WO2011059347A1

WO2011059347A1 - Corrugated board with cushioning strips protective packaging

Info

Publication number: WO2011059347A1
Application number: PCT/NZ2010/000227
Authority: WO
Inventors: Jason Paul Rogers; Patrick Petrus Antonius Maria Van Berlo; Ceri Peter Keston Wells
Original assignee: Corcel Ip Limited
Priority date: 2009-11-13
Filing date: 2010-11-15
Publication date: 2011-05-19

Abstract

The present invention relates to a packaging material including: - a substantially planar backing sheet; wherein there are a plurality of cushioning strips individually adhered to the backing sheet material to form substantially parallel rows; the cushioning strips being in the form of laminated corrugated paper board.

Description

CORRUGATED BOARD WITH CUSHIONING STRIPS PROTECTIVE

PACKAGING

TECHNICAL FIELD

The present invention relates to protective packaging. BACKGROUND ART

Protective packaging is in considerable demand with an increasing volume of goods being transported around the world. Expanded polystyrene (EPS) is a common form of protective packaging used. EPS has the properties of being very light, impact absorbing and relatively cheap to produce. These are all desirable qualities of protective packaging.

However, EPS (and other similar materials) have problems associated with them.

Firstly, most foams and polymers used in packaging tend to be environmentally unfriendly. Their manufacture requires the use of undesirable chemicals.

Furthermore, these materials can be difficult to dispose of as often they are not biodegradable and produce undesirable fumes when burned.

Another problem with the use of EPS and plastics materials is that they are largely inflexible. This means that to be effective for irregular shaped products, the polystyrene must be moulded to a shape that complements or accommodates the particular product. The requirement to produce customised moulds can be expensive, and time consuming.

However, inflexible packaging is suitable for regular shaped products. Thus boards whether made out of foam, corrugated cardboard, plastics or pulp can be used to fashion cartons and other containers.

Corrugated paper board is considerably more eco-friendly than polystyrene and plastics material when used in protective packaging. However, as this is substantially rigid, it can only be used for regular shaped products, or in

conjunction with a moulded insert such as polystyrene with the inherent problems discussed previously.

Thus, corrugated board is likewise not suitable for irregular shaped products.

One material which is suitable for irregular shaped objects is bubble-wrap. Bubble wrap is made from plastics material and has a number of the problems identified previously. However, it can be readily formed around objects. Unfortunately, bubble wrap does not have the impact resistance of more solid materials such as corrugated board and polystyrene foam. In addition bubble-wrap is prone to tearing on_^ sharp objects.

Therefore, it would be desirable if there could be provided a packaging material which is eco-friendly, sufficiently flexible to mould around irregular objects, robust, light weight and relatively inexpensive to produce.

It is an object of the present invention to address the foregoing problems or at least to provide the public with a useful choice.

All references, including any patents or patent applications cited in this

specification are hereby incorporated by reference. No admission is made that any reference constitutes prior art. The discussion of the references states what their authors assert, and the applicants reserve the right to challenge the accuracy and pertinency of the cited documents. It will be clearly understood that, although a number of prior art publications are referred to herein, this reference does not constitute an admission that any of these documents form part of the common general knowledge in the art, in New Zealand or in any other country.

Throughout this specification, the word "comprise", or variations thereof such as "comprises" or "comprising", will be understood to imply the inclusion of a stated element, integer or step, or group of elements integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.

Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

DISCLOSURE OF THE INVENTION

According to a first aspect of the present invention there is provided a packaging material including: a substantially planar backing sheet; wherein there are a plurality of cushioning strips individually adhered to the backing sheet material to form substantially parallel rows; the cushioning strips being in the form of laminated corrugated paper board.

Preferably, the packaging material includes at least one cut at least partially through the cushioning strips in at least one different direction to the rows. Preferably, the cushioning strips have been oriented so as to be positioned on the backing sheet so that the flute channels project substantially orthogonally from said backing sheet. In such embodiments the orientation of the channels make the packaging material very strong and able to withstand relatively large forces directed substantially orthogonally toward the backing sheet without the

corrugations deforming to any great extent: compared to channels which extend parallel to the plane of the backing sheet. In some preferred alternate embodiments the cushioning strips have been oriented so as to be positioned on the backing sheet so that the flute channels are disposed substantially parallel to the plane of the backing sheet. In such embodiments the cushioning strips can deform to absorb shock which may be desirable in some situations. In preferred embodiments, the packaging material includes at least one cut at least partially through the cushioning strips in at least one different direction to the rows.

Preferably, the number and direction of the cut(s) are determined by an object which is to be at least partially protectively covered by the packaging material.

A packaging material substantially as described above wherein there is provided a number of parallel cuts which intersect with a number of further parallel cuts to diagonally criss-cross across the rows.

A packaging material substantially as described above wherein there is provided a number of parallel cuts which are substantially orthogonally disposed with respect to the direction in which the rows extend. A packaging material which includes: a number of parallel cuts which intersect with a number of further parallel cuts to diagonally criss-cross across the rows; and a number of parallel cuts which are substantially orthogonally disposed with respect to the direction in which the rows extend.

According to another aspect of the present invention there is provided a method of manufacturing a packaging material including the step of: a) individually adhering a plurality of cushioned strips in the form of laminated corrugated paper board to a backing sheet material to form substantially parallel rows.

Preferably the method includes a further step of: b) cutting the cushioning strips, with one or more cuts made in at least one different direction to the rows.

Preferably, the cushioned strips have been oriented to be positioned on the backing sheet, so that that the flute channels project upwardly from said backing sheet.

In preferred embodiments, the packaging material is made from an eco-friendly product such as paper, cardboard or cellulose. However, it should be appreciated that the principles of the present invention can be utilised with other materials.

In preferred embodiments, the backing sheet material is made from Kraft paper which is widely used, particularly as a liner for corrugated board.

Again, preferably the corrugated sheet material is the same as that used for corrugated cardboard or corrugated paperboard given its biodegradability and other attributes. This should not however been seen as limiting. In a preferred embodiment an average cushioning strip may include from 3 to 5 individual laminated layers of single face paperboard (i.e. each strip of single face paperboard bonded one to the other). Thus, making a 6 to 10 ply corrugated cushioning strip.

In preferred embodiments the corrugated sheet material is positioned on the backing sheet so a side of each strip adheres to the backing rather than the crests or base of the strip.

This orientation of the strips is critical where the packaging material is to be used in a situation requiring strength. Orienting the strips of corrugated sheet material such that the side of the strip is on the backing of the board ensures that the corrugations form an array of vertical flute channels. Vertical flute channels provide a high strength construction which is resistant to crushing when heavy objects or pressure is placed thereon.

It is envisaged the length of the strip could vary according to the width of the backing sheet material onto which the strip is to be placed, which in turn is determined by the purpose for which the materials are to be used and the machinery on which the materials are made.

The depth of the strips which are placed on the backing sheet varies according to the amount of impact cushioning required of the strips.

However, in one embodiment, the depth of the strip is in the order of 9-10 mm and the width is in the order of 16-18 mm. These dimensions however are not meant to be limiting.

The term 'individually adhered', refers to the ability of the strips to be attached to the backing material, but move independently of each other as the backing material is flexed. Therefore the cushioning strips are placed on the backing material with no or a minimal gap between each strip such that they can abut each other. The strips are only bonded to the backing material not each other: this provides considerable flex. For example at the apex position where the adhered strips abut each other and intersect the backing paper they can be flexed, folded and/or bent. This mechanical flexing is easily performed in the direction that causes the backing material to fold onto itself, however it is possible to fold against the strip up to 90 degrees as the strip will deform partially Some embodiments of the present invention have additional flexibility through the provision of cuts across the cushioning strips.

It is envisaged that the cuts through the strips will be of sufficient depth to allow the strips to flex along their length. Thus, this cut may penetrate say to a depth of ¾ of the strip or all the way through the strip avoiding the backing material. It should be appreciated that by having individual aligned strips in combination with the cuts across the strips, the packaging material can flex in multiple directions. This enables the packaging material to be wrapped around irregular objects.

Thus, the inventors have discovered a way to produce a packaging material that is flexible, does not require moulding and can be made from eco-friendly products and with eco-friendly processes. Further, the use of corrugated cardboard means that potential consumers merely have to grasp the concept of using a known product in a different form. In addition the packaging material of the present invention can be delivered in large rolls from which a desired amount can be cut as required. BRIEF DESCRIPTION OF DRAWINGS

Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which: illustrates packaging material wherein the cushioning strips have been oriented so as to be positioned on the backing sheet, so that the flute channels project orthogonally from said backing sheet, in accordance with one preferred embodiment of the present invention; illustrates a side view of the packaging material shown in Figure 1 wherein the backing sheet is in a planar configuration; illustrates a side view of the packaging material of Figure 3 when the backing sheet is flexed; illustrates board of Figure 1 which has been modified to include a number of parallel cuts across the rows of cushioning strips in accordance with a further preferred embodiment of the present invention, shows an alternate embodiment of the present invention in perspective view where the cushioning strips have been oriented so as to be positioned on the backing sheet, so that the flute channels run in a direction parallel with the plane of said backing sheet; shows an end on view of Figure 5 looking from direction of arrow A; shows a side view of Figure 5 looking from direction of arrow B; Figure 8 illustrates a side view of Figure 7 when the backing sheet is flexed;

Figures 9A and 9B illustrate top plan and perspective views respectively of the the flexed backing sheet of Figure 8; and

Figure 10 a further preferred embodiment of the present invention wherein the cushioning strips have a series of intersecting parallel lines, crisscrossed over the rows.

BEST MODES FOR CARRYING OUT THE INVENTION

Figures 1 - 3 illustrate a sheet of packaging material generally indicated by arrow (1 ) made in accordance with one embodiment of the present invention. A close up generally indicated by arrow (2) with a portion of the board is also shown.

The packaging material (1 ) includes a backing layer (3) which is made from Kraft paper.

On the backing paper (3) are a number of cushioning strips (4a-4e) which are located parallel to each other along the backing paper (3).

The cushioning strips collectively referred to for simplicity as (4) are likewise made of Kraft paper.

The strips (4) are made up of a number of flutes (5) attached to support layers (6). This combination of flutes (5) and support layers (6) is what is known as single faced corrugated board.

Although the ridges and channels of the flutes (5) are shown as being substantially angular, it is envisaged that in preferred embodiments these will be rounded as normally found in corrugated paper board.

In this embodiment, it can be seen that a cushioning strip is comprised of four layers of corrugated material laid on its side so the flute channels project substantially orthogonally from the backing sheet. As can be seen when the strips 4 are oriented in this manner on the backing layer the wave-like pattern of the flutes is visible as this forms an outer surface of the packaging material.

It can be seen that the cushioning strips (4a-4e) abut each other on the _^backing layer (3). However, importantly the strips (4a-4e) are only adhered to the backing layer (3), and not each other. This allows the board (1 ) to flex along the parallel intersections (400) between the cushioning strips (4a-4l) -refer Figure 3.

In Figure 4 the board (1 ) also has a number of parallel cuts (7) which cut across the cushioning strips (4a-4e) down to the backing layer (3).

The cuts (7) enable the board (1 ) to flex along the length of the cushioning strips (4) without distorting same.

As can be seen, the provision of abutting cushioning strips (4) in combination with the cut (7) provides a board which can flex in two directions (i.e. longitudinal and transverse). Figure 4 illustrates this well.

Figures 5 - 8, 9A and 9B illustrate a sheet of packaging material generally indicated by arrow (10) made in accordance with one embodiment of the present invention.

The packaging material (10) includes a backing layer (30) which is made from Kraft paper. On the backing paper (30) are a number of cushioning strips 4 (as depicted by (4a- 4g) which are located parallel to each other along the backing paper (30).

The cushioning strips are likewise made of Kraft paper.

The strips (4) are made up of a number of flutes (5) attached to support layers (6). The combination of flutes (5) and a support layer (6) is known as single faced corrugated board.

Although the ridges and channels of the flutes (5).

In this embodiment, it can be seen that a cushioning strip is comprised of four layers of corrugated material (i.e. single face corrugated board) with the cushioning strips laid on their backs so the flute channels are disposed transversely across the backing layer (30) such that the axis of the channels is parallel to plane of said backing sheet.

It can be seen that the cushioning strips (4a-4f) abut each other on the backing layer (30). Importantly, the strips (4a-4f) are only adhered to the backing layer (30), and not each other. This allows the board (10) to flex along the parallel intersections (400) between the cushioning strips (4a-4e) -refer Figure 8.

In Figure 10 the packaging material (100) also has a number of parallel cuts (70) which intersect with a number of further parallel cuts (80) to diagonally criss-cross across the packaging material and rows of cushioning strips (4a-4p). These cuts across the cushioning strips (4) extend down through the layers to finish just above the backing layer (not shown).

The cuts (70, 80) enable the board (1 ) to flex along multiple axes over the length of the packaging material (100). The packaging material may in addition to the diagonal cuts (70, 80) have a series of parallel vertical cuts (not shown) which each pass across the cushioning strips.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope of the appended claims.

Claims

What we claim is:

1. A packaging material including: a substantially planar backing sheet; wherein there are a plurality of cushioning strips individually adhered to the backing sheet material to form substantially parallel rows; the cushioning strips being in the form of laminated corrugated paper board,

2. A packaging material as claimed in claim 1 wherein the cushioning strips have been oriented so as to be positioned on the backing sheet, so that the flute channels project upwardly from said backing sheet.

3. A packaging material as claimed in claim 1 wherein the cushioning strips have been positioned on the backing sheet, such that the flute channels extend in a direction parallel with the plane of said backing sheet.

4. A packaging material as claimed in any one of claims 1 to 3 wherein each cushioning strip includes from three to five individual laminated layers of single face paper board.

5. A packaging material as claimed in any one of claims 1 to 3 wherein the parallel cushioning strips are located transversely across the backing sheet material.

6. A packaging material as claimed in any one of claims 1 to 5 wherein the packaging material includes at least one cut at least partially through the cushioning strips in at least one different direction to the rows.

7. A packaging material as claimed in claim 6 wherein the number and direction of the cut(s) are determined by an object which is to be at least partially protectively covered by the packaging material.

8. A packaging material as claimed in claim 6 wherein there is provided a number of parallel cuts which intersect with a number of further parallel cuts to diagonally criss-cross across the rows.

9. A packaging material as claimed in claim 6 wherein there is provided a number of parallel cuts which are substantially orthogonally disposed with respect to the direction in which the rows extend.

10. A packaging material which includes: a number of parallel cuts which intersect with a number of further parallel cuts to diagonally criss-cross across the rows; and a number of parallel cuts which are substantially orthogonally disposed with respect to the direction in which the rows extend.

11. A method of manufacturing a packaging material including the step of: a) individually adhering a plurality of cushioned strips in the form of laminated corrugated paper board to a backing sheet material to form substantially parallel rows.

12. A method as claimed in claim 11 wherein there is the additional step of: b) cutting the cushioning strips, with one or more cuts made in at least one different direction to the rows.

13. A method of manufacturing a packaging material as claimed in claim 11 or claim 12 wherein the cushioned strips have been oriented to be positioned on the backing sheet, so that that the flute channels project substantially orthogonally from said backing sheet.

14. A method as claimed in claim 11 or claim 12 wherein the cushioning strips have been oriented so as to be positioned on the backing sheet so that the flute channels are disposed substantially parallel to the plane of the backing sheet.

15. A packaging material substantially as described herein with reference to any example and/or drawing thereof.

16. A method of manufacturing a packaging material substantially as

described herein with reference to any example and/or drawing thereof.