GB2546974A

GB2546974A - Packaging material

Info

Publication number: GB2546974A
Application number: GB1601652.9A
Authority: GB
Inventors: Andrew Smith Jordan
Original assignee: Oddity Innovations Ltd
Current assignee: Oddity Innovations Ltd
Priority date: 2016-01-29
Filing date: 2016-01-29
Publication date: 2017-08-09
Also published as: GB201601652D0; WO2017129995A1

Abstract

A material 20 for packing or wrapping an article includes a first, outer layer (22, figure 2c) and second, inner layer (24) releasably bonded together with an adhesive (26). The inner layer may be configured to protect an item packaged by the material, and may comprise pockets of trapped air 42 (i.e. bubble wrap). The outer layer may form an external surface of the packaged item. The outer layer and inner layer may include perforations along a main track 32, 34 which allow a user to selectively remove portions of the material to a desired size according to the size of the item to be packaged. The inner layer may include further perforations along a sub-track (38, figure 3b) which allow portions of the inner layer to be removed to expose a portion of the adhesive layer remaining on the first layer. The portion of the first layer including the exposed portion of adhesive can be attached to another portion of the material to allow an item to be packaged or wrapped accordingly.

Description

Packaging Material

Field

The present disclosure relates to packaging material for packaging items.

Background

Packaging forms a key consideration for businesses when sending a parcel to a customer. It is often desirable for packaging to provide adequate protection for the contents of the parcel. Selecting the most appropriate packaging while minimising cost and waste may be problematic and time-consuming.

Figure 1 is illustrative of some problems associated with existing packaging, and shows an item 10 to be sent in a parcel. The item 10 is provided in a packet 12 that is too large for the item 10. Additional protective packaging material 14 is provided in the space surrounding the item 10 to support/protect the item 10 in the packet 12. In this example, there is significant waste and excessive cost associated with both the oversized packet 12 and the provision of the additional protective packaging material 14.

For businesses such as low volume sellers with limited packaging resources, or even for home users, existing packaging is not sufficiently adequate, convenient, or well-suited to such businesses or individuals.

Summary

According to a first example, there is provided a material for packing or wrapping an item or article. The material may comprise a laminate. The laminate may comprise a first layer and a second layer with an adhesive disposed therebetween. The adhesive may releasably bond the first and second layers together.

In use, a user may cut, tear-off or provide a piece of the material at an appropriate size and shape to wrap or pack an item or article. Appropriate portions of the second layer may be removed so as to expose the adhesive such that the material can be wrapped around the item or article and secured by means of the exposed adhesive. In an example use, the user (in the course of packing or wrapping) may contact the exposed adhesive to parts of the upper surface of the first layer to thereby secure the material around the item or article. In another example use, the user (in the course of packing or wrapping) may contact the exposed adhesive to parts of the upper surface of the second layer (for example, by folding the material onto itself so that exposed adhesive may secure portions of the material together). In another example use, the user (in the course of packing or wrapping) may contact the exposed adhesive to another part of the material where adhesive has also been exposed (for example, by folding the material onto itself so that exposed adhesive may secure portions of the material together). Throughout this disclosure, references to the terms "wrapping", "packing", "packaging", "covering" and the like may be encompassed by the single term "packing".

The material may be used to provide packaging for an item or article. During transit or handling, the packaged item may suffer impacts (e.g. from being dropped) and/or be subject to external loads, and/or be subject to other damaging elements such as water and/or dust. The material may be configured to provide protection against external damage for an item packaged using the material. The material may comprise a protective element configured to absorb impacts. The protective element may provide a convenient way of protecting an item without the hassle and cost associated with providing separate protective components when packing an item. A user may select any desired size of the material to suit the size of the item being packaged. The ability to select any desired size or configuration of the material may allow a user to reduce waste and cost. By allowing a user to select a desired size of the material, there may be less material wasted and the packaged item may occupy a decreased volume due to the efficient use of the material. The decreased volume may decrease the cost of shipping or transporting the item. At least one of the layers may be configured to be relatively flexible to provide the packaging material with flexibility to allow a user to easily package an item.

The adhesive may be exposed by removing a portion of the second layer. Removing a portion of the second layer may allow a user to expose the adhesive at a required time, which may allow the material to be stored (for example, when rolled up) without different portions of the material sticking themselves together.

Accordingly, the material may offer an integrated solution to a user packaging an item for sending. Whereas packaging items can be a time-consuming and expensive process, the material may provide at least one feature which may reduce time spent packaging an item and/or reduce costs associated with packaging. When, in use, a portion of the adhesive is exposed, the first layer comprising the exposed adhesive may be quickly and simply attached to another portion of the material such that a user may not need to use supplementary materials (e.g. sticky tape) to securely package an item. Instead, the user may simply use the exposed adhesive, which may be an integral part of the packaging material, to securely package the item. Further, the material may be used in situ (e.g. in a shop by a customer) with no sharp implements required for cutting the material to a required size (although in some examples, the user may cut the material to size). Additionally, once the packaged item has been received by a buyer, the package may be relatively easy to open without use of a sharp implement, thereby reducing the risk of damaging the item and decreasing hassle for the buyer.

The first layer may provide an outer layer of the material, such that when an item or article is packed or wrapped with the material, the upper surface of the first layer forms an external surface of the material. Thus, the first layer may, in use, provide the outer layer or surface of a packaging. The second layer may provide an inner layer of the material, such that when an item or article is packed or wrapped with the material, the upper surface of the second layer forms an internal surface of the material. The upper surface of the first layer and the upper surface of the second layer may be defined as the respective surfaces of the material that are visible to a user before, in use, any portions of the second layer have been removed. A lower surface of the first layer and the lower surface of the second layer may be defined as the respective surfaces of the material that are not visible to a user before, in use, any portions of the second layer have been removed (however, when in use, a portion of the second layer is removed, the lower surfaces of the first and second layers may be revealed).

The first layer may be configured to provide a form of protection to the second layer. The first layer may be configured to provide protection to a wrapped or packed item or article. The first layer may be configured to be substantially damage-resistant, for example, the first layer may be tear-resistant, wear-resistant, water-proof, water-resistant, dust-proof and the like. Providing a substantially damage-resistant first layer may protect the second layer from further damage caused by an external object, for example, when the wrapped or packed item or article is transported or handled. The first layer may be substantially opaque to prevent the wrapped item or article from being visually inspected without opening the item or article. The first layer may serve to protect the item or article when the wrapped item is being handled or transported.

The second layer may be configured to provide a protective layer for a wrapped or packed item or article. For example, the second layer may comprise at least one of: bubbled portions such as bubble wrap, wadding, padding, foam, and the like. The second layer may serve to protect the wrapped item from external impacts and loading, such as may occur during handling or transportation. The first layer may comprise protective features also associated with the second layer. The second layer may comprise protective features also associated with the first layer. For example, the first layer may comprise padding to provide protection from external impacts and loading, such as may occur during handling or transportation.

The first and second layers may be coextensive, for example, so that each layer may be aligned with each other in the form of a laminate and extends over the same area.

The second layer may comprise padding configured to provide protection for an item or article when, in use, the item or article is packed or wrapped with the material.

The adhesive may adhere to the first layer. The adhesive may adhere to the second layer. The adhesive may have limited adherence or no adherence to the second layer. The adhesive may be configured to provide different adhering properties with respect to the first and second layers. The second layer may comprise at least one portion configured to be selectively removable so as to expose the adhesive. The adhesive may be configured to remain substantially bonded to the first layer such that, in use, when a portion of the second layer is removed from the material to expose the adhesive, the adhesive may remain substantially bonded to the first layer. The second layer may comprise a plurality of selectively removable portions. Each portion may be individually and discretely removable from the adhesive. Selectively removing at least one portion of the second layer may allow a user to select a desired size and shape of adhesive to be exposed, for example, to allow for efficient packing or wrapping of an item or article using the material.

The second layer may comprise perforations along a sub-track defining a boundary of at least one portion of the second layer. Providing perforations in the second layer may allow a user to selectively tear along the perforations so as to allow at least one portion of the second layer to be removed as required. In some examples, the second layer may comprise a form of weakness along the sub-track. The form of weakness may be in the form of perforations as described herein, or may be in the form of any appropriate weakness to allow a user to selectively tear along the weakness. A weakness may be formed in the second layer by modifying or adapting the second layer, for example, by heating or chemically altering the material in a region to either increase or decrease the relative strength of the material in or around the weakness, and/or by adding at least one further layer to the material in regions requiring increased strength.

The second layer may comprise at least one pocket of trapped gas configured to provide padding. The at least one trapped pocket of gas may be arranged adjacent to the perforations in the second layer. The second layer may comprise a bubble wrap material. The second layer may comprise any appropriate form of protective material to provide padding. For example, the second layer may comprise any of a padding structure, foam, wadding, and the like.

The first and second layers may comprise co-extending portions configured to be selectively removable from the material. The first and second layers may be selectively removed from the material as required by a user. The co-extending portions may be individually and discretely removable from the material. In use, a user may remove at least co-extending portion to provide the material in an appropriate or required size.

The first layer and the second layer may comprise perforations along a main track defining a boundary of at least one co-extending portion of the packaging material. Providing perforations in the co-extending portion may allow a user to selectively tear along the perforations so as to allow at least one portion of the material to be selectively removed as required. Selectively removing at least one co-extending portion may allow a user to select a desired size and shape of the material. In some examples, the first layer and/or the second layer may comprise a form of weakness along the main-track. The form of weakness may be in the form of perforations as described herein, or may be in the form of any appropriate weakness to allow a user to selectively tear along the weakness. A weakness may be formed in the first layer or the second layer by modifying or adapting either or both of the first layer and/or the second layer, for example, by heating or chemically altering the material in a region to either increase or decrease the relative strength of the material in or around the weakness, and/or by adding at least one further layer to the material in regions requiring increased strength.

The material may comprise instructions for a user on how to select which selectively removable portion of the second layer may be removed in order to appropriately package an item. The material may comprise instructions for a user on how to select which selectively removable portion of the material may be removed in order to appropriately package an item. The instructions may be printed on any externally visible layer of the material.

The first layer may comprise at least one weakened portion defining a boundary of at least one selectively removable portion of the material. The second layer may comprise at least one weakened portion defining a boundary of at least one selectively removable portion of the material. The weakened portion may be provided in a predetermined position (for example, along a track or line) such that at least one of the layers of the material is selectively removable in portions as selected by a user. The weakened portion of at least one of the first, second and any other provided layers may be in the form of perforations. The weakened portion may define at least one line or track forming a border of at least one selectively removable portion. The weakened portion may comprise material that is thinner than the material surrounding the weakened portion. The weakened portion may be provided by chemically altering the material in the region of the weakened portion, for example, by varying the temperature and/or by chemically altering (e.g. etching) the region. A plurality of layers may aligned together to provide at least one of the first and second layers of the material. At least one of said plurality of layers may comprise at least one weakened portion. The weakened portion may allow a user to selectively tear along the weakened portion as required to provide the material in a required configuration or size.

At least one further layer may be provided, which layer may comprise at least one weakened portion defining a boundary of at least one selectively removable portion of the material. The at least one further layer may incorporate one or more features described herein which are associated with either, or both of, the first and second layers. The further layer may be attached to the first layer. The further layer may be attached to the second layer. The further layer may sandwich the second layer between the further layer and the first layer, for example, to mask or hide the second layer. The further layer may include graphic markings to assist a user packaging an item. The graphic marks may indicate the location of weakened portions and/or provide instructions for the user. The further layer may provide additional strength and/or resistance to external damage to the material. The further layer may be substantially puncture resistant to protect any of the first and second layers, and/or any other layer of the material.

Where the weakened portion is in the form of perforations, the perforations may be configured to have a different separation (for example, tearing) threshold force. For example, the main track may comprise perforations configured to relatively increase or decrease the amount of force required to remove the portion separated by the main track, whereas the sub-track may comprise perforations configured to relatively decrease or increase the amount of force required to remove the portion separated by the sub-track. In some examples, the dimension of the perforations and the separation between adjacent perforations may define a force required to remove the portion. For example, a longer separation between perforations and/or a shorter perforation may increase the amount of force required to remove the portion, whereas a relatively shorter separation between the perforations and/or a relatively longer perforation may relatively decrease the amount of force required to remove the portion. Accordingly, a user may find it easier to remove a selectively removable portion of the second layer, for example, to make it easier to package an item by making it easier to expose the adhesive. The user may find it relatively more difficult to remove a selectively removable portion of the material itself, for example, to avoid unwanted breaking, tearing or ripping of the material when an item is packed, and thus may prevent the item from being accidentally unwrapped or unpacked during handling or transport. In other examples, the perforations may be configured to make it relatively easier to removable a selectively removable portion of the material itself, than it is to selectively remove a portion of the second layer.

In some examples only the second layer may comprise at least one weakened portion, whereas the first layer may not comprise any weakened portions. Thus, the material itself may be cut to size according to user requirements using scissors, for example.

The second layer may comprise at least one weakened portion along a sub-track defining the at least one pre-determined sized portion of the second layer.

The second layer may comprise at least one pocket of trapped gas within the second layer. The at least one trapped pocket of gas may be arranged adjacent to the at least one weakened portion in the second layer. The first layer may comprise at least one pocket of trapped gas within the first layer. Further layers may additionally or alternatively comprise at least one pocket of trapped gas.

The second layer may comprise a plurality of pockets of trapped gas. The pockets may be arranged in a square-packed formation relative to each other such that the at least one weakened portion along the main track or sub-track bisect rows of pockets adjacent either side of the at least one weakened portion. Organising the pockets in a square packed formation may allow straight line weakened portions of the main track or sub-track to be provided adjacent a row of pockets. Square-packed pockets may allow for simpler manufacture of the inner layer because the weakened portions of the track may be formed in straight lines adjacent rows of pockets. The weakened portions of track may be in the form of deviated lines (e.g. a sine, triangle, saw tooth pattern, or the like) in combination with, for example hexagonal packed pockets, to avoid the weakened portion puncturing or damaging any of the gas-filled pockets.

The rows of pockets in the second layer may be configured to be removable in strips to permit exposure of a portion of the adhesive remaining on the first layer.

The pockets may comprise any appropriate cross-section, for example, square, circular or rectangular. In some examples, the pockets may be in the form of a circular cross-section. The pockets may be any appropriate size, shape or dimension. The pockets may have a diameter of approximately 21mm. The pockets may have a maximum depth of approximately 10mm. The minimum separation between the edges of the pockets may be approximately 4mm. In some examples, providing pockets having a circular cross-section with at least one of a diameter of approximately 21mm, maximum depth of approximately 10mm and minimum separation of approximately 4mm may provide sufficient flexibility so that when the material is at least partially folded, the pockets do not press substantially against each other such that the pockets prevent folding. The maximum depth of the pockets may be selected from any number to two significant figures between 0.1mm and 20mm. The minimum separation between the edges of the pockets may be selected from any number to two significant figures between 0.1mm and 20mm. The maximum depth of the pockets may be selected from any of any number to two significant figures between 1.0mm and 40mm. Other dimensions for the diameter, maximum depth and minimum separation may be appropriately selected. Weakened portions, for example perforations, may be formed between adjacent pockets. Providing sufficient separation between the pockets may allow enough space for weakened portions to be provided without causing damage (e.g. punctures) to the pockets.

The adhesive may be configured to be relatively firmly bonded or adhered to the first layer. The adhesive may be configured to be relatively less-firmly bonded or adhered to the second layer, than the first layer is to the adhesive. In this way, the adhesive may remain firmly, or at least substantially, attached to the first layer to prevent separation of the first layer and the adhesive during use (e.g. during wrapping or packing), whereas a portion the second layer may be readily removed from the material to expose a portion of the adhesive provided under the removed second layer portion.

The adhesive may be provided in combination with a non-stick coating provided between the second layer and the adhesive. The non-stick coating may comprise a release agent adapted to permit separation of the second layer from the first layer, when required by a user. The non-stick coating may comprise regions with little nonstick coating such that the second layer can be relatively weakly attached to the adhesive. The adhesive may comprise a pressure-sensitive adhesive configured to form a bond when pressure is applied. The pressure-sensitive adhesive may be relatively strongly bonded to the first layer. The pressure-sensitive adhesive may be relatively weakly bonded to the second layer relative to the bonding of the first layer to the pressure-sensitive adhesive.

Various different configurations may be used alone, or in combination, to attach the first layer to the second layer, and may ensure that the second layer can be removed without substantially removing the adhesive attached to the first layer. Various means of attaching the layers together may be used. According to some examples, an adhesive as described herein may be used. However, any appropriate attachment element may be used to removably attach the layers together. For example, Velcro™ may be used. In some examples, at least one of the layers may be chemically altered, and/or heated to attach the layers together. In some examples, layers may be attached together by use of a vacuum, or partial vacuum. Any of the layers may incorporate an element configured to permit selective removal of selectively removable portions.

The material may be constructed using any appropriate material. In some examples, the material may comprise at least one plastic material. For example, the first and second layers may comprise at least one material, for example plastic material. The first and second layers may comprise the same material, which may allow for ease of recycling. Certain materials may be relatively easy to recycle, for example, where the material is constructed from a single plastic material there may be no need to separate plastic from non-plastic or different-plastic components, thereby aiding recyclability of the material. At least one of the first and second layers may comprise at least one of: polyethylene, polypropylene, polylactic acid, and the like. Polylactic acid may substantially provide the flexibility and strength of polyethylene and may provide adequate adhesive qualities to allow the adhesive layer to be attached to at least one of the first and second layers.

According to a second example, there is provided packaging material comprising a first layer. The packaging material may comprise a second layer. The second layer may comprise at least one pre-determined sized portion. The portion of the second layer may be removably attached to the first layer with an attachment element.

According to a third example, there is provided packaging material comprising a first layer. The packaging material may comprise a second layer removably attached to the first layer. The second layer may be removably attached to the first layer with an attachment element. The second layer may comprise at least one pre-determined sized portion.

Any of features associated with the first example may be combined with the second or third examples.

According to a fourth example, there is provided a process for manufacturing a material for packing or wrapping an item or article, comprising: providing a first layer and a second layer; configuring at least one of the first layer and the second layer to comprise at least one selectively removable portion; providing an adhesive between the first layer and the second layer; and bonding the first layer to the second layer.

The process for manufacturing the material may provide for a simple way of manufacturing the material. The first and second layers may be manufactured separately. The manufacturing process may comprise creating a portion of weakness in at least one of the layers. The portion of weakness may define a border of a selectively removable portion. In some examples, the portion of weakness may be in the form of perforations formed in the layer. Such portion of weakness may be in the form of a line or track defining a border of a selectively removable portion of the layer. The removable portion may be of a pre-determined size. Each of the first and second layers may require a different configuration of weakened portions, for example, to define differently sized selectively removable portions.

At least one of the layers may be configured to provide protection for a packed item from impacts and external loads which may occur during handling or transit. In some examples, the inner layer may comprise a protective layer configured to absorb impacts, spread external loads, and the like. The inner layer may be in the form of a layer comprising pockets of trapped gas, for example, so-called "bubble wrap". The portion of weakness may be adjacent to the pockets of trapped gas. The manufacturing process may allow the portion of weakness and pockets of trapped gas to be formed simultaneously within at least one layer of the packaging material, thereby increasing the efficiency of the manufacturing process.

Adapting at least one of the first layer and the second layer may comprise weakening, for example perforating, at least one of the first and second layers such that at least one of the first layer and the second layer comprise pre-determined sized user-removable portions.

The process may comprise perforating the first layer along a main track. The process may comprise perforating the second layer along a main track and a sub-track. The main track of the first layer may be aligned with the main track of the second layer.

The process may comprise perforating at least one of the first and second layers in pre-determined locations of the first and second layers. The process may comprise perforating additional layers, for example, a third layer. At least one weakened portion in at least one of the layers may define a border associated with a selectively removable portion of at least one of the layers.

The process may comprise forming pockets of trapped gas within the second layer. At least one pocket of trapped gas may be formed adjacent to a border defined by at least one of the pre-determined portions of the second layer. Pockets of trapped gas may be defined as bubbled portions. The bubbled portion may provide protection from impacts or external loads during transit or handling.

The process may comprise adapting at least one of the first and second layers such that at least one of the first layer and the second layer comprise at least one selectively removable portion.

The process may comprise perforating the second layer, for example, along a subtrack defining a border of the selectively removable portion of the second layer.

The process may comprise forming pockets of trapped gas within the second layer configured to provide padding. At least one pocket of trapped gas may be formed adjacent to a border defined by the selectively removable portion of the second layer.

The process may comprise perforating the first layer and the second layer, for example, along a main track defining a border of a selectively removable portion of the material. The removable portion of the material may comprise a co-extending portion of the first and second layers.

According to a further example, there is provided a process for manufacturing a packaging material, comprising providing a first layer and a second layer. The process may comprise adapting at least one of the first layer and the second layer to comprise at least one pre-determined sized user-removable portion. The process may comprise providing an attachment element between the first layer and the second layer. The process may comprise attaching the first layer to the second layer.

The present disclosure may include one or more corresponding aspects, embodiments, examples or features in isolation or in various combinations whether or not specifically stated (including claimed) in that combination or in isolation. For example, features associated with particular recited examples relating to methods or processes, may be equally appropriate as features of examples relating specifically to apparatus or products, and the like.

The above summary is intended to be merely exemplary and non-limiting.

Brief description of the drawings

These and other aspects of the present disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:

Figure 1 is a schematic view illustrating an item packaged using conventional packaging;

Figure 2(a) is a schematic side view of a material for packing an item;

Figures 2(b)-(d) are schematic exploded side views of components of the material;

Figures 3(a)-(b) are top views of an outer and inner layer of the material, respectively;

Figures 4(a)-(b) are schematic cross-sections of an example of the material;

Figures 5(a)-(b) are schematic cross sections of a further example of the material;

Figures 6(a)-(b) are top views of the outer layer of the material;

Figures 7(a)-(c) are top views of the inner layer of the material; and

Figures 8(a)-(d) are perspective views illustrating a user packaging process using the material.

Detailed description of the drawings

Figures 2a-2d illustrate a material 20 which includes a first, outer layer 22 and a second, inner layer 24. The outer layer 22 is coextensive with the inner layer 24 such that both layers cover the same area. The material 20 can be used to package (e.g. wrap) an item (not shown). The material 20 is configured to protect the item during transit and may include one or more layers configured to provide protection. The outer layer 22 is intended to form an external surface and the inner layer 24 is intended to form internal surface of the packaging when an item is packaged using the material 20. In other words, when in use, the outer layer 22 generally faces away from the packaged item and the inner layer 24 generally faces towards the packaged item. It will be appreciated however that an individual using the material 20 may employ any particular packaging technique that may result in the outer and inner layers 22, 24 facing in either direction, away from or towards the packaged item.

Figures 2b-2d illustrate various examples of the material 20 (in exploded views) with various components sandwiched between the outer layer 22 and the inner layer 24. The example of Figure 2b illustrates the outer and inner layers 22, 24 without any component sandwiched between the layers 22, 24. The example of Figure 2c illustrates the same outer and inner layers 22, 24 as in the example of Figure 2b, however an adhesive layer 26 is provided between the outer and inner layers 22, 24 to bond the outer and inner layers 22, 24 together. The example of Figure 2d illustrates the same outer and inner layers 22, 24 and adhesive layer 26 as in the example of Figure 2c, however a non-stick layer 28 is provided between the inner layer 24 and the adhesive layer 26 to prevent at least a portion of the inner layer 24 from sticking to the adhesive layer 26. In some examples, the adhesive layer 26 may be co-extensive with either or both the outer and inner layers 22, 24. In some examples, the adhesive layer 26 may not be co-extensive with either or both of the outer and inner layers 22, 24, for example the adhesive layer 26 may be provided in at least one discrete portion distributed in at least one area or part of the material 20. Thus, the adhesive layer 26 may not necessarily be in the form of a "layer" as such.

Referring now to Figure 3a, a top view of the outer layer 22 of material 20 is illustrated. The outer layer 22 is divided into square portions 30 which are each defined by perforated main track 32 defining at least one weakened portion of the outer layer 22 (i.e. the weakened portion is along a line defined by the main track 32). The perforations along the main track 32 allow individual square portions 30 to be separated (or torn-off) from the outer layer 22 so that the square portions 30 may be considered to be selectively removable and may be pre-determined in size. It will be appreciated that other shaped portions may be provided, for example, rectangular portions and the like.

Referring now to Figure 3b, a top view of the inner layer 24 of material 20 is illustrated. It will be appreciated that the top view of Figure 3a and the top view of Figure 3b are representative of a top and bottom view of the complete material 20, as illustrated for example by Figure 2a. The perforated main track 32 of the outer layer 22 are aligned with perforated main track 34 in the inner layer 24 defining a boundary of at least one weakened portion of the inner layer 24 (i.e. the weakened portion is along a line defined by the main track 34). Accordingly, the aligned perforations in the main track 32, 34 of the outer and inner layers 22, 24 allow individual square portions 36 (or a plurality of square portions 36) of the material 20 to be separated therefrom (or torn off) when required so that the square portions 36 may be considered to be selectively removable and may be pre-determined in size. In contrast to the outer layer 22, the inner layer 24 also includes lines of perforated sub-track 38 defining at least one weakened portion of the inner layer 24 (i.e. the weakened portion is along a line defined by the sub-track 38), which allow individual portions of the inner layer 24 to be separated (or torn off) from the remaining inner layer 24 and material 20 itself so that the individual portions of the inner layer 24 may be considered to be selectively removable and may be pre-determined in size. In the example of Figure 3b, there is one sub-track 38 either side of each perforated main track 34, thereby forming a pattern of removable sub-portions 40 in the inner layer 24. Accordingly, there are a number of square and rectangular sub-portions 40 provided by virtue of the square pattern of main track 32. For clarity purposes, the main track 34 in Figure 3b is shown as being relatively bolder/darker than the sub-track 38 so as to enable the skilled reader to visually differentiate between the main and sub-track tracks 34, 38.

Figure 3b also illustrates an array of circular bubbled portions 42 formed in the inner layer 24. Each bubbled portion 42 is formed of a trapped pocket of air within the inner layer 24. An example of a material incorporating such trapped pockets of air is commonly known as "bubble wrap", which is usually made using an impermeable plastic material. The bubbled portions 42 are situated in spaces formed between the main track 32 and the sub-track 34. As a result of the rectangular-square geometry of the tracks 32, 34, 38 in the example of Figure 3b, the bubbled portions 42 are organised in a square-type array, in other words the bubbled portions 42 are square-packed relative to each other (such that there are eight bubbled portions 42 neighbouring each bubbled portion 42, except at the edges of the material 20). Square-packing the bubbled portions 42 allows straight-line perforated tracks 32, 34, 38 to be provided adjacent a row of bubbled portions 42. In contrast to a common form of "bubble wrap" which has hexagonal-packed circular bubbled portions (i.e. with six bubbled portions neighbouring each individual bubbled portion, except at the edges of the "bubble wrap"), square-packed bubbled portions 42 may allow for simpler manufacture of the inner layer 24 because the perforated tracks 32, 34, 38 can be formed in straight lines adjacent rows of bubbled portions 42. This being said, it is also possible for the perforated tracks 32, 34, 38 to be in the form of deviating lines (e.g. a sine, triangle, saw tooth pattern, or the like) in combination with, for example hexagonal-packed bubble portions, to avoid the perforations puncturing any of the bubbled portions 42. Use of square-packed bubbled portions 42 provides rows of spaces between the bubbled portions, said rows forming perpendicular axes of symmetry of the material 20. Said rows allow the material 20 to be folded along either of these axes of symmetry, thereby providing a flexible material 20.

Referring now to Figure 4a, there is shown a simplified sectional view of the material 20 including the outer layer 22 and the inner layer 24, the inner layer 24 including bubbled portions 42. An expanded simplified sectional view of the material 20 is shown in Figure 4b, in which the bubbled portion 42 has an external-facing surface 44 (i.e. an external surface of the material 20 itself) in the form of a dual-layer of impermeable material. An internal-facing surface (i.e. within the material 20 itself) of the bubbled portion 42, which is located between the bubbled portion 42 and the outer layer 22, is not shown for clarity purposes, but is also in the form of a dual-layer of impermeable material.

The inner layer 24 is in the form of a protective layer of what is sometimes known as quad-layer plastic sheet bubble wrap, in which pockets of gas (e.g. air or another gas) are trapped between the middle two layers of the quad-layer plastic sheet (i.e. a dual layer of plastic sheet either side of the pockets of trapped gas). The dual layers of plastic sheet either side of the pockets help to retain the trapped gas in the pocket and reduce the likelihood of punctures or ruptures. Each of the layers of the plastic sheet bubble wrap has a thickness of approximately 0.05mm. It will be appreciated that other types of protective layers may be provided as part of or forming the inner layer 24, for example, a dual layer bubble wrap (i.e. where only one layer of plastic sheet is provided either side of the pockets of trapped gas), foam-based padding, corrugated cardboard, and the like. The outer layer 22 protects the inner layer 24, particularly when the inner layer 24 is in form of "bubble wrap", from punctures. The outer layer 22 may hide the contents of the package from view when in opaque form if the inner layer 24 is transparent or translucent.

The bubbled portions 42 are circular in horizontal cross-section and have a diameter of 21mm at their widest point. The bubbled portions 42 have a maximum depth of 10mm and there is a 4mm closest separation between the adjacent bubbled portions 42 (i.e. when provided in the square-packed formation shown in the example of Figure 3b). Accordingly, a row of four adjacent bubbled portions 42 with a space of 2mm (half of 4mm) either side will have a total width of 100mm. Each square portion 36 has sides of length 100mm and therefore includes four bubbled portions 42 in each row of the square portion 36. It will be appreciated that other shapes and dimensions may be appropriate for the bubbled portions.

The space between the bubbled portions 42 allows perforated main and sub-tracks 32, 34, 38 to be provided without puncturing the bubbled portions 42. Further, the square-packed formation allows the perforated main and sub-tracks 32, 34, 38 to be provided in straight lines between rows of the bubbled portions 42. Providing the perforations in straight lines enables for simpler manufacturing of the material 20 as well as being simpler for a user to remove adapt the size of the material 20 in neat and aesthetically-pleasing edges. Further still, the 4mm space between bubbled portions 42 allows for greater flexibility of the material 20. If the bubbled portions 42 have too great a depth with insufficient spacing therebetween, the material 20 may become somewhat inflexible. It will be appreciated that the above dimensions are merely one of many possible examples, and a person of skill in the art will recognise that different dimension combinations may be provided. For example, an item requiring substantial protection may require deeper bubbled portions 42 (i.e. with a depth greater than 10mm) and therefore the space between bubbled portions 42 may need to be greater than 4mm to allow for sufficient flexibility of the material 20. It will be appreciated that a length of the material 20 may be rolled, ready for distribution to a buyer. The size of the bubbled portions 42, as well as the thickness of the outer and inner layers 22, 24 may affect the diameter of the rolled material 20. Accordingly, relatively less-deep bubbled portions 42 may allow for a smaller roll of material 20, which would likely be cheaper to distribute to a buyer. Providing at least one pre-determined sized portion of the second layer 24 may allow a user to expose the adhesive layer 26 at a required time, which could allow the material 20 to be stored (e.g. rolled) without different portions sticking themselves together which would otherwise prevent unrolling of the rolled material 20.

Although 100mm x 100mm square portions 36 have been implemented, other sizes of removable portions are contemplated. For example, depending on particular requirements, 250mm x 250mm or 125mm x 125mm square portions are possible. 100mm x 100mm square portions 36 have been found to function as a simple sizing grid and thus have proved to be a simple method of measuring a package prior to posting. If has also been found that the relatively small size of the 100mm x 100mm square portions 36 further reduce the volume of excess material required and make it easier for the user to estimate how much material 20 is required. It will be appreciated that any particular size of square portion may be used, and may be provided in different units (e.g. inches). As noted previously the portions 36 may not need to be squareshaped. Instead the portions could be rectangular or any other appropriate shape.

Referring now to Figures 5a-5b, there is shown similar simplified sectional views of the material 20 to Figures 4a-4b. In the example of Figures 5a-5b, a third, additional inner layer 46 is covering the inner layer 24. The third layer 46 may be used to mask or hide the inner layer 24, which may be considered to be somewhat unsightly, or may include instructions on use of the material 20. The third layer 46 includes track and sub-track (not shown) similar to the tracks and sub-track 32, 34, 38 so that portions of the inner and third layers 24, 46 may be removed as required by the user. The third layer 46 is firmly attached, e.g. using an adhesive, to the inner layer 24 to allow for ready removal of both of these layers 24, 46 at the same time. It is possible for the third layer 46 to be integrally formed with the inner layer 24 and outer layer 22 during the manufacturing process. The third layer 46 may provide protection for the bubbled portion 42, e.g. to resist punctures and the like.

The internal surface of the outer layer 22 is coated with a pressure-sensitive adhesive 26. An example of a pressure-sensitive adhesive that was successfully implemented in various tests of the material 20 is 3M™ Scotch-Weld™ Contact Adhesive. Other pressure-sensitive adhesives that are available on the market are envisaged as being similarly successful, depending on the type of materials used. However, the choice of adhesive depends on the choice of material for the outer layer 22 and inner layer 24 (or where appropriate, third layer 46). In some examples, the adhesive layer 26 remains unset (or is not bonded) until required by the user of material 20. In some examples, the inner layer 24 is only in contact with the adhesive layer 26 over a relatively small area and therefore is weakly bonded to the outer layer 22, and as such, may be readily removed therefrom. In some examples, the adhesive bond is strong enough so that a packaged item cannot open during transit. In some examples the adhesive bond may be configured to prevent an unauthorised third party from peeling open a sealed package to reveal its contents, and then subsequently resealing the package. Thus, the material 20 may provide a security system in which the material 20 may be only breached once sealed by tearing along a perforated track (or indeed by ripping the material 20). Providing the ability to tear along the tracks 32, 34 allows a packaged item to be readily opened at its final destination, but there still remains sufficient package security if the package arrives with tears or other damage in the material 20 itself.

Although pressure-sensitive adhesive is listed as an example of an adhesive capable of providing at least some of the described functionality of the material 20, other types of adhesives may be used. In some examples a non-stick coating may be applied to the inner layer 24 to prevent the adhesive layer 26 from substantially bonding to the inner layer 24.

Referring now to Figure 6a, there is shown a top view of the outer layer 22 with the perforated main track 32, similar to that shown in Figure 3a. In some examples, the outer layer 20 of the material 20 includes a sheet of thickness 0.15mm. Either or both of the external surface and the internal surface of the outer layer 22 may be graphically marked with, for example, a dotted pattern to highlight the locations of the perforations and/or to provided instructions on how to use the material 20.

Referring now to Figure 6b, there is shown an expanded view 48 of an intersection of perforated main track 32, as indicated in Figure 6a. Individual perforations 32 are separated from each other by main track separations 50. The length of the perforations 32 and the length of the main track separations 50 may define how readily a portion 32 may be removed (e.g. torn along pre-determined lines defined by the main track 32) from the outer layer 22. For example, relatively long separations 50 and relatively short perforations 32 may result in the portions 36 being harder to remove, whereas relatively short separations 50 and relatively long perforations 32 may result in the portions 36 being relatively easier to remove. It will be appreciated that the relative dimensions (e.g. including length, width and depth) of the perforations 32 and separations 50 can be varied to provide particular separation characteristics according to the particular material used to form the outer layer 22.

Referring now to Figure 7a, there is shown a top view of the inner layer 24 of the material 20 with the perforated main track 34 and sub-track 38, similar to that shown in Figure 3b. Similar to the outer layer 22 of the example of Figure 6a, the inner layer 24 includes square portions 36 of size 100mm x 100mm defined by main track perforations 34.

Referring now to Figure 7b, there is shown an expanded view 52 of an intersection of perforated main track 34, similar to that shown in Figure 6b. Separations 54 between perforations 34 and the dimensions of the perforations 34 similarly define separation characteristics of portions of the inner layer 24. As in Figure 6b, these dimensions may be varied to adjust the separation characteristics. The configuration of separations 54 and perforations 34 in Figure 7b appear similar to those shown in relation to separations 50 and perforations 32 in Figure 6b. It will be appreciated that different configurations (e.g. separation and dimensions) may be used if the outer layer 22 and inner layer 24 exhibit different structural characteristics affecting how easily portions may be removed therefrom.

Referring now to Figure 7c, there is shown an expanded view 56 of an intersection of perforated sub-track 38, similar to those shown in Figures 6b and 7b. In this case the separations 58 between perforations 38 are much shorter than in the similar examples of Figures 6b and 7b. Accordingly, a portion of inner layer 24 as defined along the subtrack 38 may be more readily removed from the inner layer 24 than a portion of inner layer 24 as defined by the main track 34. Similarly, a portion of inner layer 24 as defined along the main track 34 may be more readily removed from the inner layer 24 than a combined portion of outer layer 22 and inner layer 24 as defined along the aligned main track 32, 34 (owing to there being two layers to remove as opposed to a single layer). Thus in use, a user may find it relatively more easy to remove a portion of inner layer 24 from the remaining inner layer 24 than to remove a combined portion of outer and inner layer 22, 24 from the remaining material 20.

Therefore, in one possible mode of use illustrated by Figures 8a-8d, a user 60 can select a required size of material 20 by separating (e.g. tearing) the material 20 along main track 32, 34 in the direction of arrows 62 as shown in Figure 8a. Subsequently, as shown in Figure 8b, the user 60 can remove rows 64 of the inner layer 24 from along the side edges 66 of the separated material 20. Since the side edges 66 of the inner layer 24 are only connected to the rest of the inner layer 24 via sub-track 38 (which were previously explained as being easier to separate than along the main tracks 32, 34), the side edges 66 can be readily removed by pealing in a direction indicated by arrow 68. Upon removal of the rows 64, the side edges 66 of the material 20 include an exposed adhesive layer 26 which remains on an internal surface of the outer layer 22. An item (not directly shown) is placed on the inner layer 24 and the material 20 folded over the item, as shown in Figure 8c, and corresponding side edges 66 are secured to each other by bonding of the adhesive layer 26. Subsequently, markings (e.g. address details) can be added to the external surface of the material 20, as is shown in Figure 8d.

It will be appreciated that any appropriate packing or wrapping method may be used when packaging an item using the material 20. For example, a user 60 can fold, roll, cover or wrap a section of the material 20 around the item. Any reference to "packaging" herein can refer to any of these and other appropriate packaging methods.

Any reference to external/internal (or exterior/interior), unless otherwise specified, refers to the outside/inside of the material 20, respectively. For example, a reference to an internal surface refers to a surface within or inside the material 20 itself (i.e. before any portions are removed therefrom). Similarly, a reference to an external surface refers an outer-facing side of the material, irrespective of whether the outer layer 22, inner layer 24, or third layer 46 is being referred to.

It will be appreciated that the material 20 can be manufactured in various ways. In the present example, at least one of the manufacturing steps is for both the outer layer 22 and inner layer 24 to be perforated. The layers 22, 24 may be formed separately as the outer layer 22 includes a different perforation pattern to the inner layer 24. One possible method for creating a perforated pattern in a sheet material such as the inner layer 24 is to use a perforating system incorporating on a roller die system (not shown). Such a system can be incorporated with a conventional system for manufacturing "bubble wrap" type material incorporating bubbled portions 42. It will be recognised that at least one of the layers 22, 24, 46 of the material 20 can be perforated before creating bubbled portions 42. However, using (for example) a roller die system enables perforations to be made in at least one of the layers 22, 24, 26 before, during or after creating bubbled portions 42. A specially designed roller die system could simultaneously perforate and create bubbled portions 42 in at least one layer. Such a system could be used to efficiently manufacture the material 20, while avoiding the need for separate machinery to separately perform the steps of perforating and creating bubbled portions 42. Additionally, the system could be pre-configured to generate any desired pattern and distribution of perforations 32, 34, 38 and bubbled portions 42 in the material 20.

Various modifications can be made to the above examples while remaining within the scope of the invention. At least some of the possible modifications are described below.

The above examples refer to use of perforated main and sub-tracks 32, 34 and 38. One of the purposes of the perforations is to provide a weakness in certain regions of the layers so as to make separation of the portions easier. However, other types of weakness may be employed to aid in separation of portions of the layers. For example, the layers may have a certain thickness, and tracks defining edges of separable portions may have a decreased thickness making separation easier. Alternatively or in addition, the material 20 may include different materials having different physical properties, or may include structurally modified portions (e.g. by a chemical process and/or by adding additional layers and/or by removing layers) to increase or decrease material strength in desired areas of the material 20.

In the above examples, an adhesive layer 26 is used to bond the outer and inner layers 22, 24 together. However, in some examples, the adhesive layer may not be sufficiently sticky to provide for the simpler packaging as described herein. Although more hassle, it would be possible for a user to apply their own adhesive to exposed portions of the outer layer 22 when portions of the inner layer 24 are removed.

There are different ways to provide the functionality of containing and/or revealing the adhesive layer 26. A number of working options have been tested and found to offer possible ways of achieving this functionality. For example, these options include bursting gas-filled pillows (e.g. bubbled portions) to release a liquid adhesive, or peeling off sections of wax paper in-between the bubbled portions 42. It will be apparent to the skilled person that various modifications can be made to these examples without departing from the scope of the invention.

It will be appreciated that the material 20 may have multiple different configurations. For example, the material may utilise the same or different materials for the different layers, dimensions, layer type, degree of protection, and the like. For example, large, heavy and breakable items may require additional protective padding. In some examples, the material 20 may be configured to be suitable for wrapping presents instead of being suitable for sending via a delivery service.

It will be appreciated that the material 20 may include a single or multiple types of materials. The outer layer 22, inner layer 24 and third layer 46 may each comprise the same or a different material. Where the inner layer 24 includes bubbled portions 42, the inner layer 24 includes an impermeable material, for example, a plastic-based material. Examples of appropriate plastic materials include polyethylene, polypropylene, and polylactic acid, and the like. Polylactic acid may be able to provide the flexibility and strength of polyethylene while providing adequate adhesive qualities and may also prove to be more environmentally sustainable than polyethylene. Constructing the material 20 out of the same or substantially the same material may improve the recyclability of the material 20. Alternatively, or in addition, a paper-based material could be used, which would include further recycling and sustainability benefits. Alternatively, or in addition, at least one of layers 22, 24, 46 of the material 20 may include foam-based material.

Each individual feature described herein may be provided in isolation or in combination with any other features described herein. In view of the foregoing description, it will be evident to a person skilled in the art that various modifications may be made within the scope of the invention.

Claims

1. A material for packing or wrapping an item or article, comprising: a laminate comprising a first layer and a second layer with an adhesive disposed therebetween, wherein the adhesive releasably bonds the first and second layers together.

2. The material of claim 1, wherein the first and second layers are coextensive.

3. The material of claim 1 or 2, wherein the second layer comprises padding configured to provide protection for an item or article when, in use, the item or article is packed or wrapped with the material.

4. The material of claim 1,2 or 3, wherein the second layer comprises at least one portion configured to be selectively removable so as to expose the adhesive.

5. The material of claim 4, wherein the adhesive is configured to remain substantially bonded to the first layer such that, in use, when a portion of the second layer is removed from the material to expose the adhesive, the adhesive remains substantially bonded to the first layer.

6. The material of claim 4 or 5, wherein the second layer comprises a plurality of removable portions, wherein each portion is individually and discretely removable from the adhesive.

7. The material of claim 4, 5 or 6, wherein the second layer comprises perforations along a sub-track defining a boundary of at least one portion of the second layer.

8. The material of claim 7, wherein the second layer comprises at least one pocket of trapped gas configured to provide padding, the at least one trapped pocket of gas arranged adjacent to the perforations in the second layer.

9. The material of any one of claims 1 to 8, wherein the first and second layers comprise co-extending portions configured to be selectively removable from the material.

10. The material of claim 9, wherein the first layer and the second layer comprise perforations along a main track defining a boundary of at least one co-extending portion of the packaging material.

11. A process for manufacturing a material for packing or wrapping an item or article, comprising: providing a first layer and a second layer; configuring at least one of the first layer and the second layer to comprise at least one selectively removable portion; providing an adhesive between the first layer and the second layer; and bonding the first layer to the second layer.

12. The process of claim 11, comprising adapting at least one of the first and second layers such that at least one of the first layer and the second layer comprise at least one selectively removable portion.

13. The process of claim 12, comprising perforating the second layer along a subtrack defining a border of the selectively removable portion of the second layer.

14. The process of claim 13, comprising forming pockets of trapped gas within the second layer configured to provide padding, wherein at least one pocket of trapped gas is formed adjacent to a border defined by the selectively removable portion of the second layer.

15. The process of claim 12, 13 or 14, comprising perforating the first layer and the second layer along a main track defining a border of a selectively removable portion of the material, the removable portion of the material comprising a co-extending portion of the first and second layers.