EP3041756B1 - Verpackungsmaterial mit einer bei der schichtung und dehnung vernetzten dehnbaren geschlitzten folie, verfahren und vorrichtung zur dessen herstellung - Google Patents

Verpackungsmaterial mit einer bei der schichtung und dehnung vernetzten dehnbaren geschlitzten folie, verfahren und vorrichtung zur dessen herstellung Download PDF

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Publication number
EP3041756B1
EP3041756B1 EP14843068.9A EP14843068A EP3041756B1 EP 3041756 B1 EP3041756 B1 EP 3041756B1 EP 14843068 A EP14843068 A EP 14843068A EP 3041756 B1 EP3041756 B1 EP 3041756B1
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Prior art keywords
sheet
slit
paper
angle
expanded
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French (fr)
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EP3041756A4 (de
EP3041756A1 (de
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David Paul Goodrich
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Priority to EP20156524.9A priority Critical patent/EP3683166A1/de
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D65/02—Wrappers or flexible covers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0223—Making honeycomb cores, e.g. by piling a plurality of web sections or sheets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31D—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER, NOT PROVIDED FOR IN SUBCLASSES B31B OR B31C
    • B31D3/00—Making articles of cellular structure, e.g. insulating board
    • B31D3/02—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section
    • B31D3/0292—Making articles of cellular structure, e.g. insulating board honeycombed structures, i.e. the cells having an essentially hexagonal section involving auxiliary operations, e.g. expanding, moistening, glue-applying, joining, controlling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/03—Wrappers or envelopes with shock-absorbing properties, e.g. bubble films

Definitions

  • This invention relates to a paper packaging material that is slit, expanded and layered around an object or used as a void fill.
  • Pleated Paper of US patent 6,871,480 teaches using pleated paper laminated to one or more outer layers of tissue paper as a cushioning product.
  • the pleat height, paper fiber length, and number of pleats per foot, provide a cushioning product that crushes as force is applied.
  • This application teaches the use of pleated paper as a wrapping material.
  • Bubble Wrap® well Known in the art can be obtained with 2" to 1" (50,8 to 25,4 mm) tall bubbles for the use as a wrap and void fill. Il is capable of very good cushioning if made from a copolymer that is not recyclable or is very difficult to recycle. Homeowners are not able to recycle this type of plastic easily.
  • US Patent numbers 5.667.871 and 5.688.578 teach the use of a plurality of individual slits forming parallel spaced rows forming a hexagonal expanded sheet with and without a separator sheet. It requires machinery to stretch the paper into its three dimensional shape at the customer's location such as disclosed in US Patent 5,538,778 which teaches the method and apparatus for producing the expansion of the slit sheet material performed at the packing sites location. This material is effective when used in conjunction with the separator sheet but, the separator sheet does not add to the thickness of the material. Additional background information is disclosed in US Patent 5,782,735 relating to slit sheet packaging materials.
  • US4832228 discloses an expanded paper layer provided with a slit pattern.
  • a main object of the present invention is to overcome the shortcomings of the prior art.
  • a novel paper product is comprised of two or more slit sheet packing material layers, each layer having its own slit pattern design to create interlocking layers of expansion sheet packaging materials.
  • Each layer expands to crests a three dimensional open netting of cells of hexagons, and the like, and is designed to have limited nesting with its opposing layer, thereby maximizing the thickness of the combined layers as compared to nested layers.
  • adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer.
  • the differing slit patterns produce when expanded, inclined land area that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting. Nesting to an extent sufficient to provide interlocking, is in the range from about 10 to 20% and preferably about 9 to 15%.
  • adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer
  • the differing slit patterns produce when expanded, inclined land areas that have about the same number of rows per inch but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting and where the angle of inclination of the first layer is in the range from 50° to 85° and the angle of inclination of the second layer is in the range from 130' to 95°.
  • the angle of inclination of the first layer is in the range from 55° to 75° and optimally in the range from 55° to 65°.
  • the angle of inclination of the second layer is in the range from 125° to 105° and optimally in the range from 125° to 115°.
  • adjacent layers have substantially the same silt patterns that produce sheets which when expanded the first layer has lands that are at an angle in the range from 50° to 85° and the angle of inclination of the second layer is in the range from 130° to 95°.
  • the angle of inclination of the first layer is in the range from 55° to 75° and optimally in the range from 55° to 85°.
  • the angle of inclination of the second layer is in the range from 125° to 105° and optimally in the range from 125° to 115°.
  • the angle of inclination of the second layer is a mirror image of the angle of inclination of the first layer, thus if the first layer has an angle of inclination of 60°, the second layer has an angle of inclination of 120°. In this embodiment, the sum of the angles of inclination of the first and second sheet is 180°.
  • the slits are cut to form a straight line cut at one edge of the silt and an angled cut along the other edge of the slit, thus producing a wedge effect cut
  • the wedge effect is sufficient to produce a slit pattern that upon expansion consistently forms a uniform angle of inclination along the entire length of the slit paper.
  • sheets of paper or plastic are slit in a pattern, that upon expansion, form an expanded slit sheet as described in US Patent 5,538,778 (see for example. Figures 1 and 2 ). and US Patent 5,82,735 (see for example. Figures 19 and 20 ).
  • the slit sheets are formed into rolls. A first roll is unrolled clockwise and expanded and a second roll is unrolled counterclockwise and expanded.
  • the two rolls are expanded simultaneously in an expander device which produces two adjacent layers of interlocking expanded sheets having cells, wherein the cells have land areas that are inclined relative to unexpanded sheets, and wherein the angle of inclination of one of the adjacent expanded sheets is the mirror image of the angle of inclination of the other expanded sheet.
  • the expanded, interlocking sheets are wrapped around an object, to form at least four layers of expanded sheet material, that is, two windings of the double layers of expanded sheet material.
  • one or more layers of slit sheet material can be made from a paper comprising a soft paper such as paper towel type material so that it is soft on the hands while manually manipulating the packaging material around items being packaged.
  • a soft paper such as paper towel type material
  • one layer is of Kraft paper
  • the adjacent layer is of a paper towel material.
  • expanded slit sheets are layered such that adjacent sheets uniformly, reliably and consistently have lands with angles of inclination that are substantially reversed from each other and interlock over substantially the entire length of the sheets and preferably, over the entire length of the sheets, thereby producing an improved packing material as compared to prior art products.
  • the angles of inclination one of the adjacent sheets is the mirror image of the angles of inclination of the lands of the of the adjacent sheets.
  • slit sheet material refers to the use of offset rows of silts that form a hexagonal, or the like three dimensional paper material that is flexible and can form to the shape of an item needing wrapping.
  • cell means the hollow three dimensional shape that is created when the slit sheet material is expanded longitudinally.
  • the term "lead wall” means the part of the cell that is the full height of the hexagonal shape created from the expansion of the slit sheet material.
  • angle of inclination means the angle that the land areas of cells form with respect to the plane of the unexpanded slit sheets, wherein the cells have land areas that are inclined relative to unexpanded sheets, and wherein the angle of inclination of one of the adjacent expanded sheets is the mirror image of the angle of inclination of the other expanded sheet.
  • connecting wall means the part of the cell that is half the height of the cell created from the expansion of the slit sheet material.
  • cell size means the open space dimension created when expanding the slit sheet material.
  • slit row spacing means the distance between the rows of slit and un-slit patterns within the slit sheet material
  • Kraft paper means the industry name of paper that is measured in weight for every three thousand square feet of material Thus the weight of 50# Kraft Paper would be the weight of 3000 square feet of paper.
  • the term "basis weight” means the specification relating to paper that measures the weight of a certain square foot area of paper.
  • basis weight of 3000 square feet (279 m2) of Kraft Paper weighing 50 pounds (22,7 kg) equals a 50# basis weight.
  • the basis weight of Tissue paper is based on 2,880 square feet (267 m2).
  • recycled paper means material that is substantially made from recycled paper in the 90% range or more and is paper that has been returned to the manufacturing process, having once or more been made into a paper product, and remade into a paper sheet.
  • paper fibers are the individual component of paper that makes up a paper sheet.
  • the term "Nesting” means the grouping of cells onto or into one other such that an upper slit sheet material cell can fit within the lower slit sheet material cell to the point at which the thickness gain is not substantial.
  • the term "interlocking" means the grouping of cells onto or into one another is such that an upper slit sheet material cell can nest within the lower slit sheet material cell only to the point at which the average thickness gain of two layers is no less than 70% of the thickness of both layers of a two layer pair and preferably, no less than 80% of the thickness of both layers of a two layer pair. For example, if each layer is 0.5 inches (1,27 cm) thick, then the average thickness would be no less than 0.7 inches (1,8 cm) and preferably no less than 0.8 inches (2,0 cm).
  • adjacent means that two layers are immediately adjoining, that is, one layer overlays the other without intervening space and are touching. Layers that nest or interlock to any degree and having no intervening layers, are accordingly, in contact with each other and therefore adjacent.
  • pattern of cells of expanded sheets means the cell shape configurations such as hexagonal or oval, and cell dimensions such as leg length or width.
  • pattern means physical characteristics and dimensions and is not inclusive of decorative or ornamental features of the design of a pattern.
  • the term "average thickness” is employed to indicate that since some nesting may be present in layers of sheet that are within the definition of "interlocking" as employed here, the thickness of two adjacent layers can vary. Average thickness is measured as the sum of the thicknesses measured at a plurality of linear intervals, divided by the number of intervals in the plurality of linear intervals. Thus, if thickness measurements are taken every inch over a length of two feet, then the sum of the measurements divided by 24 equals the average thickness.
  • interlocking adjacent layers means that layers are nested to an extent that the contact between adjacent layers is sufficient to resist contraction of expanded sheets.
  • the degree of nesting depends upon the rigidity of the paper of each of the two layers, and preferably provides at least a 10% overiap (nesting) of the layers such that the thicknese of the two layers is no more than 90% of the sum of the sum of the thickness of each layer.
  • paper width after expansion means the width of the sheet of paper after expansion of the slit paper sheet
  • necking down The decrease of the width of the sheet of paper after expansion is referred to as "necking down”.
  • the "percent of necking down” is the percent decrease in paper width after expansion.
  • a 25 inch (63,5 cm) width sheet which necks down to 20 inches (50,8 cm) would be necked down 20%.
  • paper width differential means the difference in width of two adjacent layers of slip paper sheets. Since different slit patterns will yield different amounts of necking down, the paper width differential prior to the expansion step must be sufficient to yield little or no paper width differential after the expansion step. It should be understood that the sheets of expanded paper can be trimmed down to negate any paper width differential post expansion. However, this would constitute a waste of paper and require an additional step or steps, and accordinsly, it is preferable to negate any paper width differential by determining a pre-expansion paper width differential that achieves, in combination with the slit patterns of each of two adjacent sheets, a substantially identical paper widths post expansion.
  • the term "Operator” means the person that operates the machinery that automatically expands the slit sheet material that dispenses the product towards the operator.
  • switch back means the reversal of the angle of inclination of the land at some point or points along the length of a sheet of expanded slit sheet material.
  • the term "wedge effect” means the cutting of a slit to form a slit having a straight line cut along one edge and an angled cut along the other edge of the slit.
  • soft paper means the particular grade of paper used for absorbing purposes, such as tissues, drying cloths, paper toweling, napkins and handkerchiefs. While these paper products, unlike their woven fabric counterparts, are typically intended for disposable use, in the present invention soft paper is employed for its soft feel, smooth structure, and good strength in both dry and wet states.
  • Each slit pattern will require varying paper strength and thickness to perfect its crush strength and ease of stretching within the automated expander.
  • the slit pattern dimensions set forth below are one example of the composite products from the two or more varying slit sheet materials. There are a number of slit sheet variations that will work to inhibit nesting and the specific dimensions and shapes created below should not limit the patterns that can be used to make the new art.
  • the critical feature is that the slit patterns of adjacent layers differ in slit length, spacing between slits in a row, and/or the spacing between rows of slits.
  • the paper used to manufacture the slit sheet material is preferred to be recycled and is in the range of 30-80 pounds (13,6 to 36,3 kg) in basis weight dependent upon the cell size of the slit sheet expanded material.
  • Virgin paper has longer fibers and will produce a firmer product with equivalent basis weight as recycled paper.
  • a 30 (13,6 kg) recycled paper can be used for one sheet of the pair of sheets and the other can be a higher weight recycled paper or virgin paper.
  • Kraft paper is manufactured according to the Tappi T-410 (standard of 3,000 Square feet (279 m2) of material per basis weight.
  • a Kraft paper with a basis weight of 40 means that 3,000 square feet (279 m2) will weigh 40 pounds (18,1 kg).
  • the paper is about 004 inches (0,1 mm) thick but this can vary based on crushing methods to produce different surfaces.
  • the slit pattern that is approximately three-to-one in size between the length of the slit portion and the un-slit portion of the slit sheet material.
  • a 1/2" (12,7 mm) slit portion followed by a 3/16" (4,8 mm) un-slit portion is a preferred pattern in the first row.
  • Each row is 1/8" (3,2 mm) apart and bisects or is transverse to the direction of manufacturing the slit sheet material
  • Each slit pattern row below is offset to the above pattern such that the slit portion bisects the unslit pattern of the upper row and so forth.
  • This alternating pattern enables the paper to be expanded in to the web of hexagonal, diamond, square, or round shaped three dimensional cells that are created dependent upon the specific slit pattern.
  • a hexagonal pattern is created with the approximate three-to-one slit to unslit lengths. It has been established that the hexagonal shape is the strongest of all the cell shapes and therefore is the preferred embodiment to the new art. There are exceptions when a softer cushioning material is required where one of the slit sheet materials is a hexagonal layer with the adjoining layer slit sheet designed to be a square. In this instance the preferred embodiment is for both layers to substantially create hexagonal cells
  • the second layer of slit sheet material will be of the same three dimensional thickness.
  • the thickness can be created from the spacing of the rows. In this instance the spacing is 1/8" (3,2 mm) thus creating 1/4" (6,4 mm) long cells. Because these cells can only rotate short of 90 degrees toward a vertical orientation, the total height is approximately 3/16" (4,8 mm) overall.
  • the lead wall of the cell is the portion of the cell that makes up the full depth of the slit sheet when expanded. There are two lead walls created no matter what shape the cells create or slit pattern used. These two lead walls face the direction of manufacture and the surface area is made up of the un-slit area within the row and the space between the rows times 2. The depth of the lead wall can also be described as the unslit space between every other set of rows or between the first and third rows.
  • the overall height of the expanded slit sheet material can also be described as a series of rows such that the first row of slits at position "O" is followed by its offset un-slit portion of the row underneath at position 1/8" (3,2 mm) below and not until the third row appears and the offset again places a slit at position 1/4" (6,4 mm), thereby creating a total height of 1/4" (6,4 mm) for the lead walls of the hexagonal cell.
  • the first slit sheet pattern creates a 1/4" (6,4 mm) tall lead wall with each hexagonal side approximately being 3/ 16" (4,8 mm) long.
  • the second slit sheet pattern is also 1/" tall by using the 1/8" (3,2 mm) row spacing.
  • the legs of the cell are approximately 10 to 30% less or more to create an interlocking composite product. In this case the preferred size would be .4" (10,2 mm) slit x .15" (3,81 mm) unslit creating a cell that will be 20% smaller than the first slit sheet pattern.
  • the second expanded slit sheet pattern creates a cell that easily could fit inside the first expanded slit sheet material but is inhibited by the increase in quantity of the smaller cell size causing 1.2 ceils trying to fit within one cell of the first expanded sheet which, is impossible.
  • the first expanded sheet layer expands from 1" (25,4 mm) to approximately 2 1/8" (53 mm) inches depending upon paper strength and thickness
  • the 60 pound (27,2 kg) basis weight paper expands to the 2 1/8" (53 mm) inches for the 1/2" (12,7 mm) x 3/16" (4,8 mm) first slit sheet layer. This is an approximately 213% Increase in the length of the slit sheet material and the expander will need create this exact expansion properly for the first layer.
  • the second layer will be twenty percent smaller in size and therefore will expand 193% in length. Therefore the second expansion rollers within the expander machinery will have a reduced expansion ratio to accommodate this smaller amount of expansion. This reduced expansion ratio would therefore automatically reduce the smaller secondary web layer speed exiting from the expander. To maintain the same exiting speed for both layers the back rollers that set the overall exit speed will have to be adjusted to 20% faster for the second layer.
  • the paper width does not have to be exact such that if one web is slightly wider by no more than 5 to 10% then the efficiency of wrapping is maintained. This would make the loading of the expander easier as the upper web could be the lower web and visa-versa and the only difference would be the cell size on the upper web may change from smaller to larger or visa-versa.
  • two interlocked layers of expanded sheet material in accordance with the present invention measured at 3/16" + 3/16" to produce a thickness of 5/16" or .3125" (7,9 mm).
  • the loss of thickness of the two interlocked layers of expanded slit paper represents the amount of interlocking of the two adjacent, overlaid sheets of expanded slit paper of the present invention.
  • the expanded slit sheets with a tissue separator tends to flatten due to the calls having limited rigidity under a load and has a tendency to retract.
  • the interlocking design of the present invention as compared to the tissue separated design of the prior art. is more resistant to deformation under load, more resilient, and resets retraction, It has been found that in use. the design of the present invention produces a wrap that is thicker than the tissue separated design of the prior art. presumably because of its ability to retain its thickness. in contrast to the tissue separator configuration.
  • the tissue separated design of the prior ari has been found to generally retain less than 75% of its expanded length, whereas the crisscross pattern of the present invention tends to retain greater than 75% of its fully expanded length.
  • example 12 layers have a thickness of about 2" (50,8 mm) representing a loss of thickness of about 11%.
  • the nesting is limited to 10 to 20% and most preferably it is limited to 9 to 15%.
  • the concept of the expander is to continuously feed the slit sheet layers to the operator and simultaneously expand those layers for ease of use. Otherwise the operator would have to manually pull the layers on a repeating basis as more flat layers of slit sheet material are delivered. To facilitate this two rolls approximately 10" (254 mm) apart from the front to the back of the machine operate at different speeds.
  • a separate set of rubber coated feed rollers drive the first slit sheet material into the expander.
  • the second set of expander rollers at the front of the machine are Velcro coaled. grab the slits, and drive the slit sheet to its expanded configuration by operating 213% faster than the back rollers.
  • the second slit sheet material will feed into an additional set of feed rollers and expander rollers that will set the ratio of 193%.
  • the back rollers as well as the front rollers will operate 20% faster than the first set of rollers for the first slit sheet material.
  • the design of the drive system shown in FIG 6, 7, and 9 are with the use of a timing belt and corresponding gear pulley design. This does not preclude the design of typical fiat or no-teeth belt designs which provide can slip when under load.
  • the slit sheet material can be made from a variety of papers including Kraft Papers, recycled and virgin papers and the like. These papers when expanded form sharp edges that are sharp to the operator's hands and cause cuts to the skin. In most instances the operators where gloves when using slit sheet expanded paper materials.
  • the new art as described below reduces or eliminates the sharp edges to the paper by utilizing a different type of paper yet used in the manufacture of slit sheet paper.
  • Soft Paper is described in prior art US Patent 5.061.344 for a "Method of making Soft Paper".
  • 344 describes Soft paper from cellulose fibers as being manufactured by wet-forming a first fiber layer. Thereafter air-bome dry fibers are deposited directly on one or both sides of the wet-formed layer while this is still wet. so that a second and possibly a third fiber layer are formed on the first one. Fiber bindings thereby anse between the layers, The wet-formed fiber layer gives the soft paper its strength. while the dry-formed fibers give a soft surface.
  • US 5,061,344 further describes as another method of forming soft paper, dry-forming.
  • dry paper-making pulp is fluffed to form fibers which are suspended in air.
  • the air-borne fibers without addition of water or other solvent, are deposited on an air pervious wire, and these fibers are bound together by means of a suitable chemical binding agent or agents which are added thereto. Further manufacturing details are described in the "DETAILED DESCRIPTION" of the '344 patent. Additional information regarding soft paper is disclosed, for example, in publication US 20140130997 .
  • the use of this paper is within the range of 40 to 90# basis weight with the paper fibers running to the machine direction for good expansion strength.
  • the soft paper thickness is thicker than typical Kraft paper thicknesses, as well known in the art, with soft paper thicknesses varying from .006" (0,152 mm) to .012" (0,305 mm).
  • preferred basis weight for the soft paper is about 70. with a thickness of about .010" (0,254 mm)
  • Fig 1 is the top view of one layer of the slit paper prior to expansion with 100 being the width of the slit and 101 being width of the unslit dimension. 102 is the distance between the rows.
  • FIG 8 is the top view of one layer of the slit sheet expanded to its three demensional form with 800 being the open cell area created by the expansion. 801 being the lead wall or land created, and 802 being the connecting leg. It is noted that the terms lead wall and land are used interchangeably to indicate the region 801 .
  • Fig 2 is the side view of slit sheet expanded material. in accordance with the prior art. showing the nesting of two identical layers 201 and 202, with reference number 203 showing the virtually complete contact between the two layers
  • FIG 3 is the side view of the use of a separator sheet in accordance with the prior art. that negates nesting in accordance with the prior art use of a separator sheet 302 between two expanded sheet 301,
  • the reference number 303 indicates the open space between the separator sheet 302 and an expanded sheet 301.
  • FIG 4 is a side view of two expanded layers 401 and 402 of the prior art, having regions 403 where side walls of adjacent layer contact each other but nesting is minimized due to the use of differing slit patterns for layers 401 and 402.
  • Reference numeral 404 Illustrates the open space between adjacent layers of expanded sheets which has been substantially maximized due to the differing slit patterns for layers 401 and 402. It should be understood, that in use. the dimension difference between the cells of sheets 401 and 402 should be greater than illustrate in order to negate nesting to a greater extent than illustrated in FIG 4 .
  • FIG 5 is a side schematic illustration of an expanding operation in accordance with the present invention.
  • the reference numerals 500 and 502 indicate unexpanded slit sheets driven by pinch rubber rollers 503 into the expander rolls section 504 within the internal workings of the automatic expander.
  • Reference numerals 508 and 509 indicate slit sheets 500 and 502 respectively, in their expanded form.
  • the slit paper is feed counterclockwise from a first roll 1402 and clockwise from a second roll 1400 to provide for reversed angles of the lands in accordance with the present invention.
  • Expansion rollers 504 employ a hook and loop material 601. such as Velcro®, which covers the front roller section which pulls the slit paper faster than 503 feeds providing the expansion and exiting of the expanded slit paper. It should be noted that the "hook" layer of the hook and loop material is used rather than the loop portion of the hook and loop material.
  • the driving process is precisely driven with motor 608 that turns drive shaft 607 that has attached two identically drive gear pulleys 604 and 605 that engage the teeth of the drive belt 609.
  • Timing belt 609 turns gear pulley 603 that is precisely sized to create the 213% ratio to drive pulley 606 attached to timing belt 609.
  • FIG 7 is a schematic side view of the timing belt 609 and its corresponding teeth 701 that interact with the gear pulleys
  • FIG.7 shows belt 609 used to rotate the expander rolls 504 and the feed drive rolls 503.
  • Timing belt 609 turns 504 faster than 503 due to diameter difference for the guides for the two rollers
  • FiG.9 is the side perspective view of gear pulley 900 that corresponds in varying sizes to gear pulleys 603. 604. 605. and 606 in FIG.6 .
  • the teeth 901 create the open areas 902 that create the space for the timing belt in 609 FIG ? to mesh continuously creating a perfectly timed ratio as the expander system is turned.
  • Gear teeth 701 of FIG.7 fit within the open spaces between teeth 901 and create the precise drive speeds required
  • one layer can be the soft paper, and the other Kraft If the slit pattern of the soft and Kraft are the same the cells would nevertheless tend to be different because of the characteristic differences between soft paper and Kraft.
  • the use of cell designs that produce mirror image lend regions are preferred.
  • mirror image refers to a cell design which produces a desired angle of inclination and by feeding counterclockwise from a first roll 1400 and clockwise from a second roll 1402, to produce reversed angles of inclinations of the two expanded sheets form the expander.
  • the angle of inclination of a first sheet is 60°
  • the reverse fed second sheet will have an angle of inclination of 120 degrees: and is identical in fonts to the first sheet, but with the structure reversed, as by a mirror.
  • the knife is made to have a sharp edge and bevels outward from the edge so that it is sturdy This bevel creates a wedge effect on the paper Viewing the paper from the side on which the knife first penetrates the paper, "the slit entrance side", one can see a wider cut versus the underside which has a much finer looking cut The wedge effect creates this difference and this difference orients the cells to angle reversely from the direction of manufacturing. If one were to look at the expanded slit sheet at the exit of the cutting die (after cutting is achieved) the cell orientation would inhibit one from look through the expanded slit sheet as it is angled back towards the machine,
  • the cross interlocking effect can created continuously.
  • a single slitting device is used to slit a plurality of rolls of expandable paper. Two or more layers of slit sheets are fed to an expander, with the rolls being simultaneously fed alternately clockwise and counterclockwise.
  • mirror image refers to a cell design which produces a desired angle of inclination and by feeding counterclockwise from a first roll 1400 and clockwise from a second roll 1402. reversed angles of indications of the two expanded sheets are produced by the expander. Thus, if the angle of inclination of a first sheet is 60°, then the reverse fed second sheet will have an angle of inclination of 120 degrees, and is identical in form to the first sheet, but with the structure reversed, as in a mirror.
  • the slit pattern can be the same for both Kraft layers but the speed of the rolls. and consequently the extent to which the layer expand, would be different, and thus would lessen the amount of nesting. It should be noted that the tendency of the two layers to "relax" can cause the cell structures to be the same even though the expansion was different. Thus, the use of different slit patterns is preferred in order to optimize the ability to negate nesting.
  • Pre-expanded material formed in accordance with the system of US Patents 5,538.778 and 5,782,753 is not as stretched as much as it should be. There is a limitation to the stretching, due to the tissue and slit paper being on the same roll and therefore cannot be independently tensioned. Therefore the tissue gets taut and the slit sheet paper does not.
  • the new art eliminates the use of the tissue paper separator sheet in both the expander process or the pre-expanded process, a better expansion can be obtained due to the absence of interference from the tissue separator sheet.
  • the cell opening effect orients the lead wall to be either angled forward in the machine direction or angled backward from the machine direction. Angled forward orients the cells such that if one were to look downward at the cells in front of the expanding web, as the operator would, one would be able to see through the slit sheet material. If the angle is backward then the operator would see the rows of lead walls such that it is not possible to see through the expanded sheet material.
  • FIG.9 of US Patent 5,699.578 which illustrates the angled orientation of the cells of the expanded slit paper and the nesting that occurs when one sheet is laid over another layer of expanded slit paper having substantially the same angled orientation.
  • Lighter weight paper can be used to maintain the same resiliency as non-crisscross product as well as reducing costs in paper and tooling.
  • the degree of nesting is directly related to the angle of inclination of the lands schematically represented in Figs 10-12 .
  • the lead walls/lands 1001 are oriented backward to the manufacturing direction 1006 which is also the direction the expanded sheets exit the expander. This causes the eye of an operator 1005 facing the web to be inhibited from seeing through the expanded sheet but see the surface areas of the lead walls 1001.
  • the lead walls 1003 are oriented forward in the manufacturing direction 1006 which is also the direction the expanded sheets exit the expander. This causes the eye of an operator 1005 facing the web to be able to see through the expanded sheet layer.
  • FIG 12 combines the forward and backward layers of FIG 10 and FIG 11 to create a crisscross pattern with the lead walls in the backward direction interacting and bisecting lead walls 1003 leaving open spaces 1002 and 1004.
  • a first layer having lead walls 1001 are oriented backward to the manufacturing direction 1006 that is the direction in which the paper travels during the slitting operation.
  • the lead wells 1001 are oriented backward thus forming an angle of less than 90° to the plane of the paper while the forward oriented lead walls form an angle of greater than 90° to the plane of the paper.
  • the arc represented by reference number 1206 thus must be much greater than 0° and much less than 180°, and can range from 135 to 15 degrees, and preferable from 90 to 30 degrees, and most preferably is in the range from 60 to 30 degrees. It should be understand that the arc can vary slightly across regions of the paper but the angle of an inclined land must not reverse or "switch back" to the reversed angle of inclination. It should also be understood that the closer the angle of the lead walls/lands to the vertical, the thicker the composite structure.
  • the are represented by reference numeral 1010 can range from 50° to 85° and the angle of inclination 1012 of the second layer is in the range from 130° to 95°.
  • the angles of the lands 1001 and 1003 are relative to the plane 1008 of the unexpended sheet material.
  • the angle of inclination of the first layer is in the range from 55° to 75° and optimally in the range from 55° to 65°.
  • the angle of inclination of the second layer is in the range from 125° to 105° and optimally in the range from 125° to 115°.
  • angles of inclination of the two adjacent expanded sheets can be different, provided that they are in ranges previously noted, and provided the silt patterns though different, produce at least about the same or the same number of lands per inch such that the adjacent lands interlock as shown in Fig 12 .
  • angles of inclination 1010 and 1012 can be different, provided the cell dimensions produce consistent interlocking as illustrated in Fig 12 .
  • the space 102, as illustrated in Fig 1 can be varied to produce varying angles of inclination.
  • adjacent layers have substantially the same slit patterns that produce sheets which when expanded the first layer has lands that are at an angle in the range from 50° to 85° and the angle of inclination of the second layer is in the range from 130° to 95°.
  • the angle of inclination of the first layer is in the range from 55° to 75° and optimally in the range from 55° to 65°.
  • the angle of inclination of the second layer is in the range from 125" to 105° and optimal in the range from 125° to 115°.
  • the angle of inclination of the second layer is a mirror image of the angle of inclination of the first layer thus, if the first layer has an angle of inclination of 60°, the second layer has an angle of inclination of 120°. In this embodiment, the sum of the angles of inclination of the first and second sheet is 180°.
  • FIG. 13 shows that the reverse orientation of the adjacent layers of expanded sheet material serves to reduce nesting. It has been found that the low level of nesting which is exhibited by the mirror image adjacent layers serves to reinforce the composite structure due to an interlocking effect Nevertheless the result is a thicker composite structure than is obtained from a composite structure in which is not cross-expanded
  • cross-expanded* as applied to a composite expanded sill sheet material means a structure in which there is a combination of a backward orientation of the lead walls of a first expanded slit sheet or web and a forward orientation of the lead walls of an adjacent web, as shown in FIG. 13 .
  • the cell dimensions are selected to provide the minimum amount of overlap of layers, that is, minimum nesting, in order to get the maximum product height. However, there must be overlap of layers to get sufficient interlocking. The amount of overlap depends on the angle of the lands that are interlocking. The interlocking of the reversed angle layers serves to inhibit retraction of expanded sheets and provides optimum product resiliency.
  • the interlocking system of the present invention can provide at least 75% retention of expanded length as compared to less than 75% retention of expanded length using the system of US Patent 5,686,578 .
  • the controlled/limited interlocking of layers changes the properties of the wrap compared to the interleaf design because it resists flattening of the layer when under a load.
  • the two peripheral nest regions merely nest without resisting flattening of the layers under load.
  • the present invention produces a product having greater resiliency and load bearing capacity as compared to an interleaf design.
  • the feed roller 1400 is seen to rotate counter to feed roller 1402 thus orienting the rolls of unexpended slit sheet material onto the rollers of the expander such that the exit surface of a first slit paper sheet faces the exit surface of the other sheet or the slit entrance surface of a first slit paper sheet face the slit entrance surface of the other sheet, upon expansion, creates a crisscross pattern of expanded sheets.
  • the expansion process with the Expander of FIG 14 is illustrated in FIG 5 .
  • the lands 2020 and 2032 of Figure 20 of 735 want to nest because there is a perfectly sized cell of the upper sheet wanting to perfectly fit into the lower cell especially when under tension.
  • the tension shapes the hexagon and angles it perfectly with respect to the angles of the adjacent layer as illustrated in Figure 2 of 735
  • the product of the present invention employs opposing angles for adjacent layers of expanded sheets and thereby uses the tension to maximize height. As an operator stretches the lower leg of the upper expanded sheet finds its rest towards the top of the lower sheet. With a loss of tension the leg will skip downward but can never fuily nest.
  • the slit sheets of 735 nest completely, or near completely, as diagrammatically illustrated in Figure 9 of the 735 patent and thus there is a need for interleaf of US 5,688,578 , as illustrated in Figure 8 of 578.
  • angles of inclination one of the adjacent sheets is the mirror image of the angles of inclination of the lands of the other of the adjacent sheets.
  • the blade used to slit the paper is beveled to produce a sharp edge and the sharpness must be maintained to prevent the switching effect from causing a reversal of the angle of inclination of the land region of the cells.
  • the slitting operation can employ blades that press almost through the paper to a hard anvil or blades that cut through the paper to a soft round anvil
  • the tool and anvil rotate at the same speed as the paper sheet thus cutting with high precision making the slit sheet material.
  • the sharp edge is made with a beveled edge which means that it becomes increasingly narrower until it is a fine sharp edge from the cylinder to the sharp edge. This creates a wedge effect on the paper that it is cutting Even through the paper is only .004 to .012" the wedge effect is enough to produce a cell opening effect.
  • the surface of the sheet material that the blade edge initially contacts, that is the blade entrance surface is called the slit entrance or obverse side of the paper.
  • the surface that the blade exits is called the exit or reverse surface of the sheet material.
  • the wedge effect increases with increasing thickness of the paper being slit.
  • the wedge effect increases with increasing included angles of the slitting blades.
  • the wedge effect is optimized when the wedge effect is limited to one edge or side of a slit. That is the net wedge effect is based on the difference between the wedge effect on the two edges of a slit, and optimally, one edge is free of the wedge effect.
  • the use of a blade that has one cutting side that forms a 90° angle with respect to the plane of the paper being slit is preferred to obtain a stil in which one edge of the slit is free of the wedge effect.
  • increasing the included angle between the two cutting edge surfaces of a blade increases the wedge effect.
  • FIG. 19A is a fragmentary top view of the slit sheet of Figure 19 : showing the wedge surface 1900 and the straight cut edge of the slit 1902.
  • Blade 5 has the narrowest bevel angle and would not produce a product that is free of "switch back" of angles of inclination of the lands of a sheet of expanded slit paper.
  • the blade design 1600 of Fig. 16 has the same angles A and D for both bevels, and would not produce a product that is free of "switch back" of angles of inclination of the lands of a sheet of expanded slit paper.
  • the blade design 1602 has a roughly 45° bevel angle (B) and applies a wedging action against one side of the slit and a straight cut against the other edge of a slit due to the 90° angle (E).
  • the wedging action of the bevel having an angle (B) forces the surface of the paper downward along the surface of the paper at the edge of the slit while the non-beveled side of the blade have an angle (E) of about 90° applies no wedging action.
  • the blade design 1604 has a wider bevel angle (C) than the blade 1600, but similar to blade 1602, applies a wedging action against one side of the slit and a straight cut against the other edge of a slit
  • Life of slitting tool blades is based on the number of revolutions of a tool produces switch backs that are less than 20% of length of a sheet of slit paper on a roll or in flat section. At the end of the life of the slitting tool, the blades are sharpened or replaced. When the combined lengths of switch back regions exceed about 20% of the length of the roll, the blades must be replaced or re-sharpened. Optionally, the replacement or re-sharpening of the blades can be set for the combined lengths of switch back regions exceed about 10% of the length of the roll. Interlocking occurs in regions where two adjacent expanded sheets are free of switch back or where both sheets have undergone switch back in the same region.
  • At least 80% of two adjacent sheets is interlocked and most preferably, at least 90% of two adjacent sheets is interlocked.
  • no more than 20% of adjacent sheets nest due to switch back and most preferably, no more than 10% of adjacent sheets nest due to switch back.
  • the minimum desired interlocking occurs when up to 20% of adjacent sheets have undergone switch back. In regions where both sheets have undergone switch back, interlocking will occur and thus such regions are excluded from the calculation of the amount of switch back that has occurred.
  • the blades 1700, 1702, and 1704 are offset as compared to the blades of FIG. 16 .
  • the design of blade 1700 has a bevel angle (F) that can produced a wedging effect. but bevel angle (I) also can produce a slight wedging effect thus negating the beneficial effect of the bevel angle (F)
  • the blade design of blade 1702 produces a substantial wedging action due to the bevel angle (G) and no counteracting wedging from the straight side of the blade represented by angle (J)
  • the blade design of blade 1704 produces a substantial wedging action due to the bevel angle (H) and no contracting wedging from the straight side of the blade which forms and angle greater than goo with the paper that is being slit.
  • Blade 1800 of Fig. 18 is an illustration of a blade have an excessive bevel angle (K) in combination with a substantially 90° angle (L).
  • blade 1802 has different bevels for the V shaped cutting edge of blade 1802 such that a wedging effect is produce by one side of the V shaped cutting edge and no wedging effect is produced by the other side of the V shaped cutting edge because of the bevel angle of about 90° produces no wedging effect.
  • one side of the cutting edge of the blade is at an angle of substantially less than 90° with respect to the plane of the paper and the other side of the cutting edge of the blade is at an angle of at least 90° with respect to the plane of the paper, and preferably at an angle of 90°.
  • the wedging action of the slit forming blade forces one edge of a slit to be below the plane of the slit sheet, at least at the opposing ends of the slit, thus blasing the cells toward a consistent opening angle during the expansion step
  • the preferred range for the bevel angle is in the range from 1° to 3°, when measuring the angle between the two sides of the cutting region of a blade. With respect to the angles (B) and (C), the range is between 97 and 89 degrees for the beveled surface and 90 degrees for the unbeveled surface.
  • recycled paper Because virgin paper is thinner than recycled paper, recycled paper responds more substantially to the wedging action of the slit cutting blades as described above, thus optimizing the ability of the recycled paper to form a uniform, consistent angle of inclination of the lands along the entire length of an expanded slit sheet.
  • Virgin paper can be thinner than recycled paper and provide equivalent strength based on the longer cellulose fibers.
  • the thinner paper will be less effected than a recycled thicker paper equivalent and thus would need a shallower bevel angled knife.
  • the angles (B) and (C) would have to be shallower for Virgin paper than for recycled paper.
  • the included angle of the bevel should be greater for Virgin paper than for recycled paper.
  • the included angle of the beveled blade can be up to 6° for Virgin paper.
  • Non-switch back (NSB) tool resharpening versus Tissue-Layered (TL) System Tooling is $1500.00 to resharpen Non-Switch Back(NSB) Slit sheet with tissue separator Tooling can be resharpened 6 times.
  • the expander of the present invention simultaneously feeds two layers of expanded paper as compared to a separator sheet design feeding one layer of expanded sheet material and one separator sheet layer.
  • the product of the present invention requires less material to wrap an object because of the resistance to retraction and flattening of the cells, and the improved performance under compression.
  • the process of the present invention is less complex and easier to use because it eliminates the need to use a separator sheet.
  • the elimination of the separator sheet reduces the cost of the product, generally by about 30%
  • the expanded slit sheet material There are multiple end uses of the expanded slit sheet material.
  • the first is as a wrapping product.
  • the stretching process traps the goods firmly due to the inherent desire for the slit sheet material to return to its flat/undexpanded position.
  • This paper fiber memory assures a tight fit.
  • the method of wrapping of the interlocking cells maintains the locked position that maintains the strain on the fibers fighting to return to its original position.
  • a second use is as a void fill product. Since the material will not be wrapped and merely laid into the box to fill empty space, the inherent fiber memory creates an adverse effect by decreasing the angle of the hexagonal cell thus reducing the overall void fill volume. To overcome this it is necessary to super-stretch the slit sheet material so that the fibers are slightly torn thereby eliminating or minimizing the fiber memory.
  • the slit sheet expander paper tension or gearing can be adjusted for either approximately 10 to 20 percent less than full stretch for the wrapping method so that the packer performs the final stretch.
  • the cells are not fully stretched so that the final stretch, performed by the packer, makes a more secure fit.
  • Expansion would be to maximum of 90% of maximum stretch.
  • This retraction helps the wrapping method by enhancing the interlocking effect, but diminishes the value of the void fill method.
  • the desired end result is achieved when the cells are super stretched to remove the desire for the cells to retract back to the flat.
  • the super stretch would be approximately 101 to 110 percent depending upon the paper used.
  • a void fill method requires the product to remain at its maximum loft without the help of the packer.
  • the relative take-up speed and resistance speed of the feed roller(s) are adjusted to determine the degree of expansion that is being produced by the expansion equipment.
  • the expansion device can be of the type disclosed in US Patent 5.782,735 .
  • the terms "about”, “substantially”, and “approximately” when referring to a numerical value shall have their plain and ordinary meanings to a person of ordinary skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue.
  • the amount of broadening from the strict numerical boundary depends upon many factors. For example: some of the factors which may be considered include the criticality of the element and/or the effect a given amount of variation will have on the performance of the claimed subject matter, as well as other considerations known to those of skill in the art.
  • ranges is intended as a continuous range including every value between the minimum and maximum values plus the broadening of the range afforded by the use of the term “about”, “substantially”, or “approximately”
  • ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein
  • determining a given amount of variation of some the factors such as the criticality of the slit patterns, paper width differential pre- and post- expansion, paper weights and type, as well as other considerations known to those of skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue will have on the performance of the claimed subject matter, is not considered to be within the ability of one of ordinary skill in the art, or is not explicitly stated in the claims, then the terms "about”, “substantially”, and “approximately”
  • any ranges, ratios and ranges of ratios that can be formed by, or derived from, any of the data disclosed herein represent further embodiments of the present disclosure and are included as part of the disclosure as though they were explicitly set forth. This includes ranges that can be formed that do or do not include a finite upper and/or lower boundary. Accordingly, a person of ordinary skill in the art most closely related to a particular range, ratio or range of ratios will appreciate that such values are unambiguously derivable from the data presented herein.

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Claims (13)

  1. Verfahren zum Herstellen mindestens eines Paars ineinandergreifender angrenzender Schichten eines Papierverpackungsproduktes,
    wobei das Paar ineinandergreifender angrenzender Schichten aus einem ersten Bogen geschlitztes Papier (500) und einem zweiten Bogen geschlitztes Papier (502) gebildet ist,
    wobei der erste Bogen geschlitztes Papier (500) ein erstes Schlitzmuster aufweist und der zweite Bogen geschlitztes Papier (502) das erste Schlitzmuster aufweist, wobei das Schlitzmuster bei Ausdehnung Zellen bildet, die Stegbereiche (801) beinhalten, die in Bezug auf die Ebene des nicht ausgedehnten Bogens geneigt sind,
    Schlitzen des ersten Bogens geschlitztes Papier (500) und des zweiten Bogens geschlitztes Papier (502), um Schlitze (104) herzustellen, die bei Ausdehnung Stegbereiche (1001) des ersten Bogens herstellen, die Neigungswinkel (1010) im Bereich von 50 bis 85 Grad aufweisen, Ausrichten und Ausdehnen des zweiten Bogens geschlitztes Papier (502) und Bewirken, dass die Stegbereiche (1003) einen Neigungswinkel (1012) im Bereich von 130° bis 95° in Bezug auf den ersten Bogen geschlitztes Papier aufweisen,
    Schichten des ersten ausgedehnten Bogens (500) auf den zweiten ausgedehnten Bogen (502) und Bewirken, dass die Stegbereiche (1001) des ersten ausgedehnten Bogens (500) mit dem zweiten ausgedehnten Bogen (502) ineinandergreifen;
    dadurch gekennzeichnet, dass das Schlitzen des ersten Bogens (500) und des zweiten Bogens (502) einen im Wesentlichen geradlinigen Schnitt (1902) entlang einer Kante des Schlitzes und einen abgewinkelten Schnitt (1900) entlang der anderen Kante des Schlitzes bildet, wodurch eine Keilform gebildet wird, die auf einer ersten Seite des Klingeneintrittspunktes breiter ist als auf der anderen Seite des Klingeneintrittspunktes.
  2. Verfahren nach Anspruch 1, wobei der Neigungswinkel (1010) des ersten Bogens (500) und der Neigungswinkel (1012) des zweiten Bogens (502) entlang der Länge des ersten Bogens und des zweiten Bogens gleichbleibend sind.
  3. Verfahren nach Anspruch 1, wobei der Neigungswinkel (1010) des ersten Bogens (500) und der Neigungswinkel (1012) des zweiten Bogens (502) entlang der Länge des ersten Bogens und des zweiten Bogens weniger als etwa 20 % Umkehrwirkung aufweisen.
  4. Verfahren nach Anspruch 1, wobei der Neigungswinkel (1010) des ersten Bogens (500) und der Neigungswinkel (1012) des zweiten Bogens (502) entlang der Länge des ersten Bogens und des zweiten Bogens weniger als etwa 10% Umkehrwirkung aufweisen.
  5. Verfahren nach Anspruch 1, ferner umfassend den Schritt des Herstellens von Schlitzen in dem ersten und zweiten Bogen geschlitztes Papier unter Verwendung einer abgeschrägten Klinge (1602, 1604), die einen eingeschlossenen Winkel im Bereich von 1 bis 6 Grad aufweist, wobei die abgeschrägte Klinge eine erste Seite aufweist, die einen Winkel von etwa 90 Grad in Bezug auf die Ebene des Papiers, das geschlitzt wird, bildet.
  6. Verfahren nach Anspruch 1, wobei nach Ausdehnung der Neigungswinkel (1010) des ersten Bogens (500) im Bereich von 55 bis 75 Grad liegt und der Neigungswinkel (1012) des zweiten Bogens (502) im Bereich von 105 bis 125 Grad liegt.
  7. Verfahren nach Anspruch 1, ferner umfassend die folgenden Schritte:
    Wickeln in einer ersten Richtung des ersten Bogens geschlitztes Papier (500) zu einer ersten Rolle (1400), Wickeln in der umgekehrten Richtung in Bezug auf die erste Richtung eines zweiten Bogens geschlitztes Papier (502) zu einer zweiten Rolle (1402),
    Einführen des ersten Bogens geschlitztes Papier (500) von der Rolle (1400) im Uhrzeigersinn oder gegen den Uhrzeigersinn in eine erste Ausdehnvorrichtung (504),
    gleichzeitig Einführen des zweiten Bogens geschlitztes Papier (502) von der Rolle (1402) in eine zweite Ausdehnvorrichtung (504), wobei die Drehrichtung des zweiten Bogens geschlitztes Papier dieselbe Richtung ist, in der der erste Bogen geschlitztes Papier in die erste Ausdehnvorrichtung eingeführt wird, Ausdehnen des ersten Bogens geschlitztes Papier (500), wobei das erste Schlitzmuster bewirkt, dass die Stegbereiche einen Neigungswinkel (1010) im Bereich von 50 bis 85 Grad aufweisen, Ausdehnen des zweiten Bogens geschlitztes Papier (502), wobei das erste Schlitzmuster bewirkt, dass die Stegbereiche einen Neigungswinkel (1012) im Bereich von 130 bis 95 Grad aufweisen, Schichten des ersten ausgedehnten Bogens (500) auf den zweiten ausgedehnten Bogen (502), und
    Bewirken, dass die Stegbereiche des ersten ausgedehnten Bogens mit dem zweiten Bogen ineinandergreifen.
  8. Verfahren nach Anspruch 1, wobei nach der Ausdehnung der Neigungswinkel (1010) des ersten Bogens im Bereich von 55 bis 70 Grad liegt und der Neigungswinkel (1012) des zweiten Bogens im Bereich von 125 bis 110 Grad liegt.
  9. Verfahren nach Anspruch 1, ferner umfassend das Bilden des erstes Schlitzmusters und des zweiten Schlitzmusters durch Schlitzen mit einer Klinge gegen einen sich drehenden Amboss, wobei die Klinge einen eingeschlossenen Winkel im Bereich von 1 bis 3 Grad aufweist und wobei das Papier recyceltes Papier ist, wodurch eine Neigung des ersten Bogens und ein Neigungswinkel des zweiten Bogens hergestellt wird, der im Wesentlichen entlang der Länge des ersten Bogens und des zweiten Bogens gleichbleibend ist.
  10. Verfahren nach Anspruch 9, wobei der Amboss ein weicher Amboss ist und die Klinge durch das Papier und in den Amboss schneidet.
  11. Vorrichtung zum Herstellen mindestens eines Paars nicht verschachtelter angrenzender Schichten eines Papierverpackungsproduktes, eine erste Einrichtung zum Ausbilden in einer Vielzahl von Rollen (1400, 1402) aus Bogenmaterial (500, 502) von Schlitzen (104), die ein Muster aufweisen, das bei Ausdehnung der Rolle aus Bogenmaterial, das Schlitze aufweist, Zellen ergibt, die Stegbereiche (801) aufweisen, wobei die Stegbereiche einen Neigungswinkel (1010) im Bereich von etwa 50 bis 85 Grad aufweisen, wobei die erste Einrichtung Klingen (1602, 1604) beinhaltet, die einen eingeschlossenen Winkel im Bereich von etwa 1 bis 6 Grad aufweisen und eine Keilwirkung an einer Kante jedes der Schlitze bewirken, wobei die erste Einrichtung konfiguriert ist, um in dem Bogenmaterial einen im Wesentlichen geradlinigen Schnitt entlang einer Kante des Schlitzes und einen abgewinkelten Schnitt entlang der anderen Kante des Schlitzes auszubilden, wodurch eine Keilform gebildet wird, die auf einer ersten Seite des Klingeneintrittspunktes breiter als auf der anderen Seite des Klingeneintrittspunktes ist,
    eine zweite Einrichtung (503) zum Ziehen im Uhrzeigersinn in einen Ausdehnungsbereich einer ersten aus der Vielzahl von Rollen aus Bogenmaterial (502), das Schlitze aufweist,
    eine dritte Einrichtung (503) zum Ziehen gegen den Uhrzeigersinn in einen Ausdehnungsbereich einer zweiten aus der Vielzahl von Rollen aus Bogenmaterial (502), das Schlitze aufweist,
    eine vierte Einrichtung (504) zum gleichzeitigen Ausdehnen jedes aus der Vielzahl von Bogenmaterialien, die Schlitze aufweisen, Ausdehnen der ersten aus der Vielzahl von Rollen aus Bogenmaterial (500), das Schlitze aufweist, und Bewirken, dass die Stegbereiche einen Neigungswinkel (1010) im Bereich von 50 bis 85 Grad aufweisen, und Ausdehnen der zweiten aus der Vielzahl von Rollen aus Bogenmaterial (502), das Schlitze aufweist, und Bewirken, dass die Stegbereiche einen Neigungswinkel (1012) im Bereich von etwa 130 bis 95 Grad aufweisen,
    eine fünfte Einrichtung zum Schichten des ersten ausgedehnten Bogens auf den zweiten ausgedehnten Bogen, und eine sechste Einrichtung zum Bewirken, dass die Stegbereiche des ersten ausgedehnten Bogens mit dem zweiten Bogen ineinandergreifen, wobei der Neigungswinkel des ersten Bogens und des Neigungswinkel des zweiten Bogens entlang der Länge des ersten Bogens und des zweiten Bogens gleichbleibend sind.
  12. Papierverpackungsprodukt, umfassend:
    einen ersten Bogen geschlitztes Papier (500), der ein solches Schlitzmuster aufweist, dass bei Ausdehnung eine Vielzahl von Schlitzen eine Vielzahl von Zellen bildet, die Stegbereiche (801) beinhalten, die in Bezug auf die Ebene des nicht ausgedehnten Bogens geneigt sind,
    wobei die Schlitze eine Keilwirkung haben, die ausreichend ist, um zu bewirken, dass bei Ausdehnung die Stegbereiche des Bogens einen im Wesentlichen gleichbleibenden Neigungswinkel (1010) entlang der gesamten Länge des ausgedehnten Bogens und der Stegbereiche aufweisen, wobei der Neigungswinkel im Bereich von 50 bis 85 Grad liegt, wobei jeder Schlitz einen im Wesentlichen geradlinigen Schnitt entlang einer Kante des Schlitzes und einen abgewinkelten Schnitt entlang der anderen Kante des Schlitzes umfasst, wodurch eine Keilform gebildet wird, die auf einer ersten Seite des Schlitzes breiter ist als auf der anderen Seite des Schlitzes.
  13. Papierverpackungsprodukt nach Anspruch 12, ferner umfassend einen zweiten Bogen geschlitztes Papier (502), der auf den ersten Bogen geschlitztes Papier (500) geschichtet ist, wobei der erste Bogen und der zweite Bogen ausgedehnt sind, um ein Paar ineinandergreifender angrenzender Bögen geschlitztes Verpackungsmaterial zu bilden,
    wobei die Bögen geschlitztes Verpackungsmaterial ein derartiges Schlitzmuster aufweisen, dass bei Ausdehnung eine Vielzahl von Schlitzen eine Vielzahl von Zellen bildet, die Stegbereiche (801) aufweisen, die in Bezug auf die Ebene des nicht ausgedehnten Bogens geneigt sind, wobei die Schlitze eine Keilwirkung aufweisen, die ausreichend ist, um bei Ausdehnung zu bewirken, dass die Stegbereiche des ersten Bogens (500) einen Neigungswinkel (1010) im Bereich von etwa 50 bis 85 Grad entlang der Länge des ausgedehnten Bogens aufweisen, wobei der zweite aus dem Paar ineinandergreifender angrenzender ausgedehnter Bögen (502) einen Neigungswinkel (1012) im Bereich von 130 bis 95 Grad aufweist, wobei der erste ausgedehnte Bogen (500) auf dem zweiten ausgedehnten Bogen (502) geschichtet ist und mit diesem ineinandergreift.
EP14843068.9A 2013-09-06 2014-09-08 Verpackungsmaterial mit einer bei der schichtung und dehnung vernetzten dehnbaren geschlitzten folie, verfahren und vorrichtung zur dessen herstellung Active EP3041756B1 (de)

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EP20156524.9A EP3683166A1 (de) 2013-09-06 2014-09-08 Verfahren zur herstellung von mindestens einem paar ineinandergreifender angrenzender schichten eines papierverpackungsprodukts

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US201361874873P 2013-09-06 2013-09-06
PCT/US2014/054615 WO2015035335A1 (en) 2013-09-06 2014-09-08 Expandable slit sheet packaging material that interlocks when layered and expanded

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EP3041756A1 EP3041756A1 (de) 2016-07-13
EP3041756A4 EP3041756A4 (de) 2017-06-21
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EP20156524.9A Pending EP3683166A1 (de) 2013-09-06 2014-09-08 Verfahren zur herstellung von mindestens einem paar ineinandergreifender angrenzender schichten eines papierverpackungsprodukts

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US11834240B2 (en) 2013-09-06 2023-12-05 David P. Goodrich Expanded slit sheet cushioning products with novel alternating expansion patterns
US11905088B2 (en) 2013-09-06 2024-02-20 David Paul Goodrich Expanded slit sheet cushioning products with novel slit pattern and paper properties
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US11702261B2 (en) 2017-06-26 2023-07-18 David Paul Goodrich Expanded slit sheet cushioning products with novel reduced dimension slit patterns
KR20230074620A (ko) 2017-06-26 2023-05-30 데이비드 폴 굿리치 신장성 페이퍼, 및 확장된 슬릿 패키징 랩 제품 및 공간 충진 제품들의 제조에 있어서의 신장성 페이퍼의 용도
EP4310023A3 (de) 2018-08-05 2024-04-03 David Paul Goodrich Schutzprodukte, wie briefumschläge, mit einer einzigartigen kombination aus innenpolsterung aus expandiertem schlitzbogenpapier
KR20210116527A (ko) * 2019-01-22 2021-09-27 데이비드 폴 굿리치 확장가능한 슬릿 시트 용지의 손상 및/또는 찌그러짐 방지 및 취급 개선을 위한 확장 시스템
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USD946907S1 (en) 2020-07-29 2022-03-29 3M Innovative Properties Company Sheet with slits
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Publication number Publication date
EP3683166A1 (de) 2020-07-22
WO2015035335A1 (en) 2015-03-12
EP3041756A4 (de) 2017-06-21
EP3041756A1 (de) 2016-07-13

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