Packaging Wrap

1. Field of Invention.

This invention relates generally to packaging products and more particularly to laminated paper and shock absorbing material (or laminated polyethylene sheeting and shock absorbing material) packaging products which provide cushioning and clearance and also support and protection for articles in storage and transit.

2. Description of the Prior Art.

A variety of protective packaging products are used in the shipping industry and in other industries to provide cushioning and clearance for articles in transit. For example, Petriekis, U.S. Pat. No. 3,337,111, discloses two separate web units of corregated paperboard which are bonded together adhesively, scored, and folded to provide a protective corner post. Terrasi, U.S. Pat. No. 3,780,929 discloses a corner post construction in which a corrugated, laminated packing material is cut part way through and folded back on itself, with the uncut portion acting as a hinge. The claims require ply members of flat stiff corrugated sheet material. In addition, the patent suggests that the corrugations extend in a certain direction. A protective coating is applied to at least some of the edges of the corner post to protect the article from debris and the abrasiveness of the edge. Such a coating is less likely to be needed in the present invention. Suess, U.S. Pat. No. 2,692,720 also discloses corrugated packaging materials folded to provide corner protection: the claims require a multi-layered corrugated fibreboard sheet material. The design and shape of the object disclosed in Suess also differs from the present invention. Freedy, U.S. Pat. No. 3,362,609, appears to disclose a cushioning and packaging strip of at least two plies and which is peaked and slotted to provide edge protection. In its brochure on Sus-rap, it appears that linerboard is used. Freedy varies the slot widths and the thickness of the plies to accommodate various articles. The design and construction of the Freedy wrap is different from that of the present invention, because, for one reason, in the Freedy wrap the article rests upon the knocked-down material used in its construction of the top layer of the product, not upon the "base" of the wrap. Similarly, Bartell, U.S. Pat. No. 3,285,800., and Hill, U.S. Pat. No. 3,768,724 disclose the use of laminated cushioning sheets and bags, respectively, to protect articles in transit.

The present invention uses laminated paper and shock absorbing material (or laminated polyethylene sheeting and shock absorbing material) wrap where strips of the wrap are made by severing two layers of the wrap at distances from two edges of the wrap, making a hinge of the uncut layer, and folding the strips back to lie flat on the uncut layer of the wrap. A gap in which all or a portion of at least one article may rest while in storage or transit is thus provided. The article, or portion thereof protected, rests partially upon the base of the wrap when it is in the gap. Moreover, at least the layer of shock absorbing material is continuous, and the materials of construction have varying weights and/or thicknesses so as to accommodate different articles. The permissible variance in the construction materials of the present invention is probably greater than the variance in Freedy's Sus-rap as apparently only the liner board (and coating thereto) could be adjusted. The foregoing list of differences between the present invention and the prior art is not intended to be exhaustive.

The present invention comprises a wrap formed from a laminated sheet consisting of a continuous layer of a shock absorbing material between top and bottom layers in which the bottom layer and the layer of shock absorbing material are cut at distances from the respective edges to form strips. The uncut top layer provides hinges to allow the strips to rotate until the top layer of the strips lies flat upon the center portion of the uncut, top layer. The two layers are then secured together by an appropriate adhesive. Because the width of each strip is less than one half the width of the full sheet, a gap is formed on top of the sheet between the two opposing edges of folded-over strips. In this gap, a portion or all of an article to be stored or transported can be inserted. The combination of the shock absorbing material and top and bottom layers provides support and protection and also cushioning and clearance for the article while it is in storage or transit. Variations in the weight and composition of the three layers and in the thickness and the density of the shock absorbing material allow articles of varying weights to be shipped with the desired cushioning and clearance. In addition, the dimensions of the sheet and two edge strips which are cut can be selected to form gaps dimensioned to fit various products.

It is an object of this invention to provide a reliable form of packaging for the cushioning, support, and clearance of all or a portion of at least one article in storage or transit.

It is an object of this invention to provide a form of packaging which may be flexible enough to cause one packaging wrap to provide support, cushioning, and clearance for all or a portion of at least one article in storage or transit.

It is a further object of the present invention to provide a packaging wrap which alone, or in combination with at least one other packaging wrap, will provide support, cushioning, and clearance for all or a portion of at least one article in storage or transit.

It is an object of this invention to provide a packaging wrap which may use a continuous piece of shock absorbing material as one of the layers of the packaging wrap.

These and other objects, advantages, and features shall hereinafter appear, and for purposes of illustration, but not for limitation, an exemplary embodiment of the present invention is illustrated in the accompanying drawings.

FIG. 1 is a perspective view of the preferred embodiment of the present invention depicting the perimeter of a sheet of glass mounted in the gap of one wrap;

FIG. 2 is a perspective view of the preferred embodiment of the present invention depicting a portion of the perimeter of a sheet of glass mounted in the gap of two sections of the wrap (or one wrap with a portion thereof removed);

FIG. 3 is a front view of the preferred embodiment of the present invention with the two edge cuts made to form the two edge strips;

FIG. 4 is a front view of the preferred embodiment of the present invention depicting the rotating of the two edge strips of the wrap into their assembled position; and

FIG. 5 is a front view of the preferred embodiment of the present invention in its fully assembled state.

FIG. 1 depicts one packaging wrap 10 being used to cushion and protect the perimeter of a sheet of glass.

FIG. 2 depicts an assembly of two sections 10' and 10" of wrap 10 being used to support and protect a sheet of glass. As shown in FIG. 3, the packaging wrap 10 consists of a top layer 12, made of paper, polyethylene or another suitable material, a middle layer 14, made of polystyrene or suitable material for absorbing shocks and providing limited structural support, and a bottom layer 16, which can be of the same material as top layer 12. The packaging wrap 10 is made by using a cylindrical mold (not shown) which allows the middle layer 14 to be peeled off (somewhat like peeling an apple) at a desired thickness to provide a continuous length of the shock absorbing material. The middle layer 14 is then laminated to the layers 12 and 16. The top and bottom layers 12 and 16 may also be continuous. The continuity-type of fabrication is opposed to a fabrication in a precise length or "block" form of standard length. Because it is continuous, the length of the wrap is adjustable so as to accommodate all or a portion of the perimeters of various articles. The continuous nature of the layer allows for standardization of lengths, if so desired. The lengths could be substantially equal to the perimeter of an article.

The gap 48 (see FIGS. 2 and 5) is formed by cutting bottom layer 16 and middle layer 14 and folding top layer 12. First, the bottom layer 16 and middle layer 14 are cut, not necessarily parallel to the edges 23, 25, at distances from each edge 23 and 25, respectively, of wrap 10 to form a left panel 18 (comprised of top layer 12', middle layer 14', and bottom layer 16'), a center base 20, and the right panel 22 (comprised of top layer 12", middle layer 14", and bottom layer 16"). Left and right hinges 30 and 32 are formed by the portions of uncut top layer 12 adjacent to cuts 29 and 31, respectively. The top layer 12, although unsevered, is thus divided by the hinges 30 and 32 into the left top layer 12', the top layer 12, and the right top layer 12". Substantially none of the several layers are removed during this cutting operation.

Then, as illustrated in FIG. 4, a torque T is exerted on left panel 18 to rotate it about left hinge 30 until top layer 12' lies substantially flat against top layer 12 of center base 20. A similar torque is exerted with similar results on the right panel 22. Left panel 18 and right panel 22 can then be bonded with a suitable adhesive 50, to top layer 12 of base 20.

Because the widths of left panel 18 and right panel 22, respectively, are each less than one half the width of the packaging wrap 10, there is a gap 48 between the outside edges 23 and 25 of said panels when rotated over on top of center base 20 as depicted in FIG. 5. Depending upon the dimensions of the wrap, all or a portion of the perimeter (for example) of an article may be inserted into gap 48.

A second embodiment of the present invention is shown by the the portion of FIGS. 3, 4, and 5, to the right of dashed line 26. The second embodiment can be formed in a manner similar to the formation of the first embodiment: by severing wrap 10 through the bottom layer 16 and middle layer 14. The top layer 12 remains uncut to provide a hinge. Two equal panels are thus formed, the left panel 18 and the right panel 18', each consisting of a top layer 12 and 12', respectively, a middle layer 14 and 14', respectively, and a bottom layer 16 and 16' respectively. As depicted in FIG. 4, a torque is exerted to rotate the left panel 18 about the hinge 30 so that top layer 12' lies substantially flat against top layer 12. The panels can then be bonded together with a suitable adhesive 50. A gap 48' of desired dimension (shown schematically) is then removed from the right panel 18.

A third embodiment of the invention is shown to the right of dashed line in FIG. 3, Only right cut 31 is made and only the right panel 22 is formed and subsequently rotated to form a curb. Thus, in this third embodiment, a curb 25 is formed rather than a gap and the article is cushioned against surfaces 12 and 25. (The same operation could be performed on the left side of the wrap only.)

The present invention, as depicted in the accompanying illustrations, is used to wrap a portion of or all of the perimeter of an article. However, the invention may also be used to protect other portions of the article or all of an article by appropriately dimensioning the packaging wrap 10 and the gap 48 therein

The dimensions of the present invention also can be adjusted to accommodate the various sizes and weights of articles with which the invention is to be used to meet the applicable regulations concerning their packaging (i.e., the required clearance or distance between the product and the inside of the container in which it is packaged). The gap 48 may be widened or narrowed, the weight of the paper used can be increased or decreased, and the thickness and density of the shock absorbing material can be increased or decreased. In addition, other materials, such as polyethylene, can form the top layer 12 or the bottom layer 16. The preferred weights of paper vary from crepe (defined herein as the lightest weight of paper) up to 90 pounds or more. Fiberboard is one of many alternatives with the preferred weights. The increase in the weight of the paper increases the strength of the packaging wrap. The preferred thickness of the polyethylene ranges from approximately 1 mil to 6 mil. The preferred density of the shock absorbing material is between 1/2 to 2 pounds per cubic foot, but other densities will also suffice. Polystyrene is one of many shock absorbing materials which may be used. The bonding agent used to secure the left panel 18 and right panel 22 to top layer 12 must be one that is compatible with both the shock absorbing material and the other layer(s). A water-based glue, for example, is a suitable adhesive for use with paper and polystyrene. The same adhesive may also be used with polystyrene and polyethylene. The materials making up the layers may be, but need not be, flexible, depending upon the use to which the wrap will be put. Where one wrap or more than one wrap is used, the wraps may be connected, by tape, for example.

It is to be understood that while the preferred embodiment of the invention has been illustrated and described, the present invention is not limited to the precise construction herein disclosed. For example, in any of the embodiments discussed above, the bottom layer of paper or polyethylene sheeting could be omitted and only the layer of shock absorbing material cut; the strip(s) folded back as described above, and the resulting packaging wrap would remain within the scope of this invention.

Additionally, the invention encompasses the packaging wrap itself, without regard to the manner in which it is formed. It covers as well methods not depicted in the drawings. Thus, it covers two sections, each having one, two, or three layers, arranged so that one surface of one section is in contact with one surface of the other, and a portion of at least one section is removed to form a gap. It covers two sections, each consisting of one, two, or three layers, arranged so that the one surface of one section is in contact with one surface of the other section, where the width of one section is less than the width of the other section, whereby a curb is formed. It also covers a packaging wrap made up of three sections, each having one, two, or three layers, wherein one surface of two of the sections are in contact with one surface of the third section, but wherein the first two sections are not in contact with each other, whereby a gap is formed. These embodiments would appear similar to those previously discussed, except that the hinge (or hinges) 30 (or 30 and 32) would probably not be present and more of the base section (20) may be removed. It also includes embodiments where only one section (of one, two, or three layers) is formed, and a portion thereof is removed to form a gap or curb, and where a wrap or section uses, for example, two layers of shock absorbing material and only one of paper or polyethylene. In addition, any of the foregoing embodiments could be fabricated from section(s) consisting of only a single layer, more than three layers, or more than two sections.

The invention could be used to support and protect the perimeter (or portion(s) thereof) of two or more objects grouped together as well as individual objects or portions thereof. The present invention also includes using one or more than one wrap to protect the perimeter of at least one article by enclosing the perimeter of the at least one article. Other changes, modifications, and variations can be made without departing from the scope and spirit of the present invention. The right is reserved to all changes and modifications coming within the scope of the invention as defined in the appended claims.

Finally, the invention encompasses the combination of the methods and/or wraps previously discussed, e.g., severing a portion of the wrap to form one edge section and attaching a suitable piece to form a gap. Nor would the spirit of the invention be avoided by inserting, for example, some additional, but unattached layer, between the surfaces or the layers which were to be in contact with each other, or substantially flat against each other.