WO2022226253A1 - Ensemble emballage recyclable par retenue/suspension - Google Patents

Ensemble emballage recyclable par retenue/suspension Download PDF

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Publication number
WO2022226253A1
WO2022226253A1 PCT/US2022/025860 US2022025860W WO2022226253A1 WO 2022226253 A1 WO2022226253 A1 WO 2022226253A1 US 2022025860 W US2022025860 W US 2022025860W WO 2022226253 A1 WO2022226253 A1 WO 2022226253A1
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WO
WIPO (PCT)
Prior art keywords
panel
packaging assembly
sheet
web sheet
retention
Prior art date
Application number
PCT/US2022/025860
Other languages
English (en)
Inventor
Robert Babrowicz
Anant PARTE
Drew V. Speer
Michael Andrew LINDLER
Devin Croix RIDGEWAY
Original Assignee
Sealed Air Corporation (Us)
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sealed Air Corporation (Us) filed Critical Sealed Air Corporation (Us)
Publication of WO2022226253A1 publication Critical patent/WO2022226253A1/fr

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Classifications

    • 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
    • B65D75/00—Packages comprising articles or materials partially or wholly enclosed in strips, sheets, blanks, tubes, or webs of flexible sheet material, e.g. in folded wrappers
    • B65D75/28—Articles or materials wholly enclosed in composite wrappers, i.e. wrappers formed by associating or interconnecting two or more sheets or blanks
    • B65D75/30—Articles or materials enclosed between two opposed sheets or blanks having their margins united, e.g. by pressure-sensitive adhesive, crimping, heat-sealing, or welding
    • B65D75/305—Skin packages
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/44—Integral, inserted or attached portions forming internal or external fittings
    • B65D5/50—Internal supporting or protecting elements for contents
    • B65D5/5028—Elements formed separately from the container body
    • 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
    • B65D65/38—Packaging materials of special type or form
    • B65D65/46—Applications of disintegrable, dissolvable or edible materials
    • 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
    • B65D77/00—Packages formed by enclosing articles or materials in preformed containers, e.g. boxes, cartons, sacks or bags
    • B65D77/04—Articles or materials enclosed in two or more containers disposed one within another
    • B65D77/0413—Articles or materials enclosed in two or more containers disposed one within another the inner and outer containers being rigid or semi-rigid and the outer container being of polygonal cross-section formed by folding or erecting one or more blanks, e.g. carton
    • B65D77/042—Articles or materials enclosed in two or more containers disposed one within another the inner and outer containers being rigid or semi-rigid and the outer container being of polygonal cross-section formed by folding or erecting one or more blanks, e.g. carton the inner container being of polygonal cross-section formed by folding or erecting one or more blanks, e.g. carton
    • 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
    • B65D81/05—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 maintaining contents at spaced relation from package walls, or from other contents
    • B65D81/07—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 maintaining contents at spaced relation from package walls, or from other contents using resilient suspension means
    • 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
    • B65D2565/00—Wrappers or flexible covers; Packaging materials of special type or form
    • B65D2565/38—Packaging materials of special type or form
    • B65D2565/381—Details of packaging materials of special type or form
    • B65D2565/385—Details of packaging materials of special type or form especially suited for or with means facilitating recycling
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/80—Packaging reuse or recycling, e.g. of multilayer packaging

Definitions

  • the subject matter disclosed herein relates to protective packaging. More particularly, to suspension and retention packaging that is recyclable.
  • Protective packaging structures may be used to help protect a product during transport, for example, from physical shock, dust, and other contaminants.
  • a product may be enclosed in a box with additional packing materials (e.g., crumpled paper, air-filled plastic cushions, molded foam) to restrain the product movement inside the box and to cushion the product.
  • additional packing materials e.g., crumpled paper, air-filled plastic cushions, molded foam
  • retention packaging One type of packaging system is known as “retention packaging.” In typical retention packaging, a product is retained between a sheet and a rigid backing frame, which is sometimes the frame to which the sheet is attached. Another type of packaging system is known as “suspension packaging.” In typical suspension packaging, the packaged product is suspended between two sheets each attached to opposing frames sized to fit within a corresponding box. Examples of retention and suspension packaging are described in more detail in U.S. Pat. Nos.
  • a packaging assembly for retention or suspension packaging has at least one frame and at least one web sheet attached to the frame.
  • the web sheet is primarily made from polyvinyl alcohol polymer(s) and includes an effective amount of plasticizer.
  • the packaging assembly be sufficient to retain or suspend a product.
  • the retention packaging assembly being able to be recycled without the need to separate the web sheet from the frame.
  • An advantage that may be realized in the practice of some disclosed embodiments of the packaging assembly is that the entire packaging assembly may be considered recyclable without the need to separate the web sheet from frames or panels.
  • a retention packaging assembly comprises at least one frame and at least one web sheet attached to the frame.
  • the web sheet having at least 80 wt% polyvinyl alcohol polymer and at least 5 wt% of a plasticizer.
  • the web sheet having at least 75, 100, 200, or 300% elongation at yield in either the longitudinal or transverse directions as measured in accordance with ASTM D882 and elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 40%, 45%, 50%, 55%, 60%, 65%, 70% and 75%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.
  • the retention packaging assembly having a fiber yield of at least 80% based on the total weight of the retention packaging assembly or 85% based on the bone dry fiber charge to the pulper, each tested in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • a suspension packaging assembly comprises a first frame and a first web sheet attached to the first frame.
  • the first web sheet comprising at least 80 wt% polyvinyl alcohol polymer and at least 5 wt% of a plasticizer.
  • the first web sheet having at least 75, 100, 200, or 300% elongation at yield in either the longitudinal or transverse directions as measured in accordance with ASTM D882 and elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 40%, 45%, 50%, 55%, 60%, 65%, 70% and 75%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.
  • the suspension packaging assembly also comprise a second frame and a second web sheet attached to the second frame.
  • the first web sheet comprising at least 80 wt% polyvinyl alcohol polymer and at least 5 wt% of a plasticizer.
  • the second web sheet having at least 75, 100, 200, or 300% elongation at yield in either the longitudinal or transverse directions as measured in accordance with ASTM D882 and elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 40%, 45%, 50%, 55%, 60%, 65%, 70% and 75%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.
  • a product is situated between the first and second web sheets.
  • the retention packaging assembly without accounting for the product, having a fiber yield of at least 80% based on the total weight of the retention packaging assembly or 85% based on the bone dry fiber charge to the pulper, each tested in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • a method of packaging a product comprises the steps of a) providing at least one frame; b) providing at least one web sheet attached to the frame; and c) situating a product between the at least one frame and the at least one web sheet, or situating a product between the at least one web sheet, and a second web sheet.
  • the at least one web sheet comprising at least 80 wt% polyvinyl alcohol polymer and at least 5 wt% of a plasticizer.
  • the web sheet having at least 75, 100, 200, or 300% elongation at yield in either the longitudinal or transverse directions as measured in accordance with ASTM D882 and elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 40%, 45%, 50%, 55%, 60%, 65%, 70% and 75%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.
  • the combination of the at least one frame and at least one web sheet having a fiber yield of at least 80% based on the total weight of the retention packaging assembly or 85% based on the bone dry fiber charge to the pulper, each tested in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • FIG. 1 A depicts a top view of an embodiment of a base panel that is usable as part of a retention packaging system
  • Figs. IB and 1C depict top and bottom views, respectively, of an embodiment of a sheet panel that is usable with the base panel depicted in Fig. 1 A as part of a retention packaging system;
  • Figs. 2A to 2J depict an embodiment of forming the base panel depicted in Fig. 1A and the sheet panel depicted in Figs. IB and 1C into a retention packaging system;
  • Figs. 3K to 3N depict an embodiment of placing the retention packaging system depicted in Figs. 31 and 3J into a container;
  • Figs. 3A to 3J depict another embodiment of forming the base panel depicted in Fig. 1A and the sheet panel depicted in Figs. IB and 1C into a retention packaging system;
  • FIGs. 3K to 3N depict an embodiment of placing the retention packaging system depicted in Figs. 21 and 2J into a container;
  • FIG. 4A depicts a top view of another embodiment of a base panel that is usable as part of a retention packaging system
  • Figs. 4B and 4C depict top and bottom views, respectively, of another embodiment of a sheet panel that is usable with the base panel depicted in Fig. 4A as part of a retention packaging system;
  • Figs. 5A to 5J depict an embodiment of forming the base panel depicted in Fig. 4A and the sheet panel depicted in Figs. 4B and 4C into a retention packaging system;
  • Figs. 5K to 5N depict an embodiment of placing the retention packaging system depicted in Figs. 51 and 5J into a container;
  • Fig. 6A depicts a top view of another embodiment of a base panel that is usable as part of a retention packaging system
  • Figs. 6B and 6C depict top and bottom views, respectively, of another embodiment of a sheet panel that is usable with the base panel depicted in Fig. 4A as part of a retention packaging system;
  • Figs. 7A to 7J depict an embodiment of forming the base panel depicted in Fig. 6A and the sheet panel depicted in Figs. 6B and 6C into a retention packaging system;
  • FIGs. 7K to 7N depict an embodiment of placing the retention packaging system depicted in Figs. 71 and 7J into a container;
  • Figs. 8A and 8B depict top and bottom views, respectively, of an embodiment of a retention package assembly;
  • Figs. 9A, 9B, 9C, and 9D depict, respectively, front, top, back sectional, and front sectional views of a first folded state of the retention packaging assembly depicted in Figs.
  • FIGs. 10A and 10B depict, respectively, front and top views of a second folded state the retention packaging assembly depicted in Figs. 8A and 8B;
  • FIGs. 11 A and 1 IB depict, respectively, front and top views of a third folded state the retention packaging assembly depicted in Figs. 8A and 8B;
  • FIGs. 12A and 12B depict, respectively, front and top views of a fourth folded state the retention packaging assembly depicted in Figs. 8A and 8B;
  • Figs. 13 A and 13B depict an embodiment of placing an object in the retention packaging assembly depicted in Figs. 8A and 8B while the retention packaging assembly is in the fourth folded state;
  • FIGs. 14A and 14B depict, respectively, front and top views of a fifth folded state the retention packaging assembly depicted in Figs. 8A and 8B;
  • FIGs. 15A and 15B depict, respectively, front and top views of a sixth folded state the retention packaging assembly depicted in Figs. 8A and 8B;
  • FIGs. 16A and 16B depict, respectively, front and top views of a final folded state the retention packaging assembly depicted in Figs. 8A and 8B B;
  • Figs. 17A to 17C depict an embodiment, respectively, unfolded and final folded states of a retention packaging assembly.
  • Embodiments of retention packaging systems described herein include multiple pieces, such as a base panel and a web sheet, to form a retention packaging system or suspension packaging system.
  • Base panels, and any of the panels and frames of the various embodiments described herein may comprise a substantially rigid, lightweight, foldable material, for example, a panel, or any of the portions of a panel, may be formed of one or more of any of the following materials: cellulosic-based materials (e.g., cardboard, corrugated cardboard, paperboard), or other repulpable materials such as certain plastics, and compressed foams.
  • a panel may comprise corrugated cardboard such as, any of single-wall B-flute, C-flute, and/or E-flute corrugated cardboard, B/C double-wall corrugated cardboard, and/or E/B double-wall corrugated cardboard.
  • the panel, and any of the panels and frames of the various embodiments described herein may have an average thickness of, for example, at most about, and/or at least about, any of the following thicknesses: 0.75, 1.5, 3.0, 4.6, 6.3,
  • the panels have a minimum bursting strength (per Mullen Bursting Test) of any of non-test, 150, 175, 200, 250, 275, and 350 psi.
  • the panels or frames are repulpable and/or recyclable.
  • the panels or frames are a major component of cellulosic-based materials (e.g., cardboard, corrugated cardboard, paperboard), or other repulpable materials such as certain plastics, and compressed foams.
  • the panels or frames are at least 80 wt%, 85 wt%, 90 wt% or 95 wt% repulpable materials. In some embodiments, the panels or frames are at least 95 wt% cardboard.
  • a web sheet is attached to the panel and extends over (i.e., across) the panel and opening if present.
  • the web sheet may completely cover the panel or may extend over the panel and only partially cover the panel.
  • the web sheet may be attached to panel.
  • the web sheet is attached to the panel by adhering with adhesive; however, the sheet may be attached to the panel, for example, by one or more of any of the following: adhering (e.g., with hot melt adhesive), gluing, heat welding, ultrasonic welding, stapling, tacking, fastening, clipping (see, e.g., U.S.
  • Patent 5,694,744 to Jones which is incorporated herein in its entirety by reference
  • tab/slot engagement see, e.g., U.S. Patent 6,073,761 to Jones, which is incorporated herein in its entirety by reference
  • anchoring, retaining and/or securing see, e.g., U.S. Patent Application Publication 2004/0108239 A1 to McDonald et al. published June 10, 2004, which is incorporated herein in its entirety by reference.
  • the web sheet may be attached to a panel along attachment zones with adhesive.
  • the attachment zones may be discontinuous or periodic, for example by having attachment areas corresponding to the comer regions of the central portion of the panel.
  • the attachment zones may extend continuously to circumscribe or surround the entirety of a panel.
  • the web sheet is attachable to the panel in a number of different locations. This allows the web sheet to be arranged with respect to the panel to accommodate a number of different sizes and/or shapes of objects.
  • adhesives for attaching sheets to frames are known to those of skill in the art, and of course depend on the composition of the materials to be adhered.
  • a polyvinyl alcohol based sheet may be adhered with a polyvinyl acetate emulsion adhesive.
  • adhesives of the pressure-sensitive adhesive class in particular to attach corrugated cardboard of the frame to the box.
  • the assembly can be recycled as a single processing stream without requiring separation of the web sheet from the panel.
  • the term “repulpable” means a sample has a fiber yield from the repulpability test as described in the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill which is at least 80% based on the total weight, or 85% based on the bone dry fiber charge to the pulper.
  • the packaging assembly exceeds the thresholds for repulpability in the preceding paragraph.
  • the packaging assembly has a fiber yield of at least 80.% based on the total weight of the retention packaging assembly as tested in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • the packaging assembly has a fiber yield of at least 90%, 95% or 99% based on the total weight of the retention packaging assembly tested in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • the web sheet surprisingly allows for the entire packaging assembly to be repulpable and also provides necessary physical parameters to retain a product within the packaging assembly.
  • the sheet has an elastic recovery in either or both of the transverse and longitudinal directions of at least any of the following values: 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80% and 85%, measured according to ASTM D5459 at 100% strain, 30 seconds relaxation time, and 60 second recovery time.
  • the web sheet further has an elongation at yield in either or both of the transverse and longitudinal directions of at least any of the following values:200%, 250%, 300%, 350% and 400%, measured according to ASTM D882.
  • the products are consumer goods.
  • the product may be electronic consumer goods include, but are not limited to a mobile electronic device, computer, monitor, television, tablet, phone, e-reader and gaming console.
  • multiple consumer goods are packaged within a single packaging assembly.
  • the web sheet is made predominantly from polyvinyl alcohol polymers and includes a plasticizer yielded the desired result.
  • the web sheet is made from a plasticizer along with a blend of at least two distinct polyvinyl alcohol polymers having a degree of hydrolysis of 98% or more.
  • the polyvinyl alcohol polymer being present in the web sheet in amount from 80-95 wt%.
  • the first polyvinyl alcohol polymer has molecular weight being at least two times, four time, 10 times or 15 times the molecular weight of the second polyvinyl alcohol polymer.
  • the plasticizer being present in amount from 5-20 wt%, 6-15 wt% or from 8-10 wt%.
  • Suitable plasticizers include, polyhydric alcohols, polyethylene glycols, glycerol, diols, triols and blends thereof.
  • polyhydric alcohols polyethylene glycols, glycerol, diols, triols and blends thereof.
  • propylene glycol ethylene glycol, polyethylene glycol, glycerol, sorbitol, mannitol, erythritol, pentaerythritol, dipentaerythritol, trimethylolpropane and di trimethylolpropane.
  • the first polyvinyl alcohol polymer having a higher molecular weight than the second polyvinyl alcohol polymer.
  • the first polyvinyl alcohol polymer being present in the web sheet in a greater wt% than the second polyvinyl alcohol polymer.
  • the blend of polyvinyl alcohol polymers can be present in between any of the following ratio for first polyvinyl alcohol polymer as compared to the second polyvinyl alcohol polymer: 2:1 to 10:1, 3:1 to 7:1, 4:1 to 6:1 or 4.5:1 to 5.5:1. While not being limited to a particular mechanism, it is believed that the blend of plasticized polyvinyl alcohol polymers having distinct molecular weights results in a film having the desired elastic recovery and elongation at yield. Another possible mechanism is to implement physical crosslinks such as through electrostatic or hydrogen bonding interactions.
  • the web sheet may have a composition and thickness providing acceptable performance properties (e.g., flexibility, elasticity, optics, strength) for the given packaging application of expected use.
  • the web sheet may have a thickness of at most any of the following: 10 mils, 6 mils, 5 mils, 4 mils, 3 mils, 2 mils, 1.5 mils, and 1 mil. (A "mil” is equal to 0.001 inch.)
  • the web sheet may also have a thickness of at least any of the following: 0.5 mils, 1 mil, 1.5 mils, 2 mils, and 3 mils.
  • the web sheet further includes effective amounts of additives such as slip or antiblock agents, tackifiers, pigments, processing aids and the like.
  • additives are used in small amounts in the formulation such as to be 0.1-5.0 wt% of the web sheet.
  • the web sheet is essentially free additives such as slip or antiblock agents, tackifiers, pigments, processing aids and the like.
  • the web sheet may be manufactured by thermoplastic film-forming processes known in the art (e.g., tubular or blown-film extrusion, coextrusion, extrusion coating, flat or cast film extrusion).
  • the web sheet may be manufactured by solvent casting. A combination of these processes may also be employed.
  • the web sheet exhibits additional physical characteristics.
  • the web sheet may have a maximum load tear resistance in either or both of the transverse and longitudinal directions of at least any of the following values: 400, 450, 500, 550, and 600 grams force, measured according to ASTM D1004.
  • the web sheet exhibits good tackiness. Tackiness can be assessed by measuring the coefficient of friction in accordance with ASTM D1894 with the stainless steel in contact with the sealant layer.
  • the web sheet exhibits a static peak coefficient of friction of at least any of 0.40, 0.45 or 0.50.
  • the web sheet exhibits a kinetic maximum coefficient of friction of at least any of 0.15, 0.20 or 0.25.
  • the web sheet exhibits a kinetic minimum coefficient of friction of at least any of 0.10, 0.15 or 0.20.
  • the web sheet exhibits a kinetic average coefficient of friction of at least any of 0.15, 0.20 or 0.25.
  • the web sheet may have a slow puncture maximum load of at least any of the following values: 4, 4.5, 5, 5.5, 6, 6.5, and 7 pounds force, measured according to ASTM F1306 using a crosshead speed of 5 inches per minute.
  • the web sheet may have a Young’s modulus sufficient to withstand the expected handling and use conditions, yet may provide a “soft” feel that may be desirable for a packaging application.
  • the sheet may have a Young’s modulus of at least any of the following values: 2,000; 2,500; 3,000; 3,500; and 4,000 pounds/square inch.
  • the web sheet may have a Young’s modulus of no more than about any of the following values: 8,000; 10,000; 15,000; 20,000; 30,000; and 40,000 pounds/square inch.
  • the Young’s modulus is measured in accordance with ASTM D882, measured at a temperature of 73°F.
  • the web sheet may be transparent so that the packaged article (e.g., product 28) may be visible through the sheet.
  • Transparent as used herein means that the material transmits incident light with negligible scattering and little absorption, enabling objects to be seen clearly through the material under typical unaided viewing conditions (i.e., the expected use conditions of the material).
  • the transparency (i.e., clarity) of the web sheet may be at least any of the following values: 65%, 70%, 75%, 80%, 85%, and 90%, measured in accordance with ASTM D1746.
  • the web sheet may be opaque or near opaque to not allow the product to be identified through the web sheet. In embodiments, only a portion of the web sheet is opaque and may be printed. In certain embodiments, the web sheet comprises a pigment. In certain embodiments, the opacity of the microlayer is greater than about 90%. Opacity measures the degree to which a film obscures a pattern passing through it. An opaque material will have 100% opacity, while a near-opaque film is typically above 80% opacity and often above 90% opacity. Color/opacity is measured according to ASTM D6290 the “Standard Test Method for Color Determination of Plastic Pellets”. For example, a Hunter Lab spectrophotometer may be used to measure the degree of color and the extent of opacity of a film.
  • the web sheet may have good haze properties. Film haze values were measured in accordance with ASTM D 1003-00 “Standard Test Method for Haze and Luminous Transmittance of Transparent Plastics”, published July 2000, which is hereby incorporated, in its entirety, by reference thereto. The results are reported herein as “percent haze”.
  • the web sheet can exhibit a haze of less than 15 percent, or less than 14 percent, or less than 13 percent, or less than 12 percent, or less than 11 percent, measured using ASTM D 1003-00.
  • the web sheet may have a heat-shrink attribute.
  • the sheet may have any of a free shrink in at least one direction (i.e., machine or transverse directions), in each of at least two directions (i.e., machine and transverse directions), measured at any of 160°F and 180°F of at least any of the following: 7%, 10%, 15%, 20%, 25%, 30%, 40%,
  • the sheet may be non-heat shrinkable (i.e., has a total free shrink of less than 5% measured at 160°F).
  • each reference to free shrink in this application means a free shrink determined by measuring the percent dimensional change in a 10 cm x 10 cm specimen when subjected to selected heat (i.e., at a certain temperature exposure) according to ASTM D 2732.
  • Exemplary retention packaging systems are depicted in the figures as described herein. It is understood that the web sheets described herein can be used with other retention and suspension packaging systems not depicted in the figures. Additional retention and suspension packaging systems are described in more detail in U.S. Pat. Nos. 4,852,743; 4,923,065; 5,071,009; 5,287,968; 5,388,701; 5,678,695; 5,893,462; 6,010,006; 6,148,590; 6,148,591; 6,289,655; 6,302,274; 6,311,844; 8,714,357; 9,309,024; 9,828,160; 9,868,578; 10,683,154; and 10,947,007, and in U.S. Patent Application Nos. 16/074,205 and 16/311,773 the contents of each which are incorporated herein in their entirety by reference.
  • Fig. 1 A Depicted in Fig. 1 A is a top view of an embodiment of a base panel 110 that is usable as part of a retention packaging system (e.g., retention packaging system 100 described below).
  • the base panel 110 or any portion thereof comprises a substantially rigid, lightweight, foldable material.
  • the base panel 110 is configured to be folded to form a portion of a retention packaging system, example embodiments of which are described below with respect to Figs. 2A to 2J and Figs. 3A to 3J.
  • the base panel 110 includes a first tension flap 112, a second tension flap 114, a first support flap 116, a second support flap 118, and a base portion 120.
  • a first fold line 122 is located between the base portion 120 and the first tension flap 112
  • a second fold line 124 is located between the base portion 120 and the second tension flap 114
  • a third fold line 126 is located between the base portion 120 and the first support flap 116
  • a fourth fold line 128 is located between the base portion 120 and the second support flap 118.
  • a "fold line,” as used herein, represents a line along which a panel, frame, or other material has been creased, crimped, embossed, perforated, scored, or otherwise weakened so as to enhance the foldability of the panel, frame, or other material along the fold line.
  • the first and second tension flaps 112 and 114 are rotatably connected to the base portion 120 by the first and second fold lines 122 and 124, respectively.
  • the first and second support flaps 1 16 and 1 18 are rotatably connected to the base portion 120 by the third and fourth fold lines 126 and 128, respectively.
  • the fold lines depicted in Fig. 1A are dashed lines to represent creased fold lines.
  • the first and second tension flaps 112 and 114 and the first and second support flaps 116 and 118 are rotatably connected to the base portion 120 by creased fold lines (e.g., the first, second, third, and fourth fold lines 122, 124, 126, and 128).
  • fold lines are depicted with long-short-long dashed lines to represent perforated fold lines (e.g., perforated line 166 depicted in Figs. IB and 1C). While the fold lines depicted in the figures may represent particular forms of fold lines, the depicted fold lines could be replaced with any other form of fold lines.
  • Figs. IB and 1C are top and bottom views, respectively, of an embodiment of a sheet panel 140 that is usable as part of a retention packaging system (e.g., retention packaging system 100 described below).
  • the sheet panel 140 or any portion thereof comprises a substantially rigid, lightweight, foldable material, including one or more of the materials described above with respect to base panel 110.
  • the sheet panel 140 includes a first overwrap panel 142 and a second overwrap panel 144.
  • the sheet panel 140 includes at least one detachable portion between the first overwrap panel 142 and the second overwrap panel 144.
  • the at least one detachable portion between the first overwrap panel 142 and the second overwrap panel 144 includes a base reinforcing portion 146, a first detachable portion 148, and a second detachable portion 150.
  • the sheet panel 140 also includes a web sheet 152.
  • the web sheet 152 extends between and is fixedly coupled to the first overwrap panel 142 and the second overwrap panel 144.
  • the sheet web 152 is attached to the first overwrap panel 142 by attachment zones 154 and an attachment zone 155, and the sheet web 152 is attached to the second overwrap panel 144 by an attachment zone 156 and an attachment zone 157.
  • the web sheet 152 is attached to the first overwrap panel 142 by two distinct attachment zones 154 and 155, and the web sheet 152 is attached to the second overwrap panel 144 by two distinct attachment zones 156 and 157.
  • the sheet web 152 is attached to each of the first overwrap panel 142 and the second overwrap panel 144 using either a single attachment zone or any number of distinct attachment zones.
  • the web sheet 152 is attached to the first and second overwrap panels 142 and 144 by adhering with adhesive (e.g., when the attachment zones 154, 155,
  • the attachment zones 154, 155, 156, and 157 may be formed to attach the sheet 152 to the first and second overwrap panels 142 and 144 by one or more of any of the following: adhering (e.g., with hot melt adhesive), gluing, heat welding, ultrasonic welding, stapling, tacking, fastening, clipping (see, e.g., U.S. Pat. No. 5,694,744 to Jones, which is incorporated herein in its entirety by reference), tab/slot engagement (see, e.g., U.S. Pat. No.
  • the base panel 110 and/or the sheet panel 140 may be cut to the desired shapes and provided with fold lines or lines of detachability, using the known types of machinery, for example, to slit, crease, crimp, emboss, perforate, scored, or otherwise weaken the panel in desired regions.
  • attachment zones are applied to the sheet panel 140 in selected areas, for example, the attachment zones 154 and 156 shown in Fig. IB.
  • the sheet 152 is attached to the first and second overwrap panels 142 and 144 by laminating or adhering the sheet 152 with adhesive to the first and second overwrap panels 142 and 144.
  • the material of the sheet 152 is provided in roll form or unrolled form, and then cut to the desired length and width either before or after attachment to the first and second overwrap panels 142 and 144.
  • the sheet panel 140 further includes a first liner 158 on the first overwrap panel 142 and a second liner 160 on the second overwrap panel 144.
  • the first liner 158 covers a first attachment zone (not visible in Figs. IB and 1C) and the second liner 160 covers a second attachment zone (not visible in Figs. IB and 1C).
  • the first attachment zone is configured to attach the first overwrap panel 142 of the sheet panel 140 to the first tension flap 112 of the base panel 110 and the second attachment zone is configured to attach the second overwrap panel 144 of the sheet panel 140 to the second tension flap 114 of the base panel 110.
  • the first overwrap panel 142 includes fold lines 162 and 163, and the second overwrap panel 144 includes fold lines 164 and 165.
  • the first and second overwrap panels 142 and 144 are configured to be folded about one or more of the fold lines 162, 163, 164, and 165.
  • the fold lines 162 and 164 are usable to align the first and second overwrap panels 142 and 144 with respect to the first and second tension flaps 112 and 114 when attaching the first and second overwrap panels 142 and 144 to the first and second tension flaps 112 and 114.
  • the sheet panel 140 includes a perforation line 166 between the first overwrap panel 142 and the first detachable portion 148, a perforation line 168 between the first detachable portion 148 and the base reinforcing portion 146, a perforation line 170 between the second overwrap panel 144 and the second detachable portion 150, and a perforation line 172 between the second detachable portion 150 and the base reinforcing portion 146.
  • the perforation lines 166, 168, 170, and 172 are formed such that the perforation lines 166, 168, 170, and 172 are capable of being broken by hand (i.e., broken without the use of a tool, such as a box cutter). In this way, the base reinforcing portion 146, the first detachable portion 148, and the second detachable portion 150 are able to be detached from the first and second overwrap panels 142 and 144 by hand. [0073] In some embodiments, the base panel 110 and the sheet panel 140 are provided in a lay -flat configuration, such as in the configuration shown in Figs. 1 A to 1 C.
  • the base panel 110 may be provided with the first and second tension flaps 112 and 114 and the first and second support flaps 116 and 118 in an unfolded position, with each being generally coplanar with the base portion 120. Further, the perforation lines 166, 168, 170, and 172 are not yet broken. Such configurations may facilitate the provision of multiple base panels and multiple sheet panels in a convenient stacked or bundled arrangement (not illustrated). In some embodiments, the base panels and the sheet panels are supplied separately before being used to form a retention packaging system.
  • the base panel 110 and the sheet panel 140 are usable as part of a retention packaging system.
  • One embodiment of forming the base panel 110 and the sheet panel 140 in a retention packaging system 100 is depicted in Figs. 2A to 2J. More specifically, Figs. 2A and 2B depict top views of embodiments of forming the retention packaging system 100
  • FIGS. 2C and 2D depict top and front views, respectively, of an embodiment of forming the retention packaging system 100
  • Figs. 2E and 2F depict top and front views, respectively, of an embodiment of forming the retention packaging system 100;
  • Figs. 2G and 2H depict top and front views, respectively, of an embodiment of forming the retention packaging system 100; and Figs. 21 and 2J depict top and front views, respectively, of an embodiment of forming the retention packaging system 100.
  • the first detachable portion 148 has been removed from the first overwrap panel 142 and the base reinforcing portion 146.
  • the second detachable portion 150 has been removed from the second overwrap panel 144 and the base reinforcing portion 146.
  • the first detachable portion 148 is removed from the first overwrap panel 142 and the base reinforcing portion 146 by breaking the perforated lines 166 and 168.
  • the second detachable portion 150 is removed from the second overwrap panel 144 and the base reinforcing portion 146 by breaking the perforated lines 170 and 172.
  • the first and second overwrap panels 142 and 144 are discarded (e.g., recycled) after the embodiment depicted in Fig. 2A.
  • the first and second detachable portions 148 and 150 have been discarded.
  • the base reinforcing portion 146 has been withdrawn from the first and second overwrap panels 142 and 144 and the sheet 152.
  • the sheet 152 is made from a flexible material such that, in the embodiments shown in Figs. 2A and 2B, the first and second overwrap panels 142 and 144 are not in a fixed position with respect to each other.
  • the first liner 158 is removed from a first attachment zone 174 and the second liner 160 is removed from a second attachment zone 176.
  • the first attachment zone 174 is configured to attach the first overwrap panel 142 of the sheet panel 140 to the first tension flap 112 of the base panel 110.
  • the second attachment zone 176 is configured to attach the second overwrap panel 144 of the sheet panel 140 to the second tension flap 114 of the base panel 110.
  • the base reinforcing portion 146 is placed on the base portion 120 of the base panel 110. Adding the base reinforcing portion 146 to the base portion 120 adds to the strength and rigidity of the base portion 120 such that the base portion 120 is less likely to be deformed during formation and use of the retention packaging system 100. In some embodiments, the use of the base reinforcing portion 146 in addition to the base portion 120 allows the base portion 120 to be thinner than otherwise would be required to prevent deformation of the base portion 120 during formation and use of the retention packaging system 100.
  • the first and second overwrap panels 142 and 144 of the sheet panel 140 have been attached to the first and second tension flaps 112 and 114, respectively.
  • the location of the attachment of the first overwrap panel 142 on the first tension flap 112 and the location of the attachment of the second overwrap panel 144 on the second tension flap 114 are selected based on one or more of a size of an object or a desired tension in the sheet 152. In the embodiment shown in Figs.
  • the first overwrap panel 142 has been folded about the fold line 163 between the attachment zones 154 and 155
  • the second overwrap panel 144 has been folded about the fold lines 165 between the attachment zones 156 and 157.
  • the location of the attachment of the first and second overwrap panels 142 and 144 on the first and second tension flaps 112 and 114 causes the sheet 152 to be taut. It also causes the first and second tension flaps 112 and 114 to be rotated up at an angle about the first and second fold lines 122 and 124, respectively.
  • an object 180 is placed between the web sheet 152 and the base portion 120.
  • the object 180 is placed between the base reinforcing portion 146 and the sheet 152.
  • the object 180 is a box; however, the object 180 can be any type or form of an object.
  • the location of the atachment of the first overwrap panel 142 on the first tension flap 112 and the location of the atachment of the second overwrap panel 144 on the second tension flap 114 is selected based on a size of the object 180 (e.g., the height of the object 180).
  • the fold line 163 is aligned with the left end of the first tension flap 112 when the first overwrap panel 142 is atached to the first tension flap 112 and the fold line 165 is aligned with the right end of the second tension flap 114 when the second overwrap panel 144 is atached to the second tension flap 114.
  • the alignments of the fold line 163 with the left end of the first tension flap 112 and the fold line 165 with the right end of the second tension flap 114 are selected based on a size and/or height of the object 180.
  • the first and second tension flaps 112 and 114 have been rotated down about the first and second fold lines 122 and 124, respectively, until the first and second tension flaps 112 and 114 are below the base portion 120. Because the first and second overwrap panels 142 and 144 are atached to the first and second tension flaps 112 and 114, the first and second overwrap panels 142 and 144 are also located below the base portion 120. The web sheet 152 has been pulled tight over the object 180, such that the object 180 is biased toward the base reinforcing portion 146 and the base portion 120. In this way, the object 180 is retained by the retention packaging system 100.
  • the first and second tension flaps 112 and 114 are not folded back until the first and second tension flaps 112 and 114 and/or the first and second overwrap panels 142 and 144 are flush against the botom of the base portion 120.
  • the position of the first and second tension flaps 112 and 114 and the first and second overwrap panels 142 and 144 may be helpful, depending on the size of a container into which the retention packaging system 100 will be placed or a desired shock absorbance of the botom of the retention packaging system 100.
  • the first and second support flaps 116 and 118 have been folded toward the object 180 about the fold lines 126 and 128, respectively. Rotating the first and second support flaps 116 and 118 in this manner provides structural stability to the retention packaging system 100 and provides protection to the sides of the object 180. In this position, the retention packaging system 100, with the object 180 retained inside, is capable of being placed into a container.
  • FIGs. 2K to 2N depict top and side sectional views, respectively, of the retention packaging system 100 in the container 190 when the container 190 is in an open position.
  • Figs. 2M and 2N depict top and side sectional views, respectively, of the retention packaging system 100 in the container 190 when the container 190 is in a closed position.
  • the container includes top flaps 191 and sides 192. In the open position, the top flaps 191 are in a position that allows the retention packaging system 100 to be inserted into the container 190. In the closed position, the top flaps 191 are in a position that prevents the retention packaging system 100 from being removed from the container 190.
  • the first and second support flaps 1 16 and 1 18 act as a guide to position the retention packaging system 100 with respect to the sides 192 of the container 190.
  • the container 190 has dimensions (e.g., a width, a length, and a height) selected based on the dimensions of the retention packaging system 100 shown in the sixth instance in Figs. 21 and 2J.
  • the container 190 has inner dimensions (e.g., height, width, and depth) that are based on the outer dimensions of the retention packaging system 100 in the condition shown in the sixth instance.
  • FIG. 3 A to 3J Another embodiment of forming the base panel 110 and the sheet panel 140 into a retention packaging system 102 is depicted in Figs. 3 A to 3J. More specifically, Figs. 3 A and 3B depict top views of embodiments of forming the retention packaging system 102; Figs. 3C and 3D depict top and front views, respectively, of an embodiment of forming the retention packaging system 102; Figs. 3E and 3F depict top and front views, respectively, of an embodiment of forming the retention packaging system 102; Figs. 3G and 3H depict top and front views, respectively, of an embodiment of forming the retention packaging system 102; and Figs. 31 and 3J depict top and front views, respectively, of an embodiment of forming the retention packaging system 102.
  • the first detachable portion 148 and the second detachable portion 150 have been detached from the first overwrap panel 142, the second overwrap panel 144, and the base reinforcing portion 146.
  • the first and second detachable portions 148 and 150 have been discarded.
  • the base reinforcing portion 146 has been withdrawn from the first and second overwrap panels 142 and 144 and the web sheet 152.
  • the first liner 158 is removed from the first attachment zone 174 and the second liner 160 is removed from the second attachment zone 176.
  • the base reinforcing portion 146 is placed on the base portion 120 of the base panel 110.
  • the first and second overwrap panels 142 and 144 of the sheet panel 140 have been attached to the first and second tension flaps 112 and 114, respectively.
  • the first overwrap panel 142 has been folded about the fold line 162 and the second overwrap panel 144 has been folded about the fold line 164.
  • the fold line 162 was aligned with the left end of the first tension flap 112 when the first overwrap panel 142 was attached to the first tension flap 112 and the fold line 164 was aligned with the right end of the second tension flap 114 when the second overwrap panel 144 was attached to the second tension flap 114.
  • the location of the attachment of the first and second overwrap panels 142 and 144 on the first and second tension flaps 112 and 114 causes the sheet 152 to be somewhat slack, as compared with the embodiment shown in Fig. 2D.
  • first and second tension flaps 112 and 114 It also causes the first and second tension flaps 112 and 114 to be rotated up at an angle about the first and second fold lines 122 and 124, respectively.
  • the angle of the first and second tension flaps 112 and 114 shown in Fig. 3D is closer to horizontal than the angle of the first and second tension flaps 112 and 114 shown in Fig. 2D.
  • an object 182 is placed between the web sheet 152 and the base portion 120.
  • the object 182 is placed between the base reinforcing portion 146 and the embodiment sheet 152.
  • the embodiment sheet 152 is lifted upward to allow insertion of the object 182 between the embodiment sheet 152 and the base portion 120.
  • the object 182 is taller than the object 180.
  • the location of the attachment of the first overwrap panel 142 on the first tension flap 112 and the location of the attachment of the second overwrap panel 144 on the second tension flap 114 is selected based on a size of the object 182 (e.g., the height of the object 180).
  • the fold line 162 is aligned with the end of the first tension flap 112 when attaching the first overwrap panel 142 to the first tension flap 112 and the fold line 164 is aligned with the end of the first tension flap 112 when attaching the second overwrap panel 144 to the second tension flap 114 based on a size of the object 182.
  • the first and second tension flaps 112 and 114 have been rotated down about the first and second fold lines 122 and 124, respectively, until the first and second tension flaps 112 and 114 are below the base portion 120. Because the first and second overwrap panels 142 and 144 are attached to the first and second tension flaps 112 and 114, the first and second overwrap panels 142 and 144 are also located below the base portion 120. The sheet 152 has been pulled tight over the object 182, such that the object 182 is biased toward the base reinforcing portion 146 and the base portion 120. In this way, the object 182 is retained by the retention packaging system 102.
  • the same base panel 110 and sheet panel 140 are capable of being used to retain different sizes of objects (e.g., object 180 and object 182).
  • This ability to retain different sizes of objects using the same base panel 110 and sheet panel 140 is made possible, at least in part, by the ability to attach the first overwrap panel 142 to the first tension flap 112 and the second overwrap panel 144 to the second tension flap 114 in different locations.
  • the first and second support flaps 116 and 118 have been folded toward the obj ect 182 about the third and fourth fold lines 126 and 128, respectively. Rotating the first and second support flaps 116 and 118 in this manner provides structural stability to the retention packaging system 102 and provides protection to the sides of the object 182. In this position, the retention packaging system 102, with the object 182 retained inside, is capable of being placed into a container.
  • FIGs. 3K to 3N depict top and side sectional views, respectively, of the retention packaging system 102 in the container 194 when the container 194 is in an open position.
  • Figs. 3M and 3N depict top and side sectional views, respectively, of the retention packaging system 102 in the container 194 when the container 194 is in a closed position.
  • the container includes top flaps 195 and sides 196. In the open position, the top flaps 195 are in a position that allows the retention packaging system 102 to be inserted into the container 194. In the closed position, the top flaps 195 are in a position that prevents the retention packaging system 102 from being removed from the container 194.
  • the first and second support flaps 116 and 118 act as a guide to position the retention packaging system 102 with respect to the sides 196 of the container 194.
  • the container 194 has dimensions (e.g., a width, a length, and a height) selected based on the dimensions of the retention packaging system 102 shown in the sixth instance in Figs. 31 and 3J.
  • the container 194 has inner dimensions (e.g., height, width, and depth) that are based on the outer dimensions of the retention packaging system 102 in the condition shown in the sixth instance.
  • Fig. 4A is a top view of another embodiment of a base panel 210 that is usable as part of a retention packaging system (e.g., retention packaging system 200 described below).
  • the base panel 210 or any portion thereof comprises a substantially rigid, lightweight, foldable material, such as any of the materials described above with respect to base panel 1 10.
  • the base panel 210 is configured to be folded to form a portion of a retention packaging system, example embodiments of which are described below with respect to Figs. 5A to 5J.
  • the base panel 210 includes a first tension flap 212, a second tension flap 214, a first support flap 216, a second support flap 218, and a base portion 220.
  • a first fold line 222 is located between the base portion 220 and the first tension flap 212
  • a second fold line 224 is located between the base portion 220 and the second tension flap 214
  • a third fold line 226 is located between the base portion 220 and the third tension flap 216
  • a fourth fold line 228 is located between the base portion 220 and the second support flap 218.
  • the first and second tension flaps 212 and 214 are rotatably connected to the base portion 220 by the first and second fold lines 222 and 224, respectively.
  • the first and second support flaps 216 and 218 are rotatably connected to the base portion 220 by the third and fourth fold lines 226 and 228, respectively.
  • Figs. 4B and 4C are top and bottom views, respectively, of an embodiment of a sheet panel 240 that is usable as part of a retention packaging system (e.g., retention packaging system 200 described below).
  • the sheet panel 240 or any portion thereof comprises a substantially rigid, lightweight, foldable material, including one or more of the materials described above with respect to base panel 110.
  • the sheet panel 240 includes a first overwrap panel 242, a second overwrap panel 244, and a central panel 246.
  • sheet panel 240 includes at least one detachable portion between the first overwrap panel 242 and the second overwrap panel 244.
  • at least one detachable portion between the first overwrap panel 242 and the second overwrap panel 244 includes a first detachable portion 248 and a second detachable portion 250.
  • the sheet panel 240 also includes a sheet 252.
  • the sheet 252 extends between and is fixedly coupled to the first overwrap panel 242, the central panel 246, and the second overwrap panel 244.
  • the sheet 252 is attached to the first overwrap panel 242 by an attachment zone 254
  • the sheet 252 is attached to the second overwrap panel 244 by an attachment zone 256
  • the sheet 252 is attached to the central panel 246 by attachment zones 255 and 257.
  • the sheet 252 is attached to the first and second overwrap panels 242 and 244and the central panel 246 by adhering with adhesive (e.g., when the attachment zones 254 and 256 include adhesive).
  • attachment zones 254, 255, 256, and 257 may be formed to attach the sheet 252 to the first and second overwrap panels 242 and 244 and the central panel 246 by one or more of any of the following: adhering, gluing, heat welding, ultrasonic welding, stapling, tacking, fastening, clipping, tab/slot engagement, anchoring, retaining, and/or securing.
  • the sheet panel 240 further includes a first liner 258 on the first overwrap panel 242 and a second liner 260 on the second overwrap panel 244.
  • the first liner 258 covers a first attachment zone (not visible in Figs. 4B and 4C) and the second liner 260 covers a second attachment zone (not visible in Figs. 4B and 4C).
  • the first attachment zone is configured to attach the first overwrap panel 242 of the sheet panel 240 to the first tension flap 212 of the base panel 210.
  • the second attachment zone is configured to attach the second overwrap panel 244 of the sheet panel 240 to the second tension flap 214 of the base panel 210.
  • the first overwrap panel 242 includes a fold line 262 and the second overwrap panel 244 includes a fold line 264.
  • the first and second overwrap panels 242 and 244 are configured to be folded about the fold lines 262 and 264.
  • the fold lines 262 and 264 are usable to align the first and second overwrap panels 242 and 244 with respect to the first and second tension flaps 212 and 214 when attaching the first and second overwrap panels 242 and 244to the first and second tension flaps 212 and 214.
  • the sheet panel 240 includes a perforation line 266 between the first overwrap panel 242 and the first detachable portion 248, a perforation line 268 between the first detachable portion 248 and the central panel 246, a perforation line 270 between the second overwrap panel 244 and the second detachable portion 250, and a perforation line 272 between the second detachable portion 250 and the central panel 246.
  • the perforation lines 266, 268, 270, and 272 are formed such that the perforation lines 266, 268, 270, and 272 are capable of being broken by hand.
  • the base panel 210 and the sheet panel 240 are provided in a lay-flat configuration, such as in the configuration shown in Figs. 4A to 4C.
  • the base panel 210 may be provided with the first and second tension flaps 212 and 214 and the first and second support flaps 216 and 218 in an unfolded position, with each being generally coplanar with the base portion 220.
  • the perforation lines 266, 268, 270, and 272 are not yet broken.
  • Such configurations may facilitate the provision of multiple base panels and multiple sheet panels in a convenient stacked or bundled arrangement (not illustrated).
  • the base panels and the sheet panels are supplied separately before being used to form a retention packaging system.
  • the base panel 210 and the sheet panel 240 are usable as part of a retention packaging system.
  • One embodiment of forming the base panel 210 and the sheet panel 240 in a retention packaging system 200 is depicted in Figs. 5A to 5J. More specifically, Figs. 5A and 5B depict top views of embodiments of a first instance and a second instance, respectively, of forming the retention packaging system 200; Figs. 5C and 5D depict top and front views, respectively, of a third instance of forming the retention packaging system 200; Figs. 5E and 5F depict top and front views, respectively, of a fourth instance of forming the retention packaging system 200; Figs. 5G and 5H depict top and front views, respectively, of an embodiment of forming the retention packaging system 200; and Figs. 51 and 5J depict top and front views, respectively, of an embodiment of forming the retention packaging system 200.
  • the first detachable portion 248 has been removed from the first overwrap panel 242 and the central panel 246.
  • the second detachable portion 250 has been removed from the second overwrap panel 244 and the central panel 246.
  • the first detachable portion 248 is removed from the first overwrap panel 242 and the central panel 246 by breaking the perforated lines 266 and 268.
  • the second detachable portion 250 is removed from the second overwrap panel 244 and the central panel 246 by breaking the perforated lines 270 and 272.
  • the first and second detachable portions 248 and 250 are discarded (e.g., recycled) after the first instance depicted in Fig. 5A.
  • the first and second detachable portions 248 and 250 have been discarded.
  • the first liner 258 is removed from a first attachment zone 274 and the second liner 260 is removed from a second attachment zone 276.
  • the first attachment zone 274 is configured to attach the first overwrap panel 242 of the sheet panel 240 to the first tension flap 212 of the base panel 210.
  • the second attachment zone 276 is configured to attach the second overwrap panel 244 of the sheet panel 240 to the second tension flap 214 of the base panel 210.
  • the first and second overwrap panels 242 and 244 of the sheet panel 240 have been attached to the first and second tension flaps 212 and 214, respectively.
  • the first overwrap panel 242 has been folded about the fold line 262 and the second overwrap panel 244 has been folded about the fold line 264.
  • the fold line 262 is aligned with left the end of the first tension flap 212 when the first overwrap panel 242 is attached to the first tension flap 212 and the fold line 264 is aligned with the right end of the second tension flap 214 when the second overwrap panel 244 is attached to the second tension flap 214.
  • the central panel 246 is held by the sheet 252 over the base portion 220. It also causes the first and second tension flaps 212 and 214 to be rotated up at an angle about the first and second fold lines 222 and 224, respectively.
  • an object 280 is placed between the sheet 252 and the base portion 220.
  • the object 280 is a box; however, the object 280 can be any type or form of an object.
  • the sheet 252 and/or the central panel 246 is lifted upward to allow insertion of the object 280 between the sheet 252 and the base portion 220.
  • the first and second tension flaps 212 and 214 have been rotated down about the first and second fold lines 222 and 224, respectively, until the first and second tension flaps 212 and 214 are below the base portion 220. Because the first and second overwrap panels 242 and 244are attached to the first and second tension flaps 212 and 214, the first and second overwrap panels 242 and 244are also located below the base portion 220. The sheet 252 has been pulled tight over the object 280, such that the object 280 is biased toward the base portion 220. In this way, the object 280 is retained by the retention packaging system 200.
  • the sheet 252 stretches between the attachment zones 254 and 255 and the sheet 252 stretches between the attachment zones 256 and 257.
  • the portion of the sheet between the attachment zones 255 and 257 does not stretch substantially. This allows the sheet to be stretched over particular portions of the object 280 without having to stretch across the entirety of the object 280.
  • the distance between one or more of attachment zones 254 and 255, attachment zones 255 and 257, or attachment zones 256 and 257 is selected based on a desired stretch location of the sheet 252, an amount of desired tension in the sheet 252, or a size of the object 280.
  • Having multiple stretch zones in the sheet 252 may also better retain the object 280 if the sheet 252 is stretched at particular locations of the object 280 (e.g., at comers of the object 280 as shown in Fig. 5H) and not stretched over other locations of the object 280 (e.g. across a center portion of the top of the object 280 as shown in Fig. 5H).
  • the first and second support flaps 216 and 218 have been folded toward the object 280 about the third and fourth fold lines 226 and 228, respectively. Rotating the first and second support flaps 216 and 218 in this manner provides structural stability to the retention packaging system 200 and provides protection to the sides of the object 280. In this position, the retention packaging system 200, with the object 280 retained inside, is capable of being placed into a container.
  • FIG. 5K to 5N depict top and side sectional views, respectively, of the retention packaging system 200 in the container 290 when the container 290 is in an open position.
  • Figs. 5M and 5N depict top and side sectional views, respectively, of the retention packaging system 200 in the container 290 when the container 290 is in a closed position.
  • the container 290 includes top flaps 291 and sides 292. In the open position, the top flaps 291 are in a position that allows the retention packaging system 200 to be inserted into the container 290. In the closed position, the top flaps 291 are in a position that prevents the retention packaging system 200 from being removed from the container 290.
  • the first and second support flaps 216 and 218 act as a guide to position the retention packaging system 200 with respect to the sides 292 of the container 290.
  • the container 290 has dimensions (e.g., a width, a length, and a height) selected based on the dimensions of the retention packaging system 200 shown in the sixth instance in Figs. 51 and 5J.
  • the container 290 has inner dimensions (e.g., height, width, and depth) that are based on the outer dimensions of the retention packaging system 200 in the condition shown in the sixth instance.
  • one or more dimensions of the base panel 210 and/or the sheet panel 240 are selected based on a size of the object.
  • a width of the first support flap 216 i.e., the distance from the third fold line 226 to the edge of the first support flap 216 at the bottom of the depiction in Fig. 4A
  • a width of the second support flap 218 i.e., the distance from the fourth fold line 228 to the edge of the second support flap 218 at the top of the depiction in Fig. 4A
  • a width of the first tension flap 212 i.e., the distance from the first fold line 222 to the edge of the first tension flap 212 at the left of the depiction in Fig. 4A
  • a width of the second tension flap 214 i.e., the distance from the second fold line 224 to the edge of the second tension flap 214 at the right of the depiction in Fig. 4A
  • the widths of the first and second support flaps 216 and 218 are greater than the widths of the first and second tension flaps 212 and 214.
  • Fig. 6A is a top view of another embodiment of a base panel 310 that is usable as part of a retention packaging system (e.g., retention packaging system 300 described below).
  • the base panel 310 or any portion thereof comprises a substantially rigid, lightweight, foldable material, such as any of the materials described above with respect to base panel 110.
  • the base panel 310 is configured to be folded to form a portion of a retention packaging system, example embodiments of which are described below with respect to Figs. 7A to 7J.
  • the base panel 310 includes a first tension flap 312, a second tension flap 314, a first support flap 316, a second support flap 318, and a base portion 320.
  • a first fold line 322 is located between the base portion 320 and the first tension flap 312, a second fold line 324 is located between the base portion 320 and the second tension flap 314, a third fold line 326 is located between the base portion 320 and the first support flap 316, and a fourth fold line 328 is located between the base portion 320 and the second support flap 318.
  • the first and second tension flaps 312 and 314 are rotatably connected to the base portion 320 by the first and second fold lines 322 and 324, respectively.
  • the first and second support flaps 316 and 318 are rotatably connected to the base portion 320 by the third and fourth fold lines 326 and 328, respectively.
  • Figs. 6B and 6C are top and bottom views, respectively, of an embodiment of a sheet panel 340 that is usable as part of a retention packaging system (e.g., retention packaging system 300 described below).
  • the sheet panel 340 or any portion thereof comprises a substantially rigid, lightweight, foldable material, including one or more of the materials described above with respect to base panel 110.
  • the sheet panel 340 includes a first overwrap panel 342 and a second overwrap panel 344.
  • sheet panel 340 includes at least one detachable portion between the first overwrap panel 342 and the second overwrap panel 344.
  • at least one detachable portion between the first overwrap panel 342 and the second overwrap panel 344 includes a base reinforcing portion 346.
  • the sheet panel 340 also includes a sheet 352.
  • the sheet 352 extends between and is fixedly coupled to the first overwrap panel 342 and the second overwrap panel 344.
  • the sheet 352 is attached to the first overwrap panel 342 by an attachment zone 354 and the sheet 352 is attached to the second overwrap panel 344 by an attachment zone 356.
  • the sheet 352 is attached to the first and second overwrap panels 342 and 344 by adhering with adhesive (e.g., when the attachment zones 354 and 356 include adhesive).
  • the attachment zones 354 and 356 may be formed to attach the sheet 352 to the first and second overwrap panels 342 and 344 and the base reinforcing portion 346 by one or more of any of the following: adhering, gluing, heat welding, ultrasonic welding, stapling, tacking, fastening, clipping, tab/slot engagement, anchoring, retaining, and/or securing.
  • the sheet panel 340 further includes a first liner 358 on the first overwrap panel 342 and a second liner 360 on the second overwrap panel 344.
  • the first liner 358 covers a first attachment zone (not visible in Figs. 6B and 6C) and the second liner 360 covers a second attachment zone (not visible in Figs. 6B and 6C).
  • the first attachment zone is configured to attach the first overwrap panel 342 of the sheet panel 340 to the first tension flap 312 of the base panel 310.
  • the second attachment zone is configured to attach the second overwrap panel 344 of the sheet panel 340 to the second tension flap 314 of the base panel 310. In the embodiment shown in Figs.
  • the first and second attachment zones covered by the first and second liners 358 and 360 are on one side of the first and second overwrap panels 342 and 344, and the sheet 352 is attached via the attachment zones 354 and 356 to the other side of the first and second overwrap panels 342 and 344.
  • the first overwrap panel 342 includes fold lines 362 and 363 and the second overwrap panel 344 includes fold lines 364 and 365.
  • the first and second overwrap panels 342 and 344 are configured to be folded about the fold lines 362 and 364.
  • the fold lines 362, 363, 364, and 365 are usable to align the first and second overwrap panels 342 and 344 with respect to the first and second tension flaps 312 and 314 when attaching the first and second overwrap panels 342 and 344 to the first and second tension flaps 312 and 314.
  • the sheet panel 340 includes a perforation line 366 between the first overwrap panel 342 and the base reinforcing portion 346 and a perforation line 370 between the second overwrap panel 344 and the base reinforcing portion 346.
  • the perforation lines 366 and 370 are formed such that the perforation lines 366 and 370 are capable of being broken by hand.
  • the base panel 310 and the sheet panel 340 are provided in a lay -flat configuration, such as in the configuration shown in Figs. 6A to 6C.
  • the base panel 310 may be provided with the first and second tension flaps 312 and 314 and the first and second support flaps 316 and 318 in an unfolded position, with each being generally coplanar with the base portion 320.
  • the perforation lines 366 and 370 are not yet broken.
  • Such configurations may facilitate the provision of multiple base panels and multiple sheet panels in a convenient stacked or bundled arrangement (not illustrated).
  • the base panels and the sheet panels are supplied separately before being used to form a retention packaging system.
  • the base panel 310 and the sheet panel 340 are usable as part of a retention packaging system.
  • One embodiment of forming the base panel 310 and the sheet panel 340 in a retention packaging system 300 is depicted in Figs. 7A to 7J. More specifically, Figs. 7A and 7B depict top views of embodiments of embodiments of forming the retention packaging system 300; Figs. 7C and 7D depict top and front views, respectively, of an embodiment of forming the retention packaging system 300; Figs. 7E and 7F depict top and front views, respectively, of an embodiment of forming the retention packaging system 300; [0125] Figs. 7G and 7H depict top and front views, respectively, of an embodiment of forming the retention packaging system 300; and Figs. 71 and 7J depict top and front views, respectively, of an embodiment of forming the retention packaging system 300.
  • the base reinforcing portion 346 has been detached from the first overwrap panel 342 and the second overwrap panel 344.
  • the base reinforcing portion 346 has been placed on the base portion 320.
  • the first liner 358 is removed from the first attachment zone 374 and the second liner 360 is removed from the second attachment zone 376.
  • the first and second overwrap panels 342 and 344 of the sheet panel 340 have been attached to the first and second tension flaps 312 and 314, respectively.
  • the first overwrap panel 342 has been folded about the fold lines 362 and 363, and the fold line 362 is aligned with the left end of the first tension flap 312.
  • the second overwrap panel 344 has been folded about the fold lines 364 and 365, and the fold line 365 is aligned with the right end of the second tension flap 314.
  • the location of the attachment of the first and second overwrap panels 342 and 344 on the first and second tension flaps 312 and 314 causes the sheet 352 to be somewhat slack. It also causes the first and second tension flaps 312 and 314 to be rotated up at an angle about the first and second fold lines 322 and 324, respectively. In addition, the sheet 352 is attached to the outer sides of the first and second overwrap panels 342 and 344.
  • an object 380 is placed between the sheet 352 and the base portion 320.
  • the object 380 is placed between the base reinforcing portion 346 and the sheet 352.
  • the web sheet 352 is lifted upward to allow insertion of the object 380 between the web sheet 352 and the base portion 320.
  • the location of the attachment of the first overwrap panel 342 on the first tension flap 312 and the location of the attachment of the second overwrap panel 344 on the second tension flap 314 is selected based on a size of the object 380 (e.g., the height of the object 380).
  • the fold line 362 is selected to be aligned with the left end of the first tension flap 312 when attaching the first overwrap panel 342 to the first tension flap 312 and the fold line 364 is selected to be aligned with the right end of the second tension flap 314 when attaching the second overwrap panel 344 to the second tension flap 314 based on a size of the object 380.
  • first and second tension flaps 312 and 314 have been rotated down about the first and second fold lines 322 and 324, respectively, until the first and second tension flaps 312 and 314 are below the base portion 320. Because the first and second overwrap panels 342 and 344 are attached to the first and second tension flaps 312 and 314, portions of the first and second overwrap panels 342 and 344 are also located below the base portion 320. In the depicted embodiment, a portion of each of the first and second overwrap panels 342 and 344 is located above the base portion 320 along sides of the object 380.
  • first and second overwrap panels 342 and 344 strengthen the first and second fold lines 322 and 324. This strengthening reduces the possibility of false scoring of the base portion 320 due to the force of the tension in the sheet 352.
  • the sheet 352 has been pulled tight over the object 380, such that the object 380 is biased toward the base reinforcing portion 346 and the base portion 320. In this way, the object 380 is retained by the retention packaging system 300.
  • the first and second support flaps 316 and 318 have been folded toward the object 380 about the third and fourth fold lines 326 and 328, respectively. Rotating the first and second support flaps 316 and 318 in this manner provides structural stability to the retention packaging system 300 and provides protection to the sides of the object 380. In this position, the retention packaging system 300, with the object 380 retained inside, is capable of being placed into a container.
  • FIGs. 7K to 7N depict top and side sectional views, respectively, of the retention packaging system 300 in the container 390 when the container 390 is in an open position.
  • Figs. 7M and 7N depict top and side sectional views, respectively, of the retention packaging system 300 in the container 390 when the container 390 is in a closed position.
  • the container 390 includes top flaps 391 and sides 392. In the open position, the top flaps 391 are in a position that allows the retention packaging system 300 to be inserted into the container 390. In the closed position, the top flaps 391 are in a position that prevents the retention packaging system 300 from being removed from the container 390.
  • the first and second support flaps 316 and 318 act as a guide to position the retention packaging system 300 with respect to the sides 392 of the container 390.
  • the container 390 has dimensions (e.g., a width, a length, and a height) selected based on the dimensions of the retention packaging system 300 shown in the sixth instance in Figs. 51 and 5J.
  • the container 390 has inner dimensions (e.g., height, width, and depth) that are based on the outer dimensions of the retention packaging system 300 in the condition shown in the sixth instance.
  • FIGs. 8A and 8B are top and bottom views, respectively, of an embodiment of a retention package assembly 400.
  • the retention package assembly 400 includes a frame 402.
  • the frame 402 or any portion thereof comprises a substantially rigid, lightweight, foldable material.
  • frame 402, or any of the portions of frame 402 described herein are formed of one or more of any of the following materials: cellulosic-based materials (e.g., cardboard, corrugated cardboard, paperboard) or other repulpable materials such as certain plastics, and compressed foams.
  • cellulosic-based materials e.g., cardboard, corrugated cardboard, paperboard
  • repulpable materials such as certain plastics, and compressed foams.
  • frame 402 may comprise corrugated cardboard, such as any of single-wall B-flute, C-flute, and/or E-flute corrugated cardboard, B/C double-wall corrugated cardboard, E/B double-wall corrugated cardboard, or any combination thereof.
  • the frame 402 is configured to be folded into a container, as shown in the instances from Fig. 9A to Fig. 16B.
  • the frame 402 includes a bottom panel 404, a first front panel 406, a sheet panel 408, a back panel 410, a top panel 412, and a second front panel 414.
  • a fold line is located between each of the bottom panel 404 and the first front panel 406, the first front panel 406 and the sheet panel 408, the bottom panel 404 and the back panel 410, the back panel 410 and the top panel 412, and the top panel 412 and the second front panel 414.
  • Fold lines are depicted in Figs.
  • the bottom panel 404 is foldably connected to the first front panel 406 by a creased fold line.
  • the first front panel 406 is foldably connected to the sheet panel 408 by a fold line that includes two slits in between three partially-perforated portions.
  • the bottom panel 404 is foldably connected to the back panel 410 by a creased fold line.
  • the back panel 410 is foldably connected to the top panel 412 by a creased fold line.
  • top panel 412 is foldably connected to the second front panel 414 by a creased fold line. While the fold lines depicted in Figs. 8A and 8B are particular forms of fold lines, the depicted fold lines could be replaced with any other form of fold lines.
  • the bottom panel 404 is also foldably connected to a left side panel 416 by a creased fold line.
  • the left side panel 416 includes a left side outer portion 418 and a left side inner portion 419.
  • the left side outer portion 418 is foldably connected to the left side inner portion 419 by two fold lines that are partially-perforated fold lines.
  • the left side panel 416 includes a left locking tab 420.
  • the bottom panel 404 includes a left slot 422 configured to receive the left locking tab 420.
  • the left slot 422 is configured to receive the left locking tab 420 when the fold line between the bottom panel 404 and the left side panel 416 and the fold lines between the left side outer portion 418 and the left side inner portion 419 are folded at approximately 90° angles.
  • the bottom panel 404 is also foldably connected to a right side panel 424 by a creased fold line.
  • the right side panel 424 includes a right side outer portion 426 and a right side inner portion 427.
  • the right side outer portion 426 is foldably connected to the right side inner portion 427 by two fold lines that are partially -perforated fold lines.
  • the right side panel 424 includes a right locking tab 428.
  • the bottom panel 404 includes a right slot 430 configured to receive the right locking tab 428.
  • the right slot 430 is configured to receive the right locking tab 428 when the fold line between the bottom panel 404 and the right side panel 424 and the fold lines between the right side outer portion 426 and the right side inner portion 427 are folded at approximately 90° angles.
  • the first front panel 406 is foldably connected to a left first front flap 432 by a creased fold line.
  • the first front panel 406 is also foldably connected to a right first front flap 434 by a creased fold line.
  • the back panel 410 is foldably connected to a left back flap 436 by a creased fold line.
  • the back panel 410 is also foldably connected to a right back flap 438 by a creased fold line.
  • the top panel 412 is foldably connected to a left top flap 440 by a creased fold line.
  • the top panel 412 is also foldably connected to a left attachment flap 442.
  • the left top flap 440 and the left attachment flap 442 are foldably connected to a first end of the top panel 412 (e.g., the left end as shown in Fig. 8A) and are capable of being folded with respect to the top panel 412 independently of each other.
  • the top panel 412 is also foldably connected to a right top flap 444 by a creased fold line.
  • the top panel 412 is also foldably connected to a right attachment flap 446.
  • the right top flap 444 and the right attachment flap 446 are foldably connected to a second end of the top panel 412 (e.g., the right end as shown in Fig. 8A) and are capable of being folded with respect to the top panel 412 independently of each other.
  • the second front panel 414 is foldably connected to a left second front flap 448 by a creased fold line.
  • the second front panel 414 is also foldably connected to a right second front flap 450 by a creased fold line.
  • a liner 452 located over an attachment zone (not visible in Fig. 1A).
  • the liner 452 covers a first portion of the attachment zone located on the top panel 412 and a second portion of the attachment zone located on the left attachment flap 442 and the right attachment flap 446.
  • the attachment zone is a single continuous attachment zone that extends from the left attachment flap 442, to the top panel 412, and to the right attachment flap 446.
  • the liner 452 is capable of being removed to expose the adhesive zone to permit the adhesive zone to be adhered to the sheet panel 408.
  • the sheet panel 408 includes a front flap 454, a back flap 456, and an attachment end 458.
  • the front flap 454 is located between a perforation line 460 and the fold line between the first front panel 406 and the sheet panel 408.
  • the back flap 456 is located between the perforation line 460 and slots 462.
  • the attachment end 458 is located on the end of the sheet panel 408 beyond the slots 462.
  • three partially- perforated fold lines are located between the slots 462 and between each of the slots 462 and the sides of the sheet panel 408.
  • the retention packaging assembly 400 includes a web sheet 464.
  • the web sheet 464 extends from the attachment end 458 of the sheet panel 408 to the first front panel 406.
  • the web sheet 464 is attached to the attachment end 458 of the sheet panel 408 by an attachment zone 466 and the sheet 464 is attached to the first front panel 406 by an attachment zone 468.
  • the both of the attachment zones 466 and 468 include two distinct attachment zones such that one of the attachment zones 466 and 468 is located near the comers of the sheet 464.
  • the attachment zones 466 and 468 can include one single continuous attachment zone or any number of distinct attachment zones.
  • the adhesive zones described herein include an adhesive.
  • the frame 402 is folded from an unfolded state (e.g., the generally coplanar state shown Figs. 8A and 8B) to a first folded state shown in Figs. 9A to 9D.
  • Figs. 9Ato 9D depict, respectively, front, top, back sectional, and front sectional views of the retention packaging assembly 400 in the first folded state.
  • the frame 402 is folded from the first folded state shown in Figs. 9A to 9D to a second folded state shown in Figs. 10A and 10B.
  • Figs. 10A and 10B depict, respectively, front and top views of the retention packaging assembly 400 in the second folded state.
  • the frame 402 is folded from the second folded state shown in Figs. 10A and 10B to a third folded state shown in Figs. 11A and 11B.
  • Figs. 11A and 1 IB depict, respectively, front and top views of the retention packaging assembly 400 in the third folded state.
  • the frame 402 is folded from the third folded state shown in Figs. 11 A and 1 IB to a fourth folded state shown in Figs. 12A and 12B.
  • Figs. 12A and 12B depict, respectively, front and top views of the retention packaging assembly 400 in the fourth folded state.
  • the front flap 454 is separated from the back flap 456 by breaking the perforation line 460.
  • the perforation line 460 is perforated such that a user is capable of breaking the perforation line 460 by pulling the front and back flaps 454 and 456 away from each other by hand. After the perforation line 460 is broken, the front flap 454 remains attached to the first front panel 406 and the back flap 456 remains attached to the top panel 412 via the attachment end 458 and the attachment zone 470.
  • the front flap 454 is rotated upward to a vertical orientation about the fold line between the first front panel 406 and the front flap 454, as shown in Fig. 12A.
  • the back flap 456 is rotated upward to a vertical orientation about one of the fold lines that extend from the slots 462, as shown in Fig. 12A.
  • the sheet 464 is held taught by the attachment zones 468 on the first front panel 406 on one side and by the attachment zones 466 on the attachment end 458 and the attachment zone 470 on the top panel 412 on the other side. In this orientation, the sheet 464 is configured to hold an object at the opening of the container.
  • FIGs. 13A and 13B Depicted in Figs. 13A and 13B is an embodiment of placing an object 472 in the retention packaging assembly 400 while the frame 402 is in the fourth folded state.
  • the object 472 is placed on the exposed portion of the sheet 464, which holds the object 472 at the opening of the container.
  • the position of the front and back flaps 454 and 456 permit placement of the object 472 on the exposed portion of the sheet 464.
  • the object 472 is a cell phone; however, the object 472 may be any other object that fits within the opening of the package.
  • the frame 402 is folded from the fourth folded state shown in Figs. 12A and 12B to a fifth folded state shown in Figs. 14A and 14B.
  • Figs. 14A and 14B depict, respectively, front and top views of the retention packaging assembly 400 in the fifth folded state.
  • the frame 402 is folded from the fifth folded state shown in Figs. 14A and 14B to a sixth folded state shown in Figs. 15A and 15B.
  • Figs. 15A and 15B depict, respectively, front and top views of the retention packaging assembly 400 in the sixth folded state.
  • the frame 402 is folded from the sixth folded state shown in Figs. 15A and 15B to a final folded state shown in Figs. 16A and 16B.
  • Figures 16A and 16B depict, respectively, front and top views of the retention packaging assembly 100 in the final folded state.
  • the retention packaging assembly 400 In the final folded state the retention packaging assembly 400 has been folded into the container in a closed configuration and the object 472 is securely retained within the container.
  • the retention packaging assembly 400 can be used to transport the object 472, such as mailing or shipping the object 472 in the retention packaging assembly 400.
  • FIG. 17A depicts the retention packaging assembly 500 in an unfolded state
  • Fig. 17B depicts the retention packaging assembly 500 in a first folded state
  • Fig. 17C depicts the retention packaging assembly 500 in a second folded state.
  • the retention packaging assembly 500 includes a frame 502.
  • the frame 502 is configured to be folded into a container.
  • the frame 502 includes bottom panels 504, a front panel 506, a sheet panel 508, a back panel 510, a top panel 512, a left side panel 516, and a right side panel 524.
  • a fold line is located between each of the bottom panels 504 and the front panel 506, the back panel 510, the left side panel 516, and the right side panel 524, respectively.
  • a fold line is located between the back panel 510 and the top panel 512, and the fold line is located between the front panel 506 and the sheet panel 508.
  • Each of these fold lines represents a foldable connection point between two panels.
  • the top panel 512 is foldably connected to a left attachment flap 542 and foldably connected to a right attachment flap 5 46.
  • Fig. 17A Depicted in Fig. 17A is a liner 552 located over an attachment zone (not visible in Fig. 17A).
  • the liner 552 covers a first portion of the attachment zone located on the top panel 512 and a second portion of the attachment zone located on the left attachment flap 542 and the right attachment flap 546.
  • the attachment zone is a single continuous attachment zone that extends from the left attachment flap 542, to the top panel 512, and to the right attachment flap 546.
  • the attachment zone includes multiple distinct portions on the left attachment flap 542, the top panel 512, and the right attachment flap 546.
  • the liner 552 is capable of being removed to expose the adhesive zone to permit the adhesive zone to be adhered to an attachment end 558 of the sheet panel 508.
  • the retention packaging assembly 500 includes a sheet 564.
  • the sheet 564 extends from the attachment end 558 of the sheet panel 508 to the front panel 506.
  • the sheet 564 is attached to the attachment end 558 and the front panel 506 by attachment zones near the comers of the sheet 564.
  • the sheet 564 may be attached to the frame 502 in any manner.
  • the sheet 564 may be formed from any of the materials described above with respect to sheet 564.
  • the frame 502 is configured to be folded from the first folded state shown in Fig. 17B to the second folded state shown in Fig. 17C.
  • the attachment end 558 of the sheet panel 508 is attached to the attachment zone 570.
  • a first side of the attachment end 558 is attached to a first portion of the attachment zone 570 on the top panel 512 and a second side of the attachment end 558 is attached to a second portion of the attachment zone 570 on the left and right attachment flaps 542 and 546.
  • the sheet 564 also spans from the first side of the opening (i.e., at the top of the front panel 506) to a second side of the opening (i.e., at the top of the back panel 510).
  • the sheet 564 is configured to hold an object at the opening, similar to the way in which the sheet 464 is configured to hold the object 472 at the opening in Figs. 13B and 13B.
  • the frame is also configured to be folded from the second folded state shown in Fig. 17C to a final folded state.
  • an object held by the sheet 564 is located between the sheet 564 and a portion of the frame 502 that is configured to bias the object toward the sheet 564.
  • Film 1 is a monolayer plasticized PVOH based blown film having a thickness of 1.0 mils made from HydropolTM 33104P available from Aquapak.
  • Film 2 is a comparative polyethylene 3-layer blown film having a total thickness of 2.5 mils. The two outer layers being 0.26 mils thick and composed of low density polyethylene homopolymer. The core layer being the remaining thickness and being a blend of 45 wt% of a very low density ethylene/octene copolymer and 55 wt% of a very low density ethylene/octene copolymer.
  • Film 3 is a comparative monolayer PVOH based extrusion cast film made from MOWIFLEXTM LP M 05 available from Kuraray.
  • Film 4 is a comparative monolayer PVOH based extrusion cast film made from MOWIFLEXTM C 30 available from Kuraray.
  • Film 5 is a monolayer PVOH based solvent cast film having a thickness of 1.6 mils made from MonoSol Ml 030 available from Kuraray.
  • Film 6 is a monolayer PVOH based solvent cast film having a thickness of 1.6 mils made from MonoSol M7030 available from Kuraray.
  • Film 7 is a comparative monolayer PVOH based solvent cast film having a thickness of 1.9 mils made from S-400C available from Mitsubishi.
  • Film 8 is a monolayer PVOH based film having a thickness of 3.0 mils made from L0902 available from Poval.
  • Samples were prepared in accordance with the Aug. 16, 2013, revision of the “Voluntary Standard For Repulping and Recycling Corrugated Fiberboard Treated to Improve Its Performance in the Presence of Water and Water Vapor” provided by the Fibre Box Association of Elk Grove Village, Ill.
  • the test parameters were scaled down by a factor of 2.5 (for example the sample size from 25g to lOg, water of step 3 reduced from 1500 ml to 600 ml, screen size area reduced by a factor of 2.5). The results are reported in Table 1 below.
  • the web sheet must also meet performance characteristics for retention and suspension packaging. As shown in Table 2, Film 1 containing a blend of polyvinyl alcohol polymer and plasticizer is shown to have good results as compared to other polyvinyl alcohol polymer-based films.
  • Films 3 and 4 did not contain plasticizer and did not have measurable elastic recovery due to the limited elongation at yield required to test elastic recovery.
  • Film 2 is a polyethylene-based retention packaging web sheet and results of Film 1 are compared.
  • Film 1 demonstrated good physical properties, even at a thinner gauge as compared to the polyethylene-based Film 2. This could allow for the use of less material in the package to yield similar results. Alternatively, this could also allow for the use of a similar amount of material with increased toughness and performance characteristics.
  • Table 4 demonstrates physical properties of additional PVOH based films. Films 5, 6 and 8 including plasticizers within the monolayer blend. Films 5, 6 and 8 demonstrated acceptable recovery. Films 5 - 8 were attached to a frame with a product disposed between the frame and the web sheet to form a retention packaging system such as depicted in Figs. 3A to 3J. The product was a rectangular box of a size typically used for mobile electronic packaging.
  • Film 7 was not able to be elongated sufficiently to package a product.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
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Abstract

Un ensemble emballage destiné à un emballage par retenue ou par suspension est divulgué. L'ensemble emballage comprend au moins un cadre et au moins un voile de fibres fixé au cadre. Le voile de fibres est principalement constitué d'un ou plusieurs polymères d'alcool polyvinylique et comprend une quantité efficace de plastifiant. L'ensemble emballage suffit pour retenir ou suspendre un produit. L'ensemble emballage par retenue peut être recyclé sans qu'il ne soit nécessaire de séparer le voile de fibres du cadre.
PCT/US2022/025860 2021-04-23 2022-04-22 Ensemble emballage recyclable par retenue/suspension WO2022226253A1 (fr)

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US63/178,647 2021-04-23

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