622, to create an interlocking structure. Interlocking can be measured as stated in the interlocking test articulated above.

One exemplary embodiment of another double slit pattern in a sheet of material700is shown schematically inFIG.7A. The sheet of material700defines an axial direction x and a transverse direction y, where the axial direction is parallel to the tension axis T. The slit pattern ofFIG.7Ashows that differing rows can have differently positioned slits. With specific reference to the implementation of this general concept into an example, the single-slit pattern ofFIG.7Aincludes a first set of rows712athat include slits710of a first shape and position and a second set of rows712bthat includes the same slit shape but the slits710are positioned differently (in this case, inverted) and offset in the axial direction x. The slit shape in both the first set of rows712aand the second set of rows712bis substantially the same except for the inversion. In addition to being positioned differently, the slits ofFIG.7Aare nested such that the terminal ends of the slits710in adjacent rows are aligned along a transverse axis, or the slits710in one row extend past an axis defined by the terminal ends of the slits710in an adjacent row creating a nested arrangement.

The double-slit pattern is formed in material700and includes a plurality of slits710that each include a first terminal end714, a second terminal end716, and a midpoint718. A plurality of individual slits710are aligned to form rows712that are generally perpendicular to tension axis T. Material forming an axial beam720is present between adjacent slits710in a row712. The axial beam720extends through an adjacent transverse beam730a,730b. In the exemplary embodiment ofFIG.7A, slits710are not discrete straight lines (like slits610of the slit pattern ofFIG.6A) but instead include two generally axial portions721,723that are generally parallel to the tension axis T and that are connected to a generally transverse portion725that is generally perpendicular to the tension axis T. In this embodiment, slits710are generally u-shaped and the intersection points of axial portions721,723and generally transverse portion725are generally perpendicular to one another.

The plurality of slits710through the sheet700define a plurality of axially extending beams720arranged in columns along the axial length of the sheet. The plurality of slits710form a first plurality of axial beams720aforming a first column702a. A transverse portion725of a slit of the plurality of slits710is disposed axially between beams720a. Unlike previously described examples, in this example each beam is not separated by a transverse portion725of a slit710. Rather, each series of two beams720ain the first column702aalternates with a series of two transverse portions725of corresponding slits710in the column. As such, the first column702ahas a first group of slits740aeach having a transverse portion725athat is axially between beams in the first plurality of beams720a.

The plurality of slits710also define a second plurality of beams720bextending in the axial direction x. The second plurality of beams720bform a second column702bextending across the sheet700in the axial direction x. The second plurality of beams720bare spaced from the first plurality of beams720ain the transverse direction y. Between beams720bin the axial direction x is a transverse portion725of a slit in a second group of slits740bof the plurality of slits710. Similar to the first column702a, in this example in the second column702bthere is a series of two consecutive beams720balternating with two consecutive transverse portions725of slits along the length of the column702b.

The first plurality of beams720aand the second plurality of beams720bare staggered in the axial and transverse directions. In the current example, each slit in the first group of slits740ahas an axial portion721(the first axial portion721) that defines a beam in the second plurality of beams720b. Each slit in the second group of slits740bof the plurality of slits710has an axial portion723(the second axial portion723) that defines a beam in the first plurality of beams720a. Each beam of the first plurality of beams720ais aligned with axis (i1, as an example) defined by a terminus724bof a beam of the second plurality of beams720b.

In the current embodiment, the sheet of material700defines a plurality of slits710that define a first plurality of beams720ain a first column702aand a second plurality of beams720bin a second column702b. The first column702aand the second column702balternate across the width of the sheet in the transverse direction y. In other words, the first plurality of beams720aand the second plurality of beams720bform a repeating pattern of beams across the transverse width of the sheet of material700. In some embodiments, the plurality of slits710can similarly define a third plurality of beams defining a third column that alternates with the first column702aand the second column702bacross the width of the sheet. In some embodiments, the plurality of slits710can similarly define a fourth plurality of beams defining a fourth column that alternates with the first column702a, the second column702b, and the third column across the width of the sheet.

Material700includes first slits710a, second slits710b, third slits710c, and fourth slits710d, each forming a corresponding first row712a, second row712b, third row712cand fourth row712d, respectively. Each row of slits extends across the width of the sheet of material700in the transverse direction y. The first row712a, second row712b, third row712cand fourth row712dform a repeating pattern of rows along the axial length of the sheet of material700. In the current example, the second slits710bare nested with the third slits710cand the first slits710aare nested with the fourth slits710d. As such, a first terminal end segment (corresponding to the first axial portion721) defining the first terminal end714of each slit in the second plurality of slits710bintersects an imaginary line i1connecting the terminal ends714,716of a slit in the third plurality of slits710c. More particularly, a first terminal end714of each slit in the second plurality of slits710bis aligned with the imaginary line i1connecting the terminal ends714,716of a slit in the third plurality of slits710c. Similarly, a first terminal end segment (corresponding to the first axial portion721) defining the first terminal end714of each slit in the first plurality of slits710aintersects an imaginary line i2connecting the terminal ends714,716of a slit in the fourth plurality of slits710d. In particular, a first terminal end714of each slit in the first plurality of slits710ais aligned with the imaginary line i2connecting the terminal ends714,716of a slit in the fourth plurality of slits710d.

First slits710aand second slits710bform transverse sides or edges of a portion of a first transverse beam730a. The first transverse beam730aextends across the transverse width of the material700. The length of the first transverse beam730aacross the width of the material is uninterrupted by intervening slits. The second slits710band the third slits710cform a folding wall region736. The third slits710cand the fourth slits710dform transverse sides or edges of a portion of a second transverse beam730b. The transverse beam730ais directly adjacent to folding wall region736. The folding wall region736is directly adjacent to the second transverse beam730b. The folding wall region generally includes all the area enclosed by the second slits710band the third slits710b, which excludes the axial beams720between adjacent slits710b,710c. The transverse beams730aand730bare directly adjacent folding wall region736. In particular, the folding wall region736is between the first transverse beam730aand the second transverse beam730b. Slits710aand710bare substantially aligned with one another. Slits710cand710dsubstantially aligned with one another. Slits710band710care not aligned with one another. Instead, slits710band710care phase separated or spaced from one another. In the embodiment ofFIG.7A, slits710are substantially perpendicular to the tension axis T.

When the slits710are inverted relative to one another in directly adjacent rows, this creates the opportunity for them to align with or move past one another such that one or more of the terminal ends714,716of a slit710align along a transverse axis T with the terminal ends714,716of a slit710in a directly adjacent row. These unique patterns create unique beam widths, sizes, and shapes. Because the terminal ends714,716of slits710in directly adjacent rows712aand712balign transversely to approximate an imaginary, essentially straight, single line perpendicular to the tension axis T, the size and shape of beams varies from the embodiments previously described herein. The continuous transverse region between the generally transverse portions725(which are substantially perpendicular to the tension axis T) forms a transverse beam730. This beam only occurs once between every two sets of transversely aligned, directly adjacent rows712aand712b. Transversely aligned, directly adjacent rows712aand712bare arranged such that there is no continuous transverse region between the terminal ends714,716of slits710in the directly adjacent, transversely aligned row. The area of material700into which the slits710with transversely aligned terminal ends714,716extend, subtracting the axial beam720between adjacent slits710, comprises a folding wall region736. The folding wall region736can be further described as having two generally rectangular regions731and733, where rectangular region731is bound by (1) directly adjacent generally transverse portions725of slits710which are perpendicular to the tension axis and (2) adjacent axial portions721and723on directly adjacent, opposing slits710. The axial beam720is present between adjacent slits710in a single row712. Directly adjacent the axial beam720is a region733which is the remaining material in the folding wall region736bounded in the axial direction x by the beam720and the generally transverse portion725and bounded in the transverse direction y by the two generally rectangular regions731, more specifically by the axial extensions of the adjacent axial portions721and723.

In this exemplary embodiment, the slits have two terminal ends. A straight, imaginary line extends between and connects these terminal ends. In this embodiment, the straight, imaginary line extending between and connecting the terminal ends of a first slit is substantially colinear with the straight, imaginary line extending between and connecting the terminal ends of a directly adjacent slit. In this exemplary embodiment, all of the straight, imaginary lines extending between and connecting the slit terminal ends in a single row are approximately colinear.

FIGS.7B-7Dshow a material including the slit pattern ofFIG.7Awhen exposed to tension along tension axis T. When material700is tension activated or deployed along tension axis T, portions of material700experiences tension and/or compression that causes the material to move out of the original plane of material700in its non-tensioned format. When exposed to tension along the tension axis, the transverse beams730bend into a shape that undulates to bring the axial beam720between adjacent slits closer to the adjacent beam720in the same row, while keeping the terminal ends714and716approximately in a single plane that is parallel to the original plane of material700in its pretensioned state. The undulating transverse beam730is parallel to the tension axis, specifically any line drawn parallel to the tension axis on the transverse beam730in the pretensioned state will still be substantially parallel to the tension axis in the tensioned state. In other words, each undulating slit surface is substantially a single curved line that was extended along the tension axis. The folding wall region736rotates and folds into an accordion-like shape such that all of the two generally rectangular regions731and region733are nominally flat, have folds between all adjacent generally rectangular regions731and regions733, and all flat surfaces are nominally orthogonal to the original plane of material700in its pretensioned state. The axial beam720between adjacent slits710in a row712primarily experiences tension aligned with tension axis T, this tension is balanced by the adjacent beam720that adjoins the same transverse beam730so this region or area tends to stay flat and parallel to the original plane of material700in its pretensioned state. These movements in material700form two distinct folded beams, 1) undulating beams730that are parallel to the tension axis, and 2) folded beams736that are orthogonal to the original plane of material700in its pretensioned state, as seen inFIG.7D.

Embodiments like the specific implementation ofFIGS.7A-7Dhave unique benefits. For example,FIGS.7A-7Dexemplify one set of embodiments in which portions of the material rotate to the normal axis (substantially 90° or orthogonal to the original plane of material700in its pretensioned state) when deployed or tension-activated. Additionally, some of these embodiments can withstand exposure to greater loads applied in the normal axis relative to other multi-slit patterned structures without being crushed. This means that they can provide increased or enhanced protection for things like packages being shipped and other applications. Another advantage to multi-slit patterns like the specific implementation shown inFIGS.7A-7Dis that once the construction is in its deployed (via application of tension) position, the construction substantially remains in its extended/tensioned position even once the tension is no longer applied. This feature can provide a more stable construction. Some of these benefits are a result of the increased strength of the folded wall geometry. The folded wall, or accordion shaped wall, or rotating/folding beam has a large area moment of inertia (also called moment of area or second moment of inertia) in the deployed article (deployed via the application of tension or force) where the area moment of inertia is in the plane of the original sheet. The area moment of inertia is increased relative to a straight vertical wall without folds.

Those of skill in the art will appreciate that many changes may be made to the pattern and material while still falling within the scope of the present disclosure. For example, the terminal ends of one row of slits instead of being colinear with the terminal ends of an adjacent row of slits could move past the terminal ends of the adjacent row of slits creating a nested or overlapping pattern of slits. In some embodiments, multi-slit pattern will be a triple slit, quadruple slit, or other multi-slit instead of a double slit pattern. Alternatively, the slit length, slit size, slit thickness, slit shape, row size or shape, transverse beam size or shape, and/or overlap beam size or shape can vary. The degree of curvature and slit length can vary. Further, the degrees of offset or phase offset can vary from what is shown. The slit, row, or beam pitch can vary. Further, the pattern can alternate in 2 rows, 3 rows, 4 rows, etc. The angle between the tension axis and slits can vary. Many of these changes could change the deployment pattern.

When the tension-activated material700is wrapped around an article or placed directly adjacent to itself, undulating beams730and/or folding wall regions736interlock with one another and/or opening portions722, to create an interlocking structure. Interlocking can be measured as stated in the interlocking test articulated above.

Additional multi-slit patterns are shown in, for example, U.S. Patent Application Nos. 62/952,815 and 62/058,084, assigned to the present assignee, the entirety of which is incorporated herein.

Compound Slit Patterns

FIG.8Ais a top view schematic drawing of an exemplary compound slit pattern800. A “compound slit” is defined herein as a slit that has more than two terminal ends, which is contrasted with a “simple slit,” which is defined herein as a slit with exactly two terminal ends. Compound slit patterns can be consistent with single-slit patterns or multi-slit patterns. In this example, the pattern800includes a plurality of slits810in rows of slits812. Each slit810includes a first axial portion821, a second axial portion823that is spaced from and generally parallel to first axial portion821, and a generally transverse portion825that connects first and second axial portions821,823. Each slit810includes four terminal ends: a first terminal end814, a second terminal end815, a third terminal end816, and a fourth terminal end817. Each slit810has a midpoint818.

The first terminal end814and the second terminal end815are opposite terminal ends of a first axial portion821of the slit810. The third terminal end816and the fourth terminal end817are opposite terminal ends of second axial portion823of the slit810. The first terminal end814is aligned with the second terminal end815along an axis in the axial direction x (which is parallel to the first axial portion821in the current example) and the third terminal end816is aligned with the fourth terminal817end along an axis in the axial direction (which is parallel to the second axial portion823in the current example). The first terminal end814is aligned with the third terminal end816along an axis i1in the transverse direction y and the second terminal end815is aligned with the fourth terminal817end along an axis i2in the traverse direction. The space between directly adjacent slits810in a row812a,812bcan be referred to an axial beam820. When exposed to tension, the axial beam820between adjacent slits810in a row812a,812bbecomes a non-rotating beam820(visible inFIGS.8C-8E and8G). The space bounded by the generally transverse portions825subtracting the non-rotating beams820defines a folding wall regions830a,830b.

The folding wall regions830a,830bcan be further described as having two generally rectangular regions831and833, where rectangular region831is bound by (1) directly adjacent generally transverse portions825of slits810which are perpendicular to the tension axis and (2) adjacent axial portions821and823on directly adjacent, opposing slits810. Axial beams820are between adjacent slits810in a single row812a,812b, more specifically, between the adjacent axial portions821and823. Directly adjacent the beam820is a region833which is the remaining material in the folding wall region830a,830bbounded in the axial direction by the beam820and the generally transverse portion825and bounded in the transverse direction by the two generally rectangular regions831, more specifically by the axial extensions of the adjacent axial portions821and823. Directly adjacent rows of slits810are phase offset from one another.

In the embodiment ofFIG.8A, the tension axis T is substantially parallel to the axial direction x and substantially perpendicular to the transverse direction y. The tension axis T is generally perpendicular to the direction of the rows812a,812bof slits810. The tension axis T is an axis along which tension can be provided to deploy the material into which the pattern800has been formed, which creates the rotation and upward and downward movement of portions of the material.

In the current example, unlike previous examples, there are no transverse beams extending across the width of the sheet of material in the transverse direction y. Rather, in the current example, there are folding wall regions830a,830bdefined across the transverse width of the material800that alternate along the axial length of the sheet of material800. Similar to some previous examples, in the current example the pattern of slits in the sheet of material defines a first row812aand a second row812bthat alternate along the axial length of the sheet of material800. The plurality of slits810in the sheet of material define columns of beams and rows of beams similar to that which has already been discussed. However, in the current example, each of the axial beams820extend from a first folding wall region830ato an adjacent second folding wall region830b. Furthermore, each of the axial beams820define two termini824a,824bcorresponding to the terminal ends of adjacent slits in a row.

FIG.8Bshows the primary tension lines840(e.g., the lines approximating the highest tensile stress path) formed when an article including the slit pattern ofFIG.8Ais deployed with tension along the tension axis T.FIG.8Bshows in dotted lines the primary tension lines840, which are where the greatest tensile stress will occur. Tension lines are imaginary paths through the material that carry the greatest load when tension is applied to the material along the tension axis. When tension is applied along tension axis (T), the primary tension lines840move more closely into alignment with the applied tension axis, causing the sheet to distort. Tension lines840are focused in the axial beams820between adjacent slits in the same row. When exposed to tension, these beams820become non-rotating beams820. In the embodiment ofFIG.8A, these beam820or non-rotating beams820are generally parallel to the tension axis. In the embodiment ofFIG.8A, these beams820or non-rotating beams820are generally axial. When tension is applied along the tension axis T (which in this embodiment is an axis nominally parallel to the non-rotating beams), then the tension (or the highest concentration of stress caused by that tension) exists on all the non-rotating beams820somewhat uniformly, but across sections of the folding wall region830a,830bas shown by the dotted lines.

FIGS.8C-8Gare top view schematic drawings showing how a material including the slit pattern ofFIG.8Amoves in space when tension is applied along the tension axis T. When compound slit patterns are deployed, the activation of tension along the primary tension lines840causes substantially all regions of the pattern to experience some tension or compression (tensile stress or compressing stress) and some of the regions rotate and/or and bend out of the plane of the original two-dimensional film. The tension running through the folding wall region830a,830bcauses the beams to rotate and fold at the same time to move the non-rotating beams820closer together to become more aligned with the tension axis T. InFIG.8C-8E, the non-rotating beams820are represented as being broken and connected with force vectors (arrows). This helps visualize the interaction of forces in different regions to clarify the motion of the material. Because the material800experiencing the forces is relatively thin, folding wall region830a,830bwill rotate out of plane and fold at the base of the non-rotating beams820in response to the application of tension forces. Specifically,FIG.8Cshows non-rotating beams820with force vectors acting on the folding wall region830a,830b. This action causes the material800to move into the position shown schematically inFIG.8D, in which the folding wall region830a,830bhave rotated as a consequence of the force vectors shown inFIG.8D. As shown inFIG.8E, the folding wall regions830a,830balso fold or bend in response to the force vectors shown inFIG.8C-8E. The degree of fold or bend will vary depending on many factors including, for example, the stiffness or modulus of the material, the magnitude of the tension forces, the dimensions and scale of the elements, the width of non-rotating beams, the span between non-rotating beams, etc.

FIG.8Dis a top view schematic drawing of folding wall region830a,830bshowing only the rotation from a top view perspective inFIG.8C.FIG.8Eis a schematic drawing showing a top view of the rotating beams that are both rotated and bent when fully tensioned and deployed. From a top view, folding wall region830a,830b, once rotated, form accordion folded vertical walls that can resist significant compressive force in the Z-axis (orthogonal to the x-y plane). The energy it takes to buckle the folded walls is the energy that can be absorbed by the structure to prevent damage to an object that it is wrapped around. Non-rotating beams820connect the folding wall regions830a,830b. The compound slit pattern ofFIG.8Aresults in the non-rotating beams820being staggered, which further contributes to the strength of the material when deployed. The motion of the non-rotating beams820and folding wall regions830a,830bproduces open regions822, which is visible inFIGS.8G-8J.

Returning toFIG.8A, the generally rectangular region833has a width, or transverse dimension, that is equal to the width, or transverse dimension, of the non-rotating beam820. In some embodiments, it is preferred to have this width be small relative to the width, or transverse dimension, of the rectangular region831. When the transverse width of the rectangular region833is small relative to the transverse width of the rectangular region831, then the rectangular region833will substantially crease when deployed and not be clearly independently distinguishable from the remainder of the folding wall regions830as approximated by the drawing ofFIG.8F, and as is visible inFIGS.8G and8H. In particular, in the facing view (top or bottom) of the material ofFIG.8Ithe shape of the openings822appear to be generally hexagonal, as compared to the model view inFIG.8Jwhere it is more clearly visible in the facing view that the shape of the openings822are octagonal. If the rectangular region833is wide enough, then another flat vertical section will exist at the folds of the rotating/folding beam shown inFIG.8J. Visually, this would make the hexagons look like octagons.

FIGS.8H and8Iare line drawings from photographs of the compound slit pattern ofFIG.8Aformed in a paper sheet and exposed to tension along the tension axis.FIG.8His a perspective side view, andFIG.8Iis a nearly top view, andFIG.8Jis a schematic drawing corresponding toFIG.8I.

FIG.9Ais an exemplary compound slit pattern that is substantially the same as the compound slit pattern ofFIG.8Aexcept that generally transverse portion925is a zig-zag pattern. The zig-zag pattern may advantageously improve the interlocking function of the material900. These features can increase the interlocking of the material when it is placed adjacent to another layer of the material and/or when it is wrapped around an item. Further, these features may advantageously soften the edges of the material. InFIG.9A, the generally transverse portion925has a wavy or v-wave shape. The “v” portions of the wave increase the interlocking features. The tension axis (T) is substantially parallel to the axial direction x and substantially perpendicular to the transverse direction y and to the direction of the rows of slits. The tension axis T is an axis along which tension can be provided to deploy the material into which the pattern900has been formed, which creates the rotation and upward and downward movement of portions of the material. The material deploys substantially as described above with respect toFIGS.8A-8I, as shown inFIGS.9B-9D. When multiple layers of the material are in contact, such as when wrapped around an object, then the interlocking features allow the layers to interlock with each other more strongly and/or in different ways.

Yet another compound slit pattern in a sheet of material2000is depicted inFIGS.20A-20B, which is similar to the pattern ofFIG.9Aexcept that the interlocking structures or features have a somewhat different shape. The transverse portion2025of each of the slits defines a curved line. In particular, the transverse portions2025of the slits in a row2012generally define an undulating wave or a sine wave that is interrupted by axial beams2020between each of the slits2010.FIGS.20C-20Eshow a sheet of material with the compound slit pattern ofFIGS.20A-20Bwhen the material is expanded after being placed under tension in the tension axis.

FIG.10Ais a top view schematic drawing of another exemplary compound slit pattern in a sheet of material1000that is substantially similar to the compound slit pattern ofFIG.8Aexcept that the transverse slit portions1025cumulatively define an oscillation wave form.FIGS.10B-10Dshow the compound slit pattern ofFIG.10Aformed or cut into a material and then exposed to tension along tension axis T. The material deploys substantially as described above with respect toFIGS.8A-8I.

A plurality of slits1010define rows of slits1012that are alternated along the axial length of the material1000. Each slit1010has a first axial portion1021, a second axial portion1023that is spaced from the first axial portion1021in the transverse direction y. A generally transverse portion1025that connects first and second axial portions1021,1023. Each slit1010includes four terminal ends: a first terminal end1014, a second terminal end1015, a third terminal end1016, and a fourth terminal end1017. Each slit1010has a midpoint1018.

The first terminal end1014and the second terminal end1015are opposite terminal ends of a first axial portion1021of the slit1010. The third terminal end1016and the fourth terminal end1017are opposite terminal ends of second axial portion1023of the slit1010. The first terminal end1014is aligned with the second terminal end1015along an axis extending in the axial direction (which is colinear with axial portion1021) and the third terminal end1016is aligned with the fourth terminal1017end along an axis in the axial direction (which is colinear with axial portion1023). The first terminal end1014is aligned with the third terminal end1016along an axis in the transverse direction y, similar to examples previously depicted. The second terminal end1015is aligned with the fourth terminal1017end along an axis in the traverse direction, also similar to that which has been previously depicted. The space between directly adjacent slits1010in a row1012can be referred to an axial beam1020between adjacent slits1010in a row1012. When exposed to tension, the beam1020between adjacent slits1010in a row1012is a non-rotating beam1020(visible inFIGS.10B and10D). The space bounded by the generally transverse portions1025subtracting the non-rotating beams1020defines a folding wall regions1030a,1030b.

Unlike previous embodiments, the folding wall regions1030are not a combination of generally rectangular regions. Rather, the folding wall regions are a combination of two regions, a first region1031being generally bound by (1) directly adjacent generally curved transverse portions1025of slits1010and (2) adjacent axial portions1021and1023on directly adjacent, opposing slits1010. Axial beams1020are between adjacent slits1010in a single row1012, more specifically, between the adjacent axial portions1021and1023. Directly adjacent the beam1020is a second region1033which is the remaining region in the folding wall region1030bounded in the axial direction by a terminus of the beam1020and the generally transverse portion1025. The second region1033is bounded in the transverse direction by the ends of the adjacent axial portions1021and1023. Directly adjacent rows1012of slits1010are offset from one another in the transverse direction y.

In the embodiment ofFIG.10A, the tension axis T is substantially parallel to the axial direction x and substantially perpendicular to the transverse direction y. The tension axis is generally perpendicular to the direction of the rows1012of slits1010. The tension axis is an axis along which tension can be provided to deploy the material into which the pattern1000has been formed, which creates the rotation and upward and downward movement of portions of the material.

In this example there are no transverse beams extending across the width of the sheet of material in the transverse direction y. Rather, in the current example, there are folding wall regions defined across the transverse width of the material1000that alternate along the axial length of the sheet of material1000, similar to some previous embodiments.

Additional compound slit patterns are shown in, for example, U.S. Patent Application No. 62/952,815, assigned to the present assignee, the entirety of which is incorporated herein.

Any of the embodiments shown or described herein can be combined with other embodiments shown or described herein, including that any specific features, shapes, structures, or concepts shown or described herein can be combined with any of the other specific features, shapes, structures, or concepts shown or described herein. Those of skill in the art will appreciate that many changes may be made to the compound slit patterns, formation of the patterns into materials, and deployment of those materials while still falling within the scope of the present disclosure. For example, in embodiments showing a double slit pattern, the pattern could be a triple slit, quadruple slit, or other multi-slit pattern instead of a double slit pattern. Alternatively, the slit length, slit size, slit thickness, slit shape, row size or shape, transverse beam size or shape, and/or overlap beam size or shape can vary. Further, the degrees of offset or phase offset can vary from what is shown. The slit, row, or beam pitch can vary. The angle between the tension axis and slits can vary. The alignment of the pattern relative to the tension axis and/or sides of the material may vary. Some of these changes could change the deployment pattern.

Most of the slit patterns shown herein have regions that are described as moving or buckling either upward or downward relative to the original plane of the sheet when tension is applied. The distinction between upward and downward motion is an arbitrary description used for clarity to substantially match the accompanying figures. The samples could all be flipped over turning the downward motions into upward motions and vice versa. In addition, it is normal and expected for occasional inversions to occur where the regions of the sample will flip such that similar features which had moved upward in previous regions are now moving downward and vice versa. These inversions can occur for regions as small as a single slit, or large portions of the material. These inversions are random and natural, they are a result of natural variations in materials, manufacturing, and applied forces. Although some effort was made to produce regions of material without inversions, all samples were tested with the presence of these natural variations and it is believed that performance is not significantly affected by the number or location of inversions.

All of the slit patterns shown herein are shown as being generally perpendicular to the tension axis. While in many embodiments this can provide superior performance, any of the slit patterns shown or described herein can be rotated at an angle to the tension axis. Angles less than 45 degrees from the tension axis are preferred.

Further, all of the slit patterns shown herein include single slit that are out of phase with one another by approximately one half of the transverse spacing between directly adjacent slits (or 50% of the transverse spacing). However, the patterns may be out of phase by any desired amount including for example, one third of the transverse spacing, one quarter of the transverse spacing, one sixth of the transverse spacing, one eighth of the transverse spacing, etc. In some embodiments, the phase offset is less than 1 or less than three fourths, or less than one half of the transverse spacing of directly adjacent slits in a row. In some embodiments, the phase offset is more than one fiftieth, or more than one twentieth, or more than one tenth of the transverse spacing of directly adjacent slits in a row.

In some embodiments, the minimum phase offset is such that the terminal ends of slits in alternate rows intersect a line parallel to the tension axis through the terminal ends of slits in the adjacent rows. In some embodiments, the maximum phase offset is similarly limited by the creation of a continuous path of material. If the width of the slits orthogonal to the tension axis are constant for all slits and have a value w and the gap between slits orthogonal to the tension axis are constant and have a value g, then the minimum and maximum phase offsets are:

minimum⁢phase⁢offset=gw+g,maximum⁢phase⁢offset=ww+g

The present disclosure also relates to one or more articles or materials including any of the slit patterns described herein. Some exemplary materials into which the slit patterns described herein can be formed include, for example, paper (including cardboard, corrugated paper, coated or uncoated paper, kraft paper, cotton bond, recycled paper); plastic; woven and non-woven materials and/or fabrics; elastic materials (including rubber such as natural rubber, synthetic rubber, nitrile rubber, silicone rubber, urethane rubbers, chloroprene rubber, Ethylene Vinyl Acetate or EVA rubber); inelastic materials (including polyethylene and polycarbonate); polyesters; acrylics; and polysulphones. The article can be, for example, a material, sheet, film, or any similar construction.

“Paper” as used herein refers to woven or non-woven sheet-shaped products or fabrics (which may be folded, and may be of various thicknesses) made from cellulose (particularly fibers of cellulose, (whether naturally or artificially derived)) or otherwise derivable from the pulp of plant sources such as wood, corn, grass, rice, and the like. Paper includes products made from both traditional and non-traditional paper making processes, as well as materials of the type described above that have other types of fibers embedded in the sheet, for example, reinforcement fibers. Paper may have coatings on the sheet or on the fibers themselves. Examples of non-traditional products that are “paper” within the context of this disclosure include the material available under the trade designation TRINGA from PAPTIC (Espoo, Finland), and sheet forms of the material available under the trade designation SULAPAC.

Examples of thermoplastic materials that can be used include one or more of polyolefins (e.g., polyethylene (high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE)), metallocene polyethylene, and the like, and combinations thereof, polypropylene (e.g., atactic and syndiotactic polypropylene)), polyamides (e.g. nylon), polyurethane, polyacetal (such as Delrin), polyacrylates, and polyesters (such as polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), and aliphatic polyesters such as polylactic acid), fluoroplastics (such as THV from 3M company, St. Paul, MN), and combinations thereof. Examples of thermoset materials can include one or more of polyurethanes, silicones, epoxies, melamine, phenol-formaldehyde resin, and combinations thereof. Examples of biodegradable polymers can include one or more of polylactic acid (PLA) (which as used herein is intended to encompass both poly(lactic acid) and poly(lactide)), polyglycolic acid (PGA) (which as used herein is intended to encompass both poly(glycolic acid) and poly(glycolide)), poly(caprolactone), copolymers of lactide and glycolide, poly(ethylene succinate), polyhydroxybutyrate, copolymers of two or more of lactic acid, glycolic acid, and caprolactone, polyhydroxyalkanoate, polyester urethane, degradable aliphatic-aromatic copolymers, poly(hydroxybutyrate), copolymers of hydroxybutyrate and hydroxyvalerate, poly(ester amide), and combinations thereof.

The material in which the single slit pattern is formed can be of any desired thickness. In some embodiments, the material has a thickness between about 0.001 inch (0.025 mm) and about 5 inches (127 mm). In some embodiments, the material has a thickness between about 0.01 inch (0.25 mm) and about 2 inches (51 mm). In some embodiments, the material has a thickness between about 0.1 inch (2.5 mm) and about 1 inch (25.4 mm). In some embodiments, the thickness is greater than 0.001 inch, or 0.01 inch, or 0.05 inch, or 0.1 inch, or 0.5 inch, or 1 inch, or 1.5 inches, or 2 inches, or 2.5 inches, or 3 inches (76.2 mm). In some embodiments, the thickness is less than 5 inches or 4 inches, or 3 inches (76.2 mm), or 2 inches, or 1 inch, or 0.5 inch, or 0.25 inch (6.35 mm), or 0.1 inch.

In some embodiments, where the material is paper, the thickness is between about 0.003 inch (0.076 mm) and about 0.010 inch (0.25 mm). In some embodiments where the material is plastic, the thickness is between about 0.005 inch (0.13 mm) and about 0.125 inch (3.2 mm).

In some embodiments, the slit or cut pattern extends through one or more of the edges of the sheet, film, or material, such as the axial edges of the material. In some embodiments, this allows the material to be of unlimited length and also to be deployed by tension, particularly when made with non-extensible materials. The amount of edge material is the area of material surrounding and not including the single slit pattern. In some embodiments, the amount of edge material, or down-web border, can be defined as the width of the rectangle whose long axis is parallel to the tension axis and is infinitely long and can be drawn on the substrate without overlapping or touching any slits. In some embodiments, the amount of edge material is less than 0.010 inch (0.25 mm) or less than 0.001 inch (0.025 mm). In some embodiments, the width of the down-web border is less than 0.010 inch (0.25 mm) or less than 0.001 inch (0.025 mm). In some embodiments, the amount of edge material is less than 5 times the thickness of the substrate. In some embodiments, the width of the down-web border is less than 5 times the thickness of the substrate.

Cross-web slabs can be defined as rectangular regions with a rectangle whose long axis is perpendicular to the tension axis and is infinitely long and whose width is some finite number and can be drawn on the substrate without overlapping or touching any slits or cuts. In some embodiments, cross-web slabs of any width may already exist within the article as an integral part of the pattern. In some embodiments, cross-web slabs of any width may be added to the ends of a finite length article to make the article easier to deploy. In some embodiments, cross-web slabs of any width may be added intermittently to a continuously patterned article.

In some embodiments, the distance between the farthest spaced terminal ends of a single slit (also referred to as the slit length) is between about 0.25 inch (6.35 mm) long and about 3 inches (76.2 mm) long, or between about 0.5 inch and about 2 inches, or between about 1 inch and about 1.5 inches. In some embodiments, the farthest distance between terminal ends of a single slit (also referred to as slit length) is between 50 times the substrate thickness and 1000 times the substrate thickness, or between 100 and 500 times the substrate thickness. In some embodiments, the slit length is less than 1000 times the substrate thickness, or less than 900 times, or less than 800 times, or less than 700 times, or less than 600 times, or less than 500 times, or less than 400 times, or less than 300 times, or less than 200 times, or less than 100 times the substrate thickness. In some embodiments, the slit length is greater than 50 times the substrate thickness, or greater than 100 times, or greater than 200 times, or greater than 300 times, or greater than 400 times, or greater than 500 times, or greater than 600 times, or greater than 700 times, or greater than 800 times, or greater than 900 times the substrate thickness.

The slit patterns and articles described herein can be made in a number of different ways. For example, the slit patterns can be formed by extrusion, molding, laser cutting, water jetting, machining, stereolithography or other 3D printing techniques, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, other suitable negative or positive processing techniques, or combinations thereof. In particular, with reference toFIG.21, paper or another sheet material30can be fed into a nip consisting of a rotary die20and an anvil10. In this example the material30is stored in a roll configuration where the material is rolled around a central axis that may include or may omit a central core. The rotary die20has cutting surfaces22on it that correspond to the slit pattern desired to be cut into the sheet material30. The die20cuts through the material30in desired places and forms the slit pattern described herein. The same process can be used with a flat die and flat anvil.

The articles and materials described herein can be used in various ways. In one embodiment, the two dimensional sheet, material, or article has tension applied along the tension axis, which causes the slits to form the openings and/or folding walls and/or motions described herein. In some embodiments, the tension is applied by hand or with a machine.

The present disclosure describes articles that begin as a flat sheet but deploy into a three-dimensional construction upon the application of force/tension. In some embodiments, such constructions form energy absorbing structures. The patterns, articles, and constructions described herein have a large number of potential uses, at least some of which are described herein.

One exemplary use is to protect objects for shipping or storage. As stated above, existing shipping materials have a variety of drawbacks including, for example, they occupy too much space when stored before use (e.g., bubble wrap, packing peanuts) and thus increase the cost of shipping; they require special equipment to manufacture (e.g., inflatable air bags); they are not always effective (e.g., crumpled paper); and/or they are not widely recyclable (e.g., bubble wrap, packing peanuts, inflatable air bags). The tension-activated, expanding films, sheets, and articles described herein can be used to protect items during shipping without any of the above drawbacks. When made of sustainable materials, the articles described herein are effective and sustainable. Because the articles described herein are flat when manufactured, shipped, sold, and stored and only become three-dimensional when activated with tension/force by the user, these articles are more effective and efficient at making the best use of storage space and minimizing shipping/transit/packaging costs. Retailers and users can use relatively little space to house a product that will expand to 10 or 20 or 30 or 40 or more times its original size. Further, the articles described herein are simple and highly intuitive for use. The user merely pulls the product off the roll or takes flat sheets of product, applies tension across the article along the tension axis (which can be done by hand or with a machine), and then wraps the product around an item to be shipped. In many embodiments, no tape is needed because the interlocking features enable the product to interlock with another layer of itself.

In some embodiments, the slit patterns described herein create packaging materials and/or cushioning films that provide advantages over the existing offerings. For example, in some embodiments, the packaging materials and/or cushioning films of the present disclosure provide enhanced cushioning or product protection. In some embodiments, the packaging materials and/or cushioning films of the present disclosure provide similar or enhanced cushioning or product protection when compared to the existing offerings but are recyclable and/or more sustainable or environmentally friendly than existing offerings. In some embodiments, the packaging materials and/or cushioning films of the present disclosure provide similar or enhanced cushioning or product protection when compared to the existing offerings but can be expanded and wrapped around an item to be shipped. Constructions that hold their shape once tension is applied can be preferred because they may eliminate the need for tape to hold the material in place for many applications.

The following examples describe some exemplary constructions and methods of constructing various embodiments within the scope of the present application. The following examples are intended to be illustrative, but are not intended to limit the scope of the present application.

EXAMPLES

Compression Energy Test

The compression energy test was used to measure the energy absorbing ability of the samples prepared according to an Example or Comparative Example described below. For compression testing, a 36-inches (0.91 m) long and 7.5-inches (19 cm) wide sample comprising the desired slit patterns was obtained. One end of the sample was fixed on a flat surface such as a table top using an adhesive tape. Then, the sample was stretched to its full deployment elongation. The full deployment elongation of a sample is defined as the length that a sample can be stretched without tearing and with maximum out-of-plane rotation of any flap regions and/or folding wall regions relative to the plane of the material. Then, holding the non-taped end of the stretched sample to one of the long edges of a 6-inches (15.24 cm) wide and 8-inches (20.32 cm) long rectangular frame, the sample was wound around the frame along its long axis. The winding of the sample was done by “walking” the frame forward, end over end (i.e., rotating the frame 180-degrees around its long axis at a time) towards the fixed end of the sample. When the frame has been walked to the fixed end, the taped-down section of the material was carefully removed while maintaining the full deployment elongation of the test sample. The frame was disassembled and removed to form the test sample. The test samples when prepared as described here generally were shaped like “pillows”.

The compression energy testing was carried out using an MTS load frame [MTS Criterion Model C43 104E, from Mechanical Testing Systems Corporation, Eden Prairie, MN]. The test samples (“pillows”) were placed on a bottom platen large enough to hold the sample and the sample was compressed from the top using a 1.50-inch (3.81 cm) diameter foot. The compression speed was 1.0 mm/s and the maximum force was 1000 lbs [4450 N]. Force vs. displacement information along with the time stamp for each data point at a rate of 100 data points per second was recorded. Two samples for each Example/Comparative Example was tested. The average compression energy required (i.e., average total energy absorbed) to crush the samples for each Example/Comparative Example was calculated by integrating the force vs. displacement data for each sample and the average of the two samples were reported.

Comparative Example 1

Comparative Example 1 was shipping packaging material obtained from Amazon.com under trade designation “GEAMI WRAPPAK EX”. The brown paper portion, comprising the slit patterns, was used as the Comparative Example 1. “GEAMI WRAPPAK EX” is thought to be made by Ranpak Corporation, Painesville, Ohio. The slit pattern of Comparative Example 1 is that shown inFIG.1A.

Comparative Example 2

Comparative Example 2 was shipping packaging material obtained from HexcelPack LLC., [Botsford, CT] under trade designation “HEXCELWRAP”.

Comparative Examples 3-4 and Example 1

Comparative Examples 3-4 and Example 1 samples were prepared by laser cutting a slit pattern on a substrate. The substrate was a white paper obtained from Boise Paper, Lake Forest, IL. The paper is made from 100% virgin fibers with a basis weight of about 82 g/m2 when measured according to test method TAPPI T410 om-13, a thickness of about 0.0048 inch (0.12 mm) when measured according to test method TAPPI T411 om-10, a tear strength when measured according to test method T414 om-12 of about 50 g/ply in the machine direction and about 60 g/ply in the cross direction. The above referred test methods are provided by the Technical Association of the Pulp and Paper Industry (TAPPI), Atlanta, GA. The laser cutting method involved using a Model XLS 10.150D laser cutter (obtained from Universal Laser Systems, Inc., Scottsdale, AZ) cutting at 80-100% power with the z height set to 0. A default setting of “continuous cast acrylic” was used.

The slit pattern shown inFIG.11was used to form Comparative Example 3. The slit pattern of Comparative Example 3 was duplicative of that of Comparative Example 1. The slit pattern shown inFIG.12was used to form Comparative Example 4. The slit pattern of Comparative Example 4 is the slit pattern shown in FIG. 8D of U.S. Pat. No. 8,613,993 (to David M. Kuchar). The slit pattern shown inFIG.13was used to form Example 1.

Examples 2-6

Example 2-6 samples were prepared by laser cutting a slit pattern on a substrate. The substrate was a brown paper obtained from Uline, Pleasant Prairie, WI under trade designation “5-7051”. It is made from 100% recycled paper with a basis weight of about 125 g/m2when measured according to test method TAPPI T410 om-13, a thickness of about 0.0075″ (0.19 mm) when measured according to test method TAPPI T411 om-10, a tear strength when measured according to test method T414 om-12 of about 100 g/ply in the machine direction and about 135 g/ply in the cross direction. The laser cutting method involved using a Model XLS 10.150D laser cutter (obtained from Universal Laser Systems, Inc., Scottsdale, AZ) cutting at 80-100% power with the z height set to 0. A default setting of “continuous cast acrylic” was used.

The slit pattern shown inFIG.14was used to form Example 2. The slit pattern shown inFIG.15was used to form Example 3. The slit pattern shown inFIG.16was used to form Example 4. The slit pattern shown inFIG.17was used to form Example 5. The slit pattern shown inFIG.18was used to form Example 6.

Example 7

Example 7 sample was prepared by rotary die cutting a slit pattern on a substrate. The substrate was a brown paper described above in Examples 2-6. The rotary die cutting method involved using custom-made, flexible rotary dies made specifically for this slit pattern. The dies had a blade angle of 74.00 degrees and a cylinder undercut of 0.0240 inches (0.61 mm). The flexible die was mounted onto a magnetic cylinder, held in a frame, and pressed against a blank die with enough force to fully cut through the paper.

The slit pattern shown inFIG.19was used to form Example 7.

Comparative Examples 1-4 and Examples 1-7 samples were tested according to the Compression Energy Test provided above. Average Compression Energy for each of Comparative Examples 1-4 and Examples 1-7 are summarized in Table 1, below.

TABLE 1Compression Energy Test ResultsAverage CompressionEnergy (Joules)Comp. Ex. 11.86Comp. Ex. 21.39Comp. Ex. 31.66Comp. Ex. 41.49Example 13.13Example 24.76Example 34.05Example 42.28Example 54.79Example 62.49Example 73.65

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on the corresponding objects.

The above description is intended to be illustrative, and not restrictive. For example, the above-described embodiments (or one or more aspects thereof) may be used in combination with each other. The Abstract is provided to comply with 37 C.F.R. § 1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention can be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

The recitation of all numerical ranges by endpoint is meant to include all numbers subsumed within the range (i.e., the range 1 to 10 includes, for example, 1, 1.5, 3.33, and 10).

The terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.

Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other orientations than described or illustrated herein.

Those having skill in the art will appreciate that many changes may be made to the details of the above-described embodiments and implementations without departing from the underlying principles thereof. Further, various modifications and alterations of the present disclosure will become apparent to those skilled in the art without departing from the spirit and scope of the disclosure. The scope of the present application should, therefore, be determined only by the following claims and equivalents thereof.