[go: up one dir, main page]

WO2022204579A1 - Systèmes et procédés d'emballage de palettes et analogues avec du papier extensible - Google Patents

Systèmes et procédés d'emballage de palettes et analogues avec du papier extensible Download PDF

Info

Publication number
WO2022204579A1
WO2022204579A1 PCT/US2022/022059 US2022022059W WO2022204579A1 WO 2022204579 A1 WO2022204579 A1 WO 2022204579A1 US 2022022059 W US2022022059 W US 2022022059W WO 2022204579 A1 WO2022204579 A1 WO 2022204579A1
Authority
WO
WIPO (PCT)
Prior art keywords
paper
slit sheet
sheet paper
expandable slit
expandable
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/US2022/022059
Other languages
English (en)
Inventor
David Paul Goodrich
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Individual
Original Assignee
Individual
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
Priority to AU2022246177A priority Critical patent/AU2022246177A1/en
Priority to MX2023010766A priority patent/MX2023010766A/es
Priority to EP22776772.0A priority patent/EP4313775A4/fr
Priority to US17/802,012 priority patent/US20230294858A1/en
Priority to CA3212888A priority patent/CA3212888A1/fr
Priority to BR112023019314A priority patent/BR112023019314A2/pt
Application filed by Individual filed Critical Individual
Publication of WO2022204579A1 publication Critical patent/WO2022204579A1/fr
Anticipated expiration legal-status Critical
Priority to CONC2023/0013816A priority patent/CO2023013816A2/es
Priority to US18/615,179 priority patent/US20240359840A1/en
Priority to US18/792,386 priority patent/US20240391622A1/en
Ceased legal-status Critical Current

Links

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
    • B65D71/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans or pop bottles; Bales of material
    • B65D71/0088—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck
    • B65D71/0092—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck provided with one or more rigid supports, at least one dimension of the supports corresponding to a dimension of the load, e.g. skids
    • B65D71/0096—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck provided with one or more rigid supports, at least one dimension of the supports corresponding to a dimension of the load, e.g. skids the dimensions of the supports corresponding to the periphery of the load, e.g. pallets
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/006—Helical strip wrapping combined with roping
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/02—Wrapping articles or quantities of material, without changing their position during the wrapping operation, e.g. in moulds with hinged folders
    • B65B11/025—Wrapping articles or quantities of material, without changing their position during the wrapping operation, e.g. in moulds with hinged folders by webs revolving around stationary articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B11/00—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material
    • B65B11/04—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material the articles being rotated
    • B65B11/045—Wrapping, e.g. partially or wholly enclosing, articles or quantities of material, in strips, sheets or blanks, of flexible material the articles being rotated by rotating platforms supporting the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B67/00—Apparatus or devices facilitating manual packaging operations; Sack holders
    • B65B67/08—Wrapping of articles
    • B65B67/085—Wrapping of articles using hand-held dispensers for stretch films
    • 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
    • B65D2571/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans, pop bottles; Bales of material
    • B65D2571/00006—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck
    • B65D2571/00012—Bundles surrounded by a film
    • B65D2571/00018—Bundles surrounded by a film under tension
    • 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
    • B65D2571/00—Bundles of articles held together by packaging elements for convenience of storage or transport, e.g. portable segregating carrier for plural receptacles such as beer cans, pop bottles; Bales of material
    • B65D2571/00006—Palletisable loads, i.e. loads intended to be transported by means of a fork-lift truck
    • B65D2571/00012—Bundles surrounded by a film
    • B65D2571/00018—Bundles surrounded by a film under tension
    • B65D2571/0003—Mechanical characteristics of the stretch film

Definitions

  • This invention relates to the use of wrapping materials for wrapping pallets and the like.
  • EP0533520B1 entitled Method of Packaging a Palletisable Load
  • expandable slit sheet paper which can be used in embodiments of the present invention, including illustrative slit patterns and the expansion processes related thereto, etc., as found in U.S. Patents a) 5,538,778, b) 5,667,871 , c) 5,688,578, d) 5,782,735, e) 3,908,071 , f) 3,104,197, g) 3,220,116, h) 3,269,393, i) 3,908,071 , j) 6,024,832, k) 6,458,447, and I) 6,712,930, and in PCT application No. WO1984002936A1 , and in U.S.
  • the terminology "expandable” as applied to paper sheets means a paper having a slit pattern that enables expansion of the paper, such as, e.g., as disclosed in U.S. Patent Nos. (a) 5,538,778, (b) 5,667,871 , (c) 5,688,578, (d) 5,782,735 and (e) 10,226,907, and in PCT Application No. PCT/US2014/054615, the entire disclosures of which patents and PCT application are all incorporated by reference herein as though recited in full.
  • a slit pattern is configured to enable the paper to be expanded lengthwise, with a related decrease in width.
  • the slit pattern produces a paper that increases in length due to the slit pattern when processed in an expander, such as, e.g., an expander of the type described in any of the following U.S. and PCT applications (a) 2017/0203866, (b) 2018/022266, (c) 2018/0127197, and (d) PCT/US2014/054615, incorporated herein by reference in their entireties.
  • an expander such as, e.g., an expander of the type described in any of the following U.S. and PCT applications (a) 2017/0203866, (b) 2018/022266, (c) 2018/0127197, and (d) PCT/US2014/054615, incorporated herein by reference in their entireties.
  • U.S. Pat Nos. 5,667,871 and 5,688,578, slit Sheet Packing Material teach the use of a plurality of individual slits forming parallel spaced rows forming a hexagonal expanded sheet with and without a separator sheet. It requires machinery to stretch the paper into its three-dimensional shape at the customer's location such as disclosed in U.S. Pat. No. 5,538,778 which teaches the method and apparatus for producing the expansion of the slit sheet material performed at the packing site's location.
  • U.S. Pat. No. 5,782,735 discloses an expander for expanding the slit sheet material of U.S. Pat. Nos. 5,667,871 and 5,688,578.
  • FIGS. 1 (A) and 1 (B) correspond to FIGS. 1 and 3 of U.S. 5,667,871 (the ‘871 patent). These figures describe existing “slit sheet” expandable paper structure. As explained in the ‘871 patent:
  • the slit paper, indicated generally as 10, is illustrated in FIG. [1 (A)] as it would come off the slitting machine.
  • the sheets can be formed on a flat-bed slitter and produced directly as rectangular sheets, as well as on a rotary slitter and cut into individual sheets or stored directly as a continuous sheet in roll form.
  • the flexible sheet 10 is preferably manufactured from exclusively recycled paper with the grain of the paper running in the direction of arrow A.
  • the flexible sheet 10 is provided with slits 14 and slits 16 are parallel to the edges 22 and 24 of the flexible sheet 12 and perpendicular to the paper grain.
  • the slits 14 and slits 16 are placed in rows and separated from one another by land 20 and legs 21 [shown in FIG.
  • the land 20 is a consistent size and provides the support required to prevent the paper from tearing into strips when opened.
  • the cushioning effect is produced by the flexing of the lands and legs under a load. It is therefore necessary that the land 20 be of sufficient size to provide cushioning.
  • the spacing between the rows of slits 14 and slits 16 must also be of sufficient size to prevent the paper from tearing.
  • the offset positioning of the rows of slits 14 and slits 16 gives the paper resiliency when opened and is discussed in detail further hereinafter.
  • the existence of partial slits 14 and 16 at the ends 25 and 18 of the flexible sheet 10 do not hinder the efficiency of the slit paper 10.
  • the flexible sheet 10 when flat; lies in a first plane.”
  • the expanded sheet is formed of hexagonal cells 26, legs 21 and land 20 areas, as illustrated in FIG. [1 (B)]
  • the planes of the land 20 areas form an angle of at least about 45 degrees with the plane of the sheet in flat form.”
  • the slitting operation in which the slits are cut into the sheet material can take several forms.
  • rectangular sheets are provide with its total number of slits in one action.
  • the term rectangular should be understood to include rectangles in which all four sides are equal, that is, square.
  • the pressure required for the cutting action is significantly lower that which is required for the flat bed cut, since essentially only a single row or a few rows of slits are cut simultaneously.
  • expansion contemporaneous with slitting is not desirable. Therefore a critical balance must be struck between resistance to opening of the cells during the rewind step and ease of opening of cells during the expansion step. By achieving this critical balance and producing a flat, unexpanded sheet, the sheet material has an effective thickness which is as much as one twentieth of the thickness of a sheet of expanded material.
  • the compact configuration provides for the optimization of shipping and storage.”
  • slit sheet means an expandable paper sheet having a slit pattern.
  • the following are direct quotes of U.S. 5,667,871 (the ‘871 patent).
  • the length of the slit and the ratio of the land intervals between slit affects the dimensions of the polygons which are formed during the expansion step.
  • 0.008 inch thick paper having a silt pattern of a 1/2" slit, 3/16" slit spacing, and 1/8" row spacing produces a 1/4" by 3/16" land which can expand to under about one quarter of an inch thickness and will have a net effective thickness for two layers, when nested, of about 0.375 inches. It is noted that the land width is double the width of the legs. The net effect is a useful thickness expansion of roughly 20 times the unexpanded thickness of the paper. ”
  • the slit dimensions can be varied to ease the process of opening.
  • a 5/8" slit, 3/16" land by 3/16 row opens very easily since the number of hexagons is reduced. When the size of the hexagons are increased and the numbers decreased; the stretched thickness was increased, producing a very viable wrap material.
  • This sizing increases the yield of the paper and provides almost the same protection as the 1/2" slit. This sizing provides a less expensive product utilizing a larger content of post consumer waste while maintaining the integrity of the wrap product.
  • the 1/2" slit, 3/16" land by 1/8" row pattern produces a more protective wrap due to the greater number of wraps that can be made within the same volume. Thus, a 21 ⁇ 2 pound vase dropped from a thirty inch height, with only 1/2" of cumulative sheet thickness around the vase, can be protected with the 1/2" slit, 1/4 by 3/16 inch land pattern.”
  • the present inventor shows a background “Expandable Slit Sheet Packaging Material That Interlocks When Layered and Expanded.”
  • the product includes a plurality of layers, with each layer having a different slit pattern for the purposes of “interlocking” between the plural layers.
  • the differing slit patterns produce when expanded, inclined land area that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock.” While the ‘907 patent describes an example in which a slit length of 0.4 inches is included for one of the layers, it is notable that 1 ) this 0.4 inch slit length is only used in conjunction with an adjacent layer having a larger slit length of 0.5 inches, 2) this reduced slit length is not used along with a reduced distance between rows (i.e. , the distance between rows is required to be the same as that of the adjacent layer with the 0.5 inch slit length). Thus, the ‘907 patent does not teach the improved slit sheet cushioning products of the present invention, nor the advantages therefrom.
  • a pallet wrap comprising: an expandable slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction.
  • a pallet wrap comprising: an expandable slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, and a support wrap, wherein said expandable slit sheet paper is configured to be wrapped around a pallet assembly and said support wrap is configured to surround at least a portion of said expandable slit sheet paper wrapped around said pallet assembly.
  • a pallet assembly having a plurality of stacked items, boxes or containers; b) a pallet wrap including an expandable slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, said expandable slit sheet paper being wrapped around said pallet assembly.
  • said pallet wrap further includes a support wrap surrounding at least a portion of said expandable slit sheet paper wrapped around said pallet assembly.
  • a method of wrapping a pallet comprising: a) providing a pallet wrap having: an expandable slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, and b) wrapping said pallet wrap around a pallet assembly with said expandable slit sheet paper wrapped around the pallet assembly.
  • a method of wrapping a pallet comprising: a) providing a pallet wrap having: an expandable slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, and a support wrap; b) wrapping said pallet wrap around a pallet assembly with said expandable slit sheet paper wrapped around the pallet assembly and said support wrap surrounding said expandable slit sheet paper wrapped around said pallet assembly.
  • a method of making a pallet wrap system comprising: providing a pallet wrap dispenser; mounting a roll of expandable slit sheet paper on said pallet wrap dispenser.
  • step of providing a pallet wrap dispenser includes providing a pallet wrap dispenser that is configured to dispense a roll of plastic, polymeric or elastomeric material, and retrofitting said pallet wrap dispenser to dispense said roll of expandable slit sheet paper.
  • a method of retrofitting a pallet wrap dispenser that dispenses plastic, polymeric or elastomeric sheet material comprising: providing a pallet wrap dispenser that is configured to dispense plastic, polymeric or elastomeric sheet material from a roll of plastic, polymeric or elastomeric material, mounting a roll of expandable slit sheet paper on said pallet wrap dispenser.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 0.8 pounds per inch across a width of the expandable slit sheet paper.
  • expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 0.9 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.0 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.1 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.2 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.3 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.4 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.5 pounds per inch across a width of the expandable slit sheet paper.
  • said expandable slit sheet paper is an extensible paper that provides tensile strength supporting tensile loads of greater than 1.6 pounds per inch across a width of the expandable slit sheet paper.
  • said support wrap includes one or more of the following: a) reinforcing fibers or filaments; b) nylon filaments; c) polymer filaments; d) glass filaments; and/or e) natural filaments, such as, e.g., plant filaments, cotton filaments, bamboo filaments, etc.
  • said support wrap includes: reinforcing fibers or filaments extending within a lengthwise direction.
  • said support wrap includes: reinforcing fibers or filaments in combination reinforcing a tape or paper material.
  • said support wrap includes: reinforcing fibers extending within a lengthwise direction, wherein the reinforcing fibers include synthetic fibers.
  • said support wrap includes: reinforcing fibers extending within a lengthwise direction, wherein the reinforcing fibers include glass fibers or plastic fibers.
  • said support wrap includes a heavy weight non-slit paper.
  • said support wrap includes: reinforcing fibers extending within a lengthwise direction, wherein the reinforcing fibers include natural fibers, such as, e.g., plant fibers, cotton fibers, or the like.
  • expandable slit sheet paper is a paper having a weight of at least 30#.
  • expandable slit sheet paper is a paper having a weight of at least 35#.
  • expandable slit sheet paper is a paper having a weight of at least 40#.
  • expandable slit sheet paper is a paper having a weight of greater than 45#.
  • expandable slit sheet paper is a paper having a weight of greater than 50#.
  • expandable slit sheet paper is a paper having a weight of greater than 60#.
  • said expandable slit sheet paper is a paper having a weight of between 30# to 70#.
  • expandable slit sheet paper is a paper having a weight of between 40# to 70#.
  • expandable slit sheet paper is a paper having a weight of between 45# to 70#.
  • expandable slit sheet paper is a paper having a weight of between 40# to 60#.
  • expandable slit sheet paper is a paper having a weight of between 45# to 60#.
  • said expandable slit sheet paper has slits with a slit length of between 0.15 inches to 0.45 inches.
  • said expandable slit sheet paper has a slit length of 0.25 inches plus or minus 33%, a slit spacing of 0.09375 inches plus or minus 33% and a row spacing of 0.0625 inches plus or minus 33%.
  • said expandable slit sheet paper has a slit length of less than 0.45 inches.
  • said expandable slit sheet paper has a slit length of less than 0.40 inches.
  • said expandable slit sheet paper has a slit length of less than 0.35 inches.
  • said expandable slit sheet paper has a slit length of less than 0.25 inches.
  • said expandable slit sheet paper has a slit length of less than 0.20 inches.
  • said expandable slit sheet paper has a slit length of between 0.15 to 0.35 inches.
  • said expandable slit sheet paper has a slit length of between 0.20 to 0.30 inches.
  • said expandable slit sheet paper has a slit length of about 0.225 to 0.275 inches.
  • said expandable slit sheet paper has a slit pattern of slits extending in a widthwise direction, wherein dimensions of the slit pattern of the expandable slit sheet paper are proportionally reduced from an expandable slit sheet paper having a 0.5” slit length (SL), a 1/8” (0.125 inch) spacing between rows (RS), and a spacing between slits within the same row (i.e. , land length) of 3/16” (0.1875 inch)(SS).
  • said expandable slit sheet paper has a pattern of slits having slit lengths (SL) of between 0.175 to 0.325 inches, spaces between rows (RS) of between 0.043 to 0.082 inches, and spaces between slits (SS) of between 0.065 to 0.122 inches, or, more preferably, having slit lengths (SL) of between 0.2 to 0.3 inches, spaces between rows (RS) of between 0.05 to 0.075 inches, and spaces between slits (SS) of between 0.075 to 0.1125 inches.
  • said expandable slit sheet paper has a pattern of slits having slit lengths (SL) of between 0.175 to 0.325 inches and spaces between rows (RS) of between 0.043 to 0.082 inches, or, more preferably, having slit lengths (SL) of between 0.2 to 0.3 inches and spaces between rows (RS) of between 0.05 to 0.075 inches.
  • said expandable slit sheet paper has a pattern of slits having slit lengths (SL) of between 0.175 to 0.325 inches and spaces between slits (SS) of between 0.065 to 0.122 inches, or, more preferably, having slit lengths (SL) of between 0.2 to 0.3 inches and spaces between slits (SS) of between 0.075 to 0.1125 inches.
  • said expandable slit sheet paper is made with an extensible paper.
  • said expandable slit sheet paper is formed from an extensible paper that is extensible in the machine direction and the cross direction, said extensible paper having an extensibility within a range of 3 to 20% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper that is extensible in the machine direction and the cross direction without said slit pattern, said extensible paper having an extensibility within a range of 3 to 9% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 3% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 4% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 5% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 6% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 7% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 8% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 9% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 10% in the machine direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 5% in both the machine direction and the cross direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 6% in both the machine direction and the cross direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 7% in both the machine direction and the cross direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 8% in both the machine direction and the cross direction.
  • said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 9% in both the machine direction and the cross direction.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 3%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 4%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 5%.
  • said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 6%.
  • said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 7%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 8%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 9%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 10%.
  • expandable slit sheet paper is made with an extensible paper that is extensible in a machine direction in a range of between 5% to 15% and in a cross direction in a range of between 5% to 15%.
  • expandable slit sheet paper made with an extensible paper that is extensible in a machine direction in a range of between 7% to 15% and in a cross direction in a range of between 7% to 15%.
  • said expandable slit sheet paper is configured to be wrapped concurrently with said support wrap, with said support wrap overlapping said expandable slit sheet paper.
  • said expandable slit sheet paper is configured to be wrapped independently with respect to said support wrap, including at least one of: a) said expandable slit sheet paper being supplied from a supply unit that independently raises and lowers said expandable slit sheet material from a support and that independently raises and lowers said support wrap with respect to said pallet assembly; b) said expandable slit sheet paper being supplied from a supply unit that supplies said expandable slit sheet paper and said support wrap concurrently around said pallet assembly but at different vertical positions along the pallet assembly; and/or c) said expandable slit sheet paper being supplied from a supply unit that supplies said expandable slit sheet paper and said support wrap at at least some different wrapping time sequences from one another.
  • said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 8 lbs to expand the cells into any open state.
  • said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 14 lbs to tear the expandable slit sheet paper.
  • said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 16 lbs to tear the expandable slit sheet paper.
  • said pallet assembly has a pallet with a supporting surface area of at least 3 feet by 3 feet (i.e. , 36 inches by 36 inches).
  • said pallet assembly includes stacked items, boxes or containers extending to a height of at least 3 feet (i.e., 36 inches).
  • said expandable slit sheet paper is configured to not retract or to minimally retract from a fully expanded state.
  • said expandable slit sheet paper is configured to retract from a fully expanded state less than 20%, or, preferably, less than 15%, or, preferably, less than 12.5%, or, preferably, less than 10%, or, preferably, less than 7.5%, or, preferably, less than 5%, or, preferably, less than 2.5%.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 7.5 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 10 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 12.5 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 15 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 17.5 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 20 inches.
  • said expandable slit sheet paper is providing in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of between about 7.5 inches and 30 inches, or, preferably, between about 10 inches and 25 inches, or, preferably, between about 12.5 inches and 22.5 inches.
  • a pallet wrap comprising: an extensible paper sheet having an extensibility in at least a machine direction of greater than 3%.
  • the pallet wrap of embodiments 140 or 141 further including a support wrap for supporting said extensible paper sheet.
  • said pallet wrap further includes a support wrap surrounding at least a portion of said expandable slit sheet paper wrapped around said pallet assembly.
  • a pallet wrap comprising: an extensible paper sheet having an extensibility in at least a machine direction of greater than 4%, or, preferably, greater than 5%, or, preferably, greater than 6%, or, preferably, greater than 7%, or, preferably, greater than 8%, or, preferably, greater than 9%, or, preferably, greater than 10%, or, preferably, greater than 11 %, or, preferably, greater than 12%.
  • FIG. 1 (A) is a plan view of an illustrative slit sheet paper according to the background art in an unexpanded state, specifically corresponding to FIG. 1 of U.S. Patent No. 5,667,871
  • FIG. 1 (B) is a plan view of an illustrative slit sheet paper according to the background art in an expanded state, specifically corresponding to FIG. 3 of U.S. Patent No. 5,667,871 ;
  • FIG. 2(A) shows a top plan view of a sample expanded slit sheet paper employing Kraft paper, which opens in a manner substantially similar to that shown in FIG. 1 (B);
  • FIG. 2(B) shows a top view of the same expanded slit sheet paper shown in FIG. 2(A) taken at an angle to the plane of the expanded paper, such as to look directly into the expanded cells of the paper;
  • FIG. 2(C) shows a top view of the same expanded slit sheet paper shown in FIGS. 2(A) and 2(B), but taken an angle to the plane of the expanded paper opposite to that of the angle shown in FIG. 2(B);
  • FIG. 2(D) shows a top view of the same expanded slit sheet paper shown in FIGS. 2(A)-2(C), but taken from an angle to the plane of the expanded paper from a position lower to the plane of the paper proximate the lower end of FIG. 2(D);
  • FIG. 3(A) shows a top plan view of an alternating row expansion pattern of an expanded slit sheet paper according to some preferred embodiments of the present invention
  • FIG. 3(B) shows a top view of the expanded slit sheet paper shown in FIG. 3(A) taken at an angle to the plane of the paper, such as to look at the expanded slit sheet paper from a top right side of the view in FIG. 3(A);
  • FIGS. 4(A) to 4(C) show the formation of the alternating row expansion pattern employed in some embodiments of the invention, wherein FIG. 4(A) shows an illustrative slit pattern formed within a sheet of paper, FIG. 4(B) shows the slit pattern of FIG. 4(A) with regions of the paper prior to expansion highlighted for reference, and FIG. 4(C) is a photograph of an illustrative expanded slit sheet paper having a slit pattern similar to that shown in FIG. 4(B) in an expanded state;
  • FIGS. 2(A)-2(D), 3(A)-3(B) and 4(C) are photographs of actual products. Accordingly, these photographs show illustrative examples, to scale, such that these figures show illustrative examples to scale and angles and relative dimensions shown in these figures are as shown in these figures in such illustrative examples.
  • angles of lands, legs, and other portions of the expanded slit sheet paper can be, in some embodiments, as shown in such figures.
  • such shown angles and relative dimensions can be varied slightly, such as, e.g., plus or minus 15% in some examples, or plus or minus 10% in some other examples.
  • FIG. 5 is a schematic perspective view showing a pallet wrapping system and method according to a first embodiment of the invention
  • FIG. 6 is a schematic perspective view showing a pallet wrapping system and method according to a second embodiment of the invention.
  • FIGS. 7(A) and 7(B) are schematic top views of an illustrative pallet assembly demonstrating conveyance relationships between expandable slit sheet paper and support wrap in some illustrative embodiments;
  • FIG. 8 is a schematic diagram showing components of a controller or control unit in some illustrative embodiments;
  • FIG. 9 is a plan view of an illustrative pallet wrap that can be employed in some illustrative embodiments of the invention.
  • FIG. 10 is a perspective view of an illustrative pallet assembly with a banner wrapped therearound in accordance with some illustrative embodiments of the invention.
  • FIG. 11 is a schematic perspective view showing a pallet wrapping system and method according to a third embodiment of the invention.
  • FIGS. 12(A) and 12(B) are perspective views showing illustrative pallet assemblies (e.g., illustrative boxes and/or containers stacked as pallet assemblies upon a pallet) according to some illustrative examples;
  • FIG. 13 is a schematic plan view (i.e. , top view) illustrating rotation of a pallet assembly in relation to a packaging wrap according to some illustrative embodiments;
  • FIG. 14 is a schematic perspective view showing an illustrative manual pallet wrapping system and method according to another embodiment of the invention.
  • FIG. 15 is a schematic perspective view showing an illustrative embodiment of retrofitting an existing pallet wrap machine that does not dispense expandable slit sheet paper to become a pallet wrap machine that dispenses expandable slit sheet paper according to an embodiment of the present invention.
  • a novel and highly beneficial pallet wrap is provided that is made with recyclable materials.
  • a novel and highly beneficial pallet wrap is provided that is made with recyclable paper.
  • a novel and highly beneficial pallet wrap is provided that is made with an expandable slit sheet paper material.
  • a novel and highly beneficial pallet wrap is provided that is made with an extensible paper material.
  • a novel and highly beneficial pallet wrap is provided that is a) made with an expandable slit sheet paper material and b) made with an extensible paper material.
  • plastic wraps have persisted as the means for wrapping of pallets within the art, such as, e.g., seen in patents and publications incorporated herein by reference.
  • a suitable pallet wrap can be created by providing a novel and unique combination of: a) an extensible paper material having a particular range of extensibility; b) the extensible paper material being formed with an array of slits such as to form an expandable extensible slit sheet material; and c) an supporting wrap provided to support the expandable extensible slit sheet material.
  • extensibility of paper is a quality of the paper
  • %’s of extensibility described in this document pertain to extensibility as measured with respect to the paper in an unslit condition (i.e. , the % of extensibility being due to the quality of the paper rather than to the mechanics of expanding slit paper).
  • the present inventor discovered that such a novel first embodiment can provide a highly viable pallet wrap that is made with paper materials, and, very advantageously, in which the pallet wrap is recyclable.
  • the present inventor also discovered various additional embodiments achieving, e.g., the unexpected result of enabling the provision of paper and the like materials as pallet wrap materials, including, for example, various embodiments employing various novel and advantageous pallet wraps made of, e.g., recyclable materials (e.g., recyclable paper) that can be implemented without the use of an additional support wrap or other supporting elements to further support the pallet wrap.
  • recyclable materials e.g., recyclable paper
  • the preferred embodiments of the present invention unexpectedly and highly advantageously provided novel and advantageous alternatives to the plastics used to wrap around pallets as well as to the existing plastic shrink wraps used to support pallets in the existing art.
  • FIG. 5 shows an illustrative embodiment of the present invention.
  • a pallet wrap 500 is employed that is made with recyclable paper materials.
  • the pallet wrap 500 includes a first material 510 that includes an expandable slit sheet material supplied from a roll of expandable slit sheet material 210, and includes a supporting wrap 520 that is supplied from at least one roll of supporting wrap material 220.
  • a supporting wrap 520 that is supplied from at least one roll of supporting wrap material 220.
  • two rolls of supporting wrap material 220 are depicted.
  • alternative embodiments can include a single roll 220, or three rolls 220, or four rolls 220 or more.
  • the pallet wrap 500 is supplied from a pallet wrap supply unit 200.
  • the pallet wrap supply unit 200 includes at least one support 200C that rotatably supports the roll of expandable slit sheet material 210 and at least one support 200C that rotatably supports the at least one roll of supporting wrap material 220.
  • the roll of expandable slit sheet material 210 and the at least one roll of supporting wrap material 220 are supported by the same support 200C.
  • separate supports can be provided supporting the roll of expandable slit sheet material 210 and the at least one roll of supporting wrap material 220.
  • the pallet wrap supply unit 200 is configured to enable the supply rolls 210 and 220 to be controllably raised and/or lowered in order to adjust the supply height of the expandable slit sheet material 510 and the supporting wrap 520.
  • the support 200C can include a cabinet or holder structure that is configured to be controllably raised and/or lowered upon a support shaft 200S that is mounted to extend upright alongside the pallet 10 and is supported upon a support member or base 200B.
  • the support 200C is configured to be both controllably raised and controllably lowered during operation.
  • mechanisms to raise or lower the support 200C can be like that of mechanisms in the patents and publications incorporated herein by reference.
  • a supply unit 200 can be configured like that of the background supply devices of plastic wraps, etc., of the patents and publications incorporated herein by reference.
  • a mechanism to raise and lower the support 200C can include any mechanical/electrical reciprocation mechanism that can reciprocate the support 200C, such as, by way of example: a timing belt; a conveyor belt; a pulley system; an hydraulic piston; a solenoid mechanism; an electronic motor; a threaded engagement between the shaft 200S and the support 200C, such that rotation of the shaft 200S causes reciprocal movement of the support 200C; and/or other suitable mechanical/electrical reciprocation mechanism(s).
  • any mechanical/electrical reciprocation mechanism that can reciprocate the support 200C, such as, by way of example: a timing belt; a conveyor belt; a pulley system; an hydraulic piston; a solenoid mechanism; an electronic motor; a threaded engagement between the shaft 200S and the support 200C, such that rotation of the shaft 200S causes reciprocal movement of the support 200C; and/or other suitable mechanical/electrical reciprocation mechanism(s).
  • the pallet wrap 500 that is supplied from the pallet wrap supply unit 200 is preferably initially held alongside a side of a pallet assembly 10 (e.g., an assembly of items such as, e.g., a plurality of boxes) that is supported upon a pallet 110 (e.g., a horizontal support member such as, e.g., a wooden support frame or other support member).
  • a pallet assembly 10 e.g., an assembly of items such as, e.g., a plurality of boxes
  • a pallet 110 e.g., a horizontal support member such as, e.g., a wooden support frame or other support member.
  • the pallet 110 and the pallet assembly 10 thereon are supported by the pallet support unit 100.
  • the pallet support unit 100 includes a rotatable support floor member 120 upon which the pallet 110 rests, and which is controllably rotatable around a center axis 100A so as to rotate in at least a direction 100R to cause the pallet wrap 500 to unroll from the rolls 210 and 220 and surround the pallet assembly 10 as shown in FIG. 5.
  • a rotatable support floor member 120 upon which the pallet 110 rests, and which is controllably rotatable around a center axis 100A so as to rotate in at least a direction 100R to cause the pallet wrap 500 to unroll from the rolls 210 and 220 and surround the pallet assembly 10 as shown in FIG. 5.
  • FIG. 5 wraps the pallet assembly by rotation in the direction of arrow 100R, it should be appreciated that other embodiments can impart wrapping by rotation in an opposite direction and/or by rotation in either the direction of arrow 100R or an opposite direction thereto.
  • the pallet 110 is a horizontal support member that includes a frame structure configured to enable the pallet to be lifted and manipulated via pallet-moving machinery, such as, by way of example, a forklift device.
  • the pallet is provided to support a stack of boxes or containers thereon as shown in, e.g., FIG. 5.
  • the boxes or containers contain items of merchandise and/or other items which are stored within the boxes or containers for transportation and/or movement and/or storage of items of merchandise and/or other items.
  • such pallets can be employed in warehouses, storage facilities, transportation systems, such as, e.g., boats, trains, planes, trucks and/or other vehicles for transportation of items of merchandise and/or other items.
  • a pallet can support a plurality of like items that are stacked thereon.
  • like items are stacked on a pallet (pallet not shown).
  • a pallet can support a plurality of varied items, having different shapes and/or dimensions.
  • FIG. 12(B) a plurality of varied items are shown stacked on a pallet (pallet not shown).
  • the pallet assembly thereon may have different contours and, thus, may present different surface features that a pallet wrap must deal with. Additionally, in some instances, narrower boxes or packages may have higher degrees of instability. Additionally, in some instances, the weight of particular items within boxes or containers can also affect requirements. Accordingly, it should be appreciated that different pallet assemblies can present different requirements on a pallet wrap that supports the particular pallet assembly on the pallet.
  • the present invention provides a highly novel and advantageous pallet wrap 500 that includes, e.g., a highly novel and advantageous expandable slit sheet paper 510.
  • the configuration of the expandable slit sheet paper according to the preferred embodiments of the present invention provides a) increased tensile strength over prior expandable slit sheet paper (i.e. , thus, enabling the use in wrapping of pallets) and b) substantial flexibility (e.g., provided by expansion in a machine direction), along with increased ability to contour to corners of boxes and the like on the pallet assembly (such as, e.g., even in varied embodiments similar to that shown in FIG. 12(B)).
  • an expandable slit sheet paper can be expanded and wrapped around a pallet assembly, and the nature of the expandable slit sheet paper will facilitate bending, twisting and/or contouring of the expandable slit sheet paper as it is wrapped around irregular contours of the pallet assembly, altering direction of tensile stretching around the pallet assembly, bending around a non-planar surface and/or otherwise altering direction, contour, etc., as it is wrapped around the pallet assembly.
  • the rotatable support floor member 120 is caused to be rotated via a motor 100M, whereby the pallet assembly 10 can be readily and controllably rotated by rotation of the support floor member 120 which in turn rotates the pallet 110 and in turn the pallet assembly 10.
  • the support floor member 120 can be manually rotated, such as, e.g., by a user grasping one or more handle to impart rotation and/or the side of the pallet or pallet assembly.
  • a motor 100M is preferably employed.
  • the motor 100M is controlled to effect rotation by a controller 300 or control unit as shown in FIG. 5.
  • the controller 300 can include a simple on/off switch to start or stop rotation of the support floor member 120.
  • the controller can be computer controlled such as to more precisely control rotation of the support floor member 120.
  • the controller 300 also controls a reciprocal movement of the support 200C, such that the rotational movement of the support floor member 120 is controlled along with the reciprocal movement of the support 200C.
  • the controller 300 is employed to control the vertical movement of the support 200C commensurately with the rotation of the support floor member 120.
  • a user can set the relative movements, based on factors, such as, e.g., the size of the pallet assembly 10, the width of the expandable slit sheet material 510, etc., and/or other circumstances. For example, in some contexts a user may desire more overlapping of layers of the expandable slit sheet material 510 for greater support whereby the relative vertical speed of the support 200C may be moved at a slower rate with respect to the rotation of the support floor member 120.
  • FIG. 8 shows illustrative controller or control unit components according to some illustrative embodiments.
  • a controller or control unit can be provided that employs a computer or like control unit that is used to implement computerized process steps, to be carried out by devices, such as, e.g., to control operation of motors for rotating the pallet support, to control other aspects of control according to other embodiments (such as, by way of example, raising/lowering of expandable paper and/or the like) according to some embodiments.
  • the computer or control unit includes a central processing unit (CPU) 322, which can communicate with a set of input/output (I/O) device(s) 324 over a bus 326.
  • CPU central processing unit
  • the I/O devices 324 can include, for example, a keyboard, monitor or display, and/or other devices.
  • the CPU 322 can communicate with a computer readable medium (e.g., conventional volatile or non-volatile data storage devices) 328 (hereafter “memory 328”) over the bus 326.
  • a computer readable medium e.g., conventional volatile or non-volatile data storage devices
  • the interaction between a CPU 322, I/O devices 324, a bus 326, and a memory 328 can be like that known in the art.
  • Memory 328 can include, e.g., data 330.
  • the memory 328 can also store software 338.
  • the software 338 can include a number of modules 340 for implementing the steps of processes. Conventional programming techniques may be used to implement these modules.
  • Memory 328 can also store the above and/or other data file(s).
  • the various methods described herein may be implemented via a computer program product for use with a computer system.
  • This implementation may, for example, include a series of computer instructions fixed on a computer readable medium (e.g., a diskette, a CD-ROM, ROM or the like) or transmittable to a computer system via and interface device, such as a modem or the like.
  • a communication medium may be substantially tangible (e.g., communication lines) and/or substantially intangible (e.g., wireless media using microwave, light, infrared, etc.).
  • the computer instructions can be written in various programming languages and/or can be stored in memory device(s), such as semiconductor devices (e.g., chips or circuits), magnetic devices, optical devices and/or other memory devices.
  • the transmission may use any appropriate communications technology.
  • FIG. 6 shows another embodiment that is similar to the embodiment shown in FIG. 5.
  • elements that are similar to that of the embodiment shown in FIG. 5 are shown with similar reference numbers, along with the identifier “a” designating the embodiment shown in FIG. 6.
  • Flowever in contrast to the embodiment shown in FIG. 5, in the embodiment shown in FIG. 6, separate supports are provided supporting the roll of expandable slit sheet material 210a and the at least one roll of supporting wrap material 220a.
  • the roll 210a is schematically depicted as being reciprocatable upward and downward along the support shaft 200aS1
  • the roll 220a is schematically depicted as being reciprocatable upward and downward along the support shaft 200aS2.
  • support structures of the roll 210a and of the roll 220a are, thus, configured to provide independent upward and downward movement of the rolls 210a and 220a.
  • the support structures of the roll 210a and 220a include a common base support 200aC.
  • the vertical i.e.
  • up and down) movement of the rolls 210a and 220a can be imparted employing any mechanical /electrical reciprocation mechanism that can reciprocate the support 200aC, such as, by way of example: a timing belt; a conveyor belt; a pulley system; an hydraulic piston; a solenoid mechanism; an electronic motor; a threaded engagement between the shaft(s) 200aS1 and 200aS2 and the support 200aC, such that rotation of the shaft(s) cause reciprocal movement of the respective rolls; and/or other suitable mechanical/electrical reciprocation mechanism(s).
  • any mechanical /electrical reciprocation mechanism that can reciprocate the support 200aC, such as, by way of example: a timing belt; a conveyor belt; a pulley system; an hydraulic piston; a solenoid mechanism; an electronic motor; a threaded engagement between the shaft(s) 200aS1 and 200aS2 and the support 200aC, such that rotation of the shaft(s) cause reciprocal movement of the respective rolls; and/or other suitable
  • the support wrap 520 is consistently dispensed alongside the expandable slit sheet material 510, whereby the pallet wrap 500 is consistently supplied as a two-layered structure with the support wrap 520 consistently located relative to the expandable slit sheet material 510.
  • independent movement of the expandable slit sheet material 510 with respect to the support wrap 520 enables other forms of control in various embodiments.
  • the vertical positions of the expandable slit sheet material 510 and the support wrap 520 can differ from one another.
  • the structure can also be more readily employed to apply the respective expandable slit sheet material 510 and the support wrap 520 independently at different times.
  • the expandable slit sheet paper 510 can be initially applied around a portion or all of the pallet assembly 10a prior to wrapping of the support wrap 520.
  • the expandable slit sheet paper 510 can be raised and/or lowered at a different rate than that of the support wrap 520.
  • the present invention provides a novel and highly advantageous pallet wrap (e.g., 500, 500a) having substantial advantages and achieving unexpected results.
  • an expandable slit sheet paper layer 510, 510a is applied as a first layer that makes contact with the pallet assembly 10, and the support wrap 520, 520a is applied as a second layer that is wrapped over the expandable slit sheet paper layer.
  • the expandable slit sheet paper is provided from a unique and novel expandable slit sheet paper having unusually high tensile properties, while providing expansion in a lengthwise or machine direction and cushioning in a widthwise direction of the expandable slit sheet paper.
  • These qualities and characteristics are highly advantageous in the wrapping of pallets due to, for example, the shifting of items within the pallet assembly on the pallet during transport and handling, vibration and/or the like.
  • the expandable slit sheet paper can be made with very unique paper and characteristics as described herein.
  • the support wrap is utilized along with the expandable slit sheet paper in order to provide further support of the expandable slit sheet paper.
  • some embodiments can omit the support wrap and can employ only an expandable slit sheet paper as a pallet wrap according to some embodiments, in some of the preferred embodiments, a support wrap is further provided as described herein.
  • the support wrap is made of a material that does not elongate in the machine direction or lengthwise in the same manner as the expandable slit sheet material. Therefore, the support wrap is preferably employed as a reinforcing layer to help more rigidly maintain the wrapped state of the pallet assembly.
  • the support wrap is made with a narrow width material.
  • the expandable slit sheet material would surround a substantial portion of or all of the periphery of the pallet assembly 10
  • the support wrap would not surround a substantial portion or all of the periphery of the pallet assembly. Accordingly, in some preferred embodiments, the expandable slit sheet paper would be visible and not covered by the support wrap in a significant percentage of the outer periphery of the pallet assembly.
  • the support wrap includes one or more of the following: a) reinforced paper (such as, in some examples, fiber or filament reinforced paper); b) reinforced tape (such as, in some examples, fiber or filament reinforced tape); c) fiber strands or filaments (extending lengthwise within the support wrap for lengthwise reinforcement); d) a plurality of filaments or fibers (extending lengthwise); e) fiberglass; f) fiberglass filaments (extending lengthwise); g) tape (e.g., such as to resist stretching or extension); and/or h) paper tape (e.g., heavier paper and/or treated such as to resist stretching or extension).
  • the support wrap can include any existing fiber-reinforced tapes and/or fiber reinforced papers.
  • the support wrap can include fiber-reinforced papers, tapes and/or other materials as described within any of the below-listed patents and publications, the entire disclosures of which are incorporated herein by reference as if recited herein in full.
  • the support wrap can be a plurality of filaments or fibers independent of a paper or tape supporting the plurality of filaments or fibers, such as, in some examples, a plurality of filaments or fibers of the types set forth in any of the below-listed patents and publications, the entire disclosures of which are incorporated herein by reference as if recited herein in full:
  • the support wrap can include a narrow or minimal amount of plastic webbing or plastic strands or plastic ropes or plastic filaments.
  • roping of the type shown in U.S. Patent No. 8,549,819, entitled Pallet Roping and Wrapping Apparatus and Method can be employed, the entire disclosure of which patent is incorporated herein by reference as though recited herein in full.
  • the more preferred embodiments would not include amounts of plastics that would preclude or limit recyclability.
  • the support wrap employed can comprise filaments found in reinforced tapes.
  • the filaments include elongated strands or string-like members that can be wound around a roll in a similar manner to that shown in the figures related to, e.g., the rolls 220, 220a.
  • the expandable slit sheet paper can be wrapped around the pallet assembly (e.g., 10, 10a) and the filaments can be wound around an outer surface of the expandable slit sheet paper (such as, e.g., in a similar manner to any of the embodiments described above, such as, e.g., in either of the embodiments shown in FIGS. 5 and 6).
  • the support wrap can employ filaments that are either a) supported by or integrated with a tape, paper or other material or b) independently provided as the support wrap.
  • filaments can include any fibrous product that would add strength (e.g., tensile strength) to the wrapping process.
  • filaments can include one or more of the following: a) nylon filaments; b) polymer filaments; c) glass filaments; and/or d) natural filaments, such as, e.g., plant filaments, cotton filaments, bamboo filaments, etc.
  • the filaments can comprise a plurality of entwined filaments, a plurality of parallel filaments and/or a plurality of filaments otherwise fixed or bound together.
  • a support wrap e.g., 520, 520a
  • the support wrap can comprise a heavy weight paper having sufficient strength to provide a sufficient support wrap under certain circumstances (i.e. , a non-slit heavy paper can be employed in some embodiments).
  • a support wrap e.g., 520, 520a
  • a support wrap can be provided by a paper having a weight of 40# or larger.
  • a support wrap (e.g., 520, 520a) can be provided by a paper having a weight of 45# or larger.
  • a support wrap (e.g., 520, 520a) can be provided by a paper having a weight of 50# or larger.
  • a support wrap (e.g., 520, 520a) can be provided by a paper having a weight of 55# or larger.
  • a support wrap e.g., 520, 520a
  • a support wrap (e.g., 520, 520a) can be provided by a paper having a weight of 60# or larger.
  • a support wrap (e.g., 520, 520a) can be provided by a paper having a weight of 65# or larger.
  • the support wrap when such a heavy unslit paper is employed as the support wrap, the support wrap has a width that is substantially narrower than the width of the expandable slit sheet paper.
  • the width of such a heavy unslit paper type support wrap can be similar to that of any of the embodiments of support wrap widths described herein-above (i.e., excluding embodiments related to support wraps without paper, tape or the like, such as, e.g., some filament-only embodiments).
  • a support wrap e.g., 520, 520a
  • a separate roll e.g., 220, 220a
  • a support wrap can be wrapped alongside within the roll of expandable slit sheet material such as to be co-rolled as a single roll and co-dispensed from the single roll.
  • the support wrap can be glued or adhered to the expandable slit sheet paper in a manner that upon expansion of the expandable slit sheet paper, the glue or adhesion will give way or accommodate the expansion and will not interfere with such expansion.
  • the glue can be lightly adhesive to facilitate co-dispensing without interference with expansion.
  • the support wrap is designed specifically to provide reinforcement (e.g., tensile reinforcement) and preferably does not expand in a similar manner to the expandable slit sheet material, if the support wrap is co-rolled or adhered to the expandable slit sheet paper, the support wrap is preferably adapted to accommodate such elongation.
  • a support wrap 520c comprising a plurality of elongated filaments 520c is adapted such that the filaments are not arranged in a straight line, but arranged in a wavy formation, or an undulating formation, which waves or undulations are preferably sized such that the filaments reach a straight relationship upon full or near full expansion of the expandable slit sheet paper.
  • a support wrap can include four filaments provided alongside the expandable slit sheet paper, such as, e.g., shown in the example in FIG. 9.
  • a single filament can be provided.
  • two filaments can be provided.
  • three filaments can be provided.
  • five filaments can be provided.
  • six or more filaments can be provided.
  • the filaments in which filaments are applied as the support wrap, rather than having the filaments co-rolled with the expandable slit sheet paper, the filaments can be co-rolled on a filament roll such that a plurality of filaments are co-unrolled from a single roll (e.g., similar to unrolling from a roll 220, 220a).
  • each individual filament in which filaments are applied as the support wrap, but not co-rolled with the expandable slit sheet paper, each individual filament can be separately dispensed or supplied, such as, e.g., each individual filament being supplied by a separate and individual filament roll.
  • each filament roll can be mounted on a separate reciprocating mechanism (e.g., similarly to the embodiment shown in FIG. 6 in which rolls 210a and 220a are separately reciprocatable), whereby the filaments can be applied at different locations and in different patterns around the periphery of the pallet assembly.
  • a separate reciprocating mechanism e.g., similarly to the embodiment shown in FIG. 6 in which rolls 210a and 220a are separately reciprocatable
  • the illustrated embodiments show a single roll of expandable slit sheet material (e.g., 210, 210a) supplied to wrap the pallet assembly
  • two or more such rolls can be provided, which can be either co- reciprocated in some embodiments or individually reciprocated in other embodiments.
  • multiple rolls of expandable slit sheet material and/or of support wrap e.g., filaments or otherwise
  • such rolls can be distributed around the periphery of the pallet assembly in a variety of manners.
  • co-locating such rolls proximate one side of the pallet assembly can facilitate use (e.g., facilitating placement of the pallet assembly and pallet upon the support surface of the pallet support or the like).
  • a distal end of the support wrap (such as, e.g., filaments or tape) can be tied, or otherwise connected, to the pallet (e.g., 110, 110a) or to a portion of the pallet assembly.
  • a distal end of the support wrap (such as, e.g., filaments or tape) can be fixed to the pallet (e.g., 110, 110a) or to a portion of the pallet assembly by tape, adhesive, clamps, and/or other fixing elements.
  • the distal end of the expandable slit sheet material is held with respect to the pallet assembly to enable wrapping of the pallet assembly by being located beneath the support wrap such that the support wrap holds the distal end of the expandable slit sheet material against the pallet assembly and/or pallet.
  • a distal end of the expandable slit sheet paper can similarly be fixed to the pallet (e.g., 110, 110a) or to a portion of the pallet assembly by tape, adhesive, clamps, and/or other fixing elements.
  • a distal end of the expandable slit sheet paper can similarly be tied, or otherwise connected, to the pallet (e.g., 110, 110a) or to a portion of the pallet assembly.
  • a movable pin, rod, lever or clamp member can be provided proximate the pallet (e.g., 110, 110a) or proximate a lower portion of the pallet assembly (e.g., 10, 10b) that can be moved against the outer surface of the pallet and/or the pallet assembly such as to press and hold the distal end of the expandable slit sheet paper against the pallet and/or pallet assembly.
  • a pin, rod, lever or clamp member can be mounted to the support surface 120, 120a so as to be pivotally movable against the side of the pallet or pallet assembly and locked in a pressing state thereagainst.
  • a user can place an end of the expandable slit sheet paper against the pallet or lower end of the pallet assembly, can press the pin, rod, lever or clamp member thereagainst and can start the rotation of the pallet assembly to initiate wrapping.
  • the expandable slit sheet paper’s open cells between adjacent layers can provide sufficient support to retain the expandable slit sheet paper around the pallet assembly without the provision of the pin, rod, lever or clamp member and the pin, rod, lever or clamp member can be moved to a disengaged position and no longer apply retaining pressure, while the expandable slit sheet paper can remain on the pallet assembly due to engagement between layers of open cells.
  • additional tape or the like can be added if needed or desired to facilitate maintaining of the expanded slit sheet paper around the pallet assembly.
  • the expandable slit sheet paper (e.g., 510, 510a) has a width, in an unexpanded state, in a cross-direction (e.g., a direction parallel to an axis of the roll (e.g., 210, 210a)) that is between about 4 to 36 inches, and, in some preferred embodiments, that is between about 8 to 24 inches, and, in some other preferred embodiments, that is between about 12 to 19 inches, and, in some other preferred embodiments, that is between about 14.5 to 16.5 inches, and, in some illustrative embodiments, that is about 15.25 inches.
  • the support wrap (e.g., 520, 520a) has a width in a cross-direction (e.g., transverse to a length of the support wrap) that is substantially narrower than that of the expandable slit sheet paper.
  • the width is preferably less than about 4 inches in some preferred embodiments.
  • the width of the support wrap is less than about 3.5 inches. In some more preferred embodiments, the width of the support wrap is less than about 3.0 inches.
  • the width of the support wrap is less than about 2.5 inches. In some preferred embodiments, the width of the support wrap is less than about 2.0 inches. In some preferred embodiments, the width of the support wrap is less than about 1.5 inches. In some preferred embodiments, the width of the support wrap is less than about 1.0 inches. In some preferred embodiments, the width of the support wrap is less than about 0.75 inches. In some preferred embodiments, the width of the support wrap is less than about 0.5 inches. In some preferred embodiments, the width of the support wrap is less than about 0.25 inches.
  • the width is substantially less than 0.25 inches, and, in some embodiments preferably, even less than 0.1 inches, and, in some embodiments, preferably, even less than 0.05 inches and, in some embodiments, as narrow as various filaments described in the background patents and publications incorporated by reference herein.
  • a modified support wrap can be provided that includes filaments supported on or laminated to a light-weight paper sheet, such as, e.g., a light- weight Kraft sheet.
  • a light-weight paper sheet such as, e.g., a light- weight Kraft sheet.
  • the light-weight Kraft sheet can have a width of greater than 4 inches, and in some embodiments a width that is the same or similar to that of the expandable slit sheet paper in an expanded state or even in an unexpanded state, or even larger.
  • use of such an external lightweight Kraft sheet can be provided to provide a protective layer to the underlying expanded slit sheet paper, such as to, e.g., protect the expanded slit sheet paper from abrasion or the like during handling, transport and/or shipment.
  • such a light-weight Kraft sheet can involve, e.g., a paper having a weight of less than 40#, or, in some embodiments, less than 35#, or, in some embodiments, less than 30#, or, in some embodiments, less than 25#, or, in some embodiments, less than 20#.
  • the expandable slit sheet paper layer advantageously tightens everything up and provides a cushioned barrier for the outer support wrap (e.g., paper tape or the like) to hold everything together without bursting the support wrap (e.g., paper tape).
  • the support wrap e.g., tape
  • the support wrap would burst if there wasn’t the flexibility underneath it provided by the expandable slit sheet material to accommodate vibrations and/or slight load shifts of the pallet assembly.
  • a plurality of support wraps are provided across the widthwise direction of the expandable slit sheet.
  • two support wraps are provided across the widthwise direction of the expandable slit sheet.
  • three or more support wraps can be provided within the widthwise direction of the expandable sheet.
  • a single support wrap can be provided across the widthwise direction of the expandable sheet.
  • less than one support wrap can be applied per across the widthwise direction of the expandable sheet (such as, e.g., in some variations of the embodiment in FIG. 6 in which the support wrap can be spread out more widely around the periphery of the pallet assembly).
  • FIG. 5 depicts an illustrative pallet wrap supply unit 200 in which the expandable slit sheet paper 510 is fed at an angle with respect to the support wrap 520
  • other embodiments can include systems that feed the expandable slit sheet paper 510 and support wrap 520 at either greater respective angles and/or at smaller respective angles.
  • the relative angle a between the sheets 510 and 520 can be between about 15-45 degrees, in some examples, and as shown in FIG. 7(B), the relative angle a can be between about 0-10 degrees, in some examples.
  • the expandable slit sheet paper is provided from a unique and novel expandable slit sheet paper having unusually high tensile properties, while providing expansion in a lengthwise or machine direction and cushioning in a widthwise direction of the expandable slit sheet paper.
  • These qualities and characteristics are highly advantageous in the wrapping of pallets due to, for example, the shifting of items within the pallet assembly on the pallet during transport and handling, vibration and/or the like.
  • the expandable slit sheet paper can be made with very unique paper and characteristics as described herein.
  • the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 30#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 35#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 40#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 45#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 50#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 55#.
  • the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 60#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of greater than 65#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of between about 45 to 70#. In some embodiments, the expandable slit sheet paper is provided by an extensible sheet of paper having a weight of between about 50 to 65#.
  • the expandable slit sheet paper used to wrap a pallet assembly faces different functional and structural requirements than a expandable slit sheet paper used to wrap a product that is stored within a package, box or container during shipping.
  • the main function of the expandable slit sheet paper is cushioning that is applied across the width or thickness of the expanded sheet.
  • the tensile quality of the expandable slit sheet paper not of significance.
  • such wrapping of a product that is stored within a package, etc. is often performed by hand, and often involves varied application of tensile stresses, such that at at least some locations, the tensile load applied to the expandable slit sheet paper is considerably lower than that required for maximum expansion or near maximum expansion of the expandable slit sheet paper. Accordingly, in use of expandable slit sheet paper to wrap a product that is stored in a package, etc., the expandable slit sheet paper is frequently not expanded to or near to the full expansion of the expandable slit sheet paper. Moreover, the tensile forces sustained or even capable of being sustained by such prior expandable slit sheet papers were substantially less than that afforded by the preferred embodiments of the present invention.
  • some most preferred embodiments of the present invention employ a novel and highly advantages expandable slit sheet paper that includes the present inventor’s novel application of extensible paper, which leads to expandable slit sheet paper with high levels of tensile strength.
  • the present invention employs an extensible paper having a substantially higher weight than the weight of expandable slit sheet papers employed in prior expandable slit sheet papers used in the context of wrapping and protecting products stored in packages, etc.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 45# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 50# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 55# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 60# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 65# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of at least about 70# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of between about 50# to 70# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper (e.g., 510, 510c) can be employed that is an extensible paper made with paper having a weight of between about 55# to 70# and preferably an extensible paper made with a Kraft paper having such a weight.
  • an expandable slit sheet paper can be employed that includes slit arrangements according to any of the embodiments of slit sheet paper described herein.
  • the rows between adjacent slits can be of a reduced size compared to rows employed in wrapping of products placed in packaging, etc., because for wrapping of a pallet, the cushioning quality isn’t as significant as tensile strength and stretch quality of the expandable slit sheet paper. That is, the tensile strength and stretching (i.e. , due to the expansion of the cells) are of higher importance in the context of wrapping of a pallet assembly.
  • the row spacing between slits relates to the thickness in the thickness direction of the sheet upon expansion, which, thus, correlates to cushioning provided in the thickness direction.
  • the expandable slit sheet paper is wrapped around a pallet assembly (e.g., 10, 10a) while the expandable slit sheet paper is applied at or at close to full expansion throughout the entire wrapping process.
  • the expandable slit sheet paper is at or close to full expansion at least within about 50% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly.
  • the expandable slit sheet paper is at or close to full expansion at least within about 55% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly.
  • the expandable slit sheet paper is at or close to full expansion at least within about 60% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly. In addition, in some more preferred embodiments, the expandable slit sheet paper is at or close to full expansion at least within about 65% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly. In addition, in some more preferred embodiments, the expandable slit sheet paper is at or close to full expansion at least within about 70% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly.
  • the expandable slit sheet paper is at or close to full expansion at least within about 75% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly. In addition, in some more preferred embodiments, the expandable slit sheet paper is at or close to full expansion at least within about 80% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly. In addition, in some more preferred embodiments, the expandable slit sheet paper is at or close to full expansion at least within about 85% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly.
  • the expandable slit sheet paper is at or close to full expansion at least within about 90% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly. In addition, in some more preferred embodiments, the expandable slit sheet paper is at or close to full expansion at least within about 95% or more of the length of expandable slit sheet material that is wrapped around the pallet assembly.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.0 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • a maximum load in the machine direction of at least 1.0 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • an expandable slit sheet paper is narrowed when expanded from a non- expanded state to a fully expanded state due to the formation of the expanded cells.
  • employing 1 ⁇ 2 inch long slits and a expandable slit sheet paper having a width in an unexpanded state of about 15.25 inches upon full expansion, the width of the fully expanded slit sheet paper is reduced to about 11.5 inches.
  • this 11.5 inches is preferably configured to withstand a maximum load in the machine direction of at least 11.5 pounds (i.e. , 1.0 pounds/inch x 11.5 inches).
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.1 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.2 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.3 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.4 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.5 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1 .6 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.7 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.8 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 1.9 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.0 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.1 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.2 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.3 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some more preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.4 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 2.5 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of between about 1.0 to 2.5 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of between about 1.1 to 2 pounds per linear inch of the expandable slit sheet paper in a fully expanded state. In some preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of between about 1.2 to 1.75 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 3.0 pounds per linear inch of the expandable slit sheet paper in a fully expanded state, and, in some further preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 3.5 pounds per linear inch of the expandable slit sheet paper in a fully expanded state, and, in some further preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 4.0 pounds per linear inch of the expandable slit sheet paper in a fully expanded state, and, in some further preferred embodiments, the expandable slit sheet material is configured to withstand a maximum load in the machine direction of at least 4.5 pounds per linear inch of the expandable slit sheet paper in a fully expanded state.
  • an expandable slit sheet paper can be provided having a roll in an unexpanded state that is about 15.25 inches wide (i.e. , about 11.5 inches wide in an expanded state), made with 50# basis weight white wrap (i.e., wherein white is less strong due to its bleaching process), which has a tensile strength enabling the supporting of about a 15 to 18 pound load (i.e. , 15-18 lbs.), or, in some examples, about a 16 pound load.
  • a support wrap is used which substantially enhances the tensile load that can be sustained by the pallet wrap of the present invention.
  • the cushioning provided by the expanded slit sheet paper will provide a cushioning barrier that enables a higher tension to be applied.
  • a pallet assembly often has irregularities in shape (such as, e.g., related to variations in box sizes and shapes within the pallet assembly on the pallet) and configuration that can lead to tearing of the pallet wrap.
  • the expandable slit sheet paper can advantageously provide a barrier cushion that enables the pallet wrap to sustain a greater tensile load without breakage.
  • an initial layer or plural initial layers of expandable slit sheet paper can be applied at a reduced tensile load, and then one or more outer layer of expandable slit sheet paper can be applied at a higher tensile load.
  • the interior layer(s) of expandable slit sheet paper at a reduced tensile load can provide a cushioning barrier that enables a higher tensile load to be borne by the outer layer(s).
  • the above %’s of expandable slit sheet paper at or near the noted loads can relate to the outer layers rather than the inner layers that are applied to create a cushioning that enables application of such higher tensile loads in the outer layer(s).
  • prior expandable slit sheet materials simply could not sustain the tensile loads and irregularities in pallet assembly shapes and edges and would necessarily have led to failure of the product if applied as a pallet wrap.
  • expandable slit sheet papers can be employed having slit patterns according to any of the various embodiments described herein.
  • a slit sheet paper can be employed having 0.5 inch slit lengths, 0.1875 land lengths (i.e., the lengths between slits within the same row), and a row spacing of 0.125 inches (i.e., the distance between adjacent rows of slits), which is similar to some expandable slit sheet papers employed by the present inventor for wrapping of products that are contained within packaging, etc., rather than for wrapping of pallet assemblies.
  • the slit pattern employed in the expandable slit sheet paper used for pallet wrapping can be modified from the preceding example.
  • the slit pattern can include a similar ratio of sizes (i.e. , proportional size relationships between slit length, land lengths, and row spacings to that of the preceding example), but with a smaller slit pattern.
  • a smaller slit pattern can produce a stronger tensile strength having advantageous utility in the context of pallet assembly wrapping.
  • a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 10% or more. In some preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 20% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 25% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 30% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 35% or more.
  • a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 40% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 45% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 50% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 55% or more. In some more preferred embodiments, a modified slit pattern can include same ratio to that of the preceding example, but reduced in size by 60% or even more.
  • a slit pattern would include the same ratios as the first example, but reduced such as to be 49% smaller in all dimensions.
  • having a reduced size can advantageously improve tensile qualities of the wrap material, and can also reduce the overall thickness added around the periphery of the wrapped pallet assembly, whereby valuable cargo space and transportation requirements can be further minimized.
  • a smaller slit pattern can provide stronger tensile strengths due to increased number of legs per inch. Additionally, in some embodiments, stronger tensile strengths can be achieved by reducing the slit to land ratio. For example, in some embodiments, the slit to land ratio can be reduced by 5% or more, or in some embodiments by 10% or more, or in some embodiments by 15% or even more. In various embodiments, depending on the particular application (e.g., based on characteristics of the pallet assemblies being wrapped), appropriate ratio can be set for desired stretch/tension characteristics. For example, as increased stretch facilitates wrapping of uneven surfaces, in circumstances in which the pallet assembly contains more uneven or irregular surfaces, the slit patterns can be appropriately selected.
  • an expandable slit sheet paper employed as a pallet assembly wrap can alternatively have a larger slit pattern that is similar to that of the foregoing example (i.e. , of a 0.5 inch slit lengths, 0.1875 inch land lengths, and 0.125 inch row spaces) or even larger than such foregoing example.
  • a larger slit pattern can be provided to provide a better cushioning in some contexts, where desired.
  • a modified slit pattern can include same ratio to that of the above-noted foregoing example, but increased by 10% or more, or, even increased by 20% or more, or, in some examples, increased by 30% or more, or, in some examples, increased by 40% or more, or, in some examples, increased by 50% or even more.
  • a pallet wrap (e.g., 510, 510a) can be provided that includes plural types of expandable slit sheet paper materials that are employed.
  • the plural types of expandable slit sheet material can include expandable slit sheet materials having different slit patterns.
  • a first expandable slit sheet material can be provided having one of the above-noted smaller slit pattern sizes to provide increased tensile qualities
  • a second expandable slit sheet material can be provided having one of the above-noted larger slit pattern sizes to provide increased cushioning qualities.
  • the smaller slit pattern sizes can be employed as a layer underneath the larger slit pattern sizes.
  • the smaller slit pattern sizes can be employed as a layer above the larger slit pattern sizes.
  • the layers can be intermixed with the smaller slit pattern sizes being underneath some portions and above other portions of the larger pattern sizes.
  • the supply unit e.g., 200, 200a
  • the supply unit can be modified to supply two (or more) different types of expandable slit sheet paper together in tandem as a double feed (or more), one on top of the other.
  • double or triple feeding (or more) of expandable slit sheet paper in tandem can also advantageously increase supply rate and, hence, reduce time for wrapping of the pallet assembly and pallet. Moreover, such double or triple feeding (or more) can also facilitate more securely wrapping of a pallet assembly and pallet. Accordingly, in some embodiments, even expandable slit sheet paper of the same type can be double or triple fed so as to achieve such timing and/or other advantages related to such an in-tandem feeding.
  • an additional accessory sheet can be provided that is supplied as a banner that is configured to be wrapped fully one time around the pallet assembly for providing of labels (e.g., load tags, bar codes and the like).
  • a banner sheet 610 can be wrapped fully around the pallet and adhered together to be retained similarly to a ribbon around a wrapped present.
  • the banner 610 can be made with an accessory sheet of recyclable paper.
  • the banner can have a width of about 12 inches. Additionally, in some embodiments, such a banner can be used to additionally or alternatively to further stabilize the pallet assembly. In some embodiments, a plurality of banners 610 can be supplied, to even further stabilize the pallet assembly.
  • the supply unit (e.g., 200, 200a) can be modified to additionally attach a sheet to the periphery of the pallet assembly, wherein the sheet can be provided to provide load tag placement and/or other information such as, e.g., bar codes.
  • a sheet can be a common 8-1/2” x 11” sheet of paper.
  • the sheet of paper can have other sizes.
  • the supply unit can include a sheet dispenser that adheres the sheet to a portion of the unwinding roll (e.g., 210, 210a) of expandable slit sheet paper, just prior to stretching while the unexpanded paper is still on the roll itself.
  • the sheet can include an adhesive such as to fixedly adhere to the expandable slit sheet paper. This placement would inhibit stretching of the expandable slit sheet paper within the region of the sheet. However, in this manner, such a sheet can be readily applied to the side of the pallet assembly. Moreover, the small region of unexpanded sheet would not significantly interfere with the operation of the device.
  • a user can control placement of the sheet via the controller (e.g., 300), whereby the sheet can be programmed to be placed at a particular location on the periphery of the pallet assembly, taking into consideration the vertical position of the roll (e.g., 210, 210a) and the distance to the desired location alongside the pallet assembly. Additionally, in some embodiments, a plurality of such papers or sheets can be attached to one or more sides of the pallet assembly.
  • FIGS. 5 and 6 are configured to impart relative movement between the pallet assembly (e.g., 10, 10a) and the pallet wrap supplying rolls (e.g., 210, 210a, 220, 220b) by causing the pallet assembly to be rotated in relation to a fixedly located supply unit 200
  • the pallet assembly can be fixedly located and not rotated, while the supplying rolls are configured to be moved relative to the fixedly located pallet assembly.
  • various embodiments can be provided that establish different forms of relative movement between the supplying rolls and the periphery of the pallet assembly. For example, in the embodiment schematically shown in FIG.
  • a fixedly located pallet assembly 10b (which is supported on a fixedly located pallet (not shown) is provided, and a supply unit is provided that includes a conveyor member 200bT that is configured to support at least one roll of expandable slit sheet paper 210b that is reciprocated along at least one shaft 200bS1 and at least one support wrap roll 220b that is reciprocated along at least one shaft 200bS2 in a manner such that the roll(s) 210b and the roll(s) 220b are caused to follow a circular path around the periphery of the fixedly located pallet assembly 10b.
  • an operator of the equipment can handle or manage the pallet and pallet assembly while the pallet and pallet assembly are in a fixed position.
  • the track 200bT can be configured to following a rectangular or square path, whereby the roll(s) 210b and the roll(s) 220b are caused to follow a rectangular or square path around the periphery of the fixedly located pallet assembly 10b, which path can, e.g., thus, maintain the roll(s) 210b and the roll(s) 220b at locations closer to the periphery of the pallet assembly 10b during operation.
  • the roll(s) 210b can be supported in a manner so as to be independently movable relative to the roll(s) 220b, such that enhanced control can be achieved in relation to the relative wrapping rates and the like applied by the system.
  • a novel expandable slit sheet material product is preferable employed to wrap pallet assemblies.
  • the present invention advantageously combines novel paper properties with novel slit patterns for improved features and characteristics.
  • an expandable paper employs an improved slit arrangement that was unviable with prior expanded slit paper products, including a compacted slit pattern with, e.g., reduced slit lengths and reduced row spacings, along with the use of a novel extensible paper.
  • a novel slit pattern is capable of being created that provides more cells per square foot and achieves, e.g., a greater crush resistance and resiliency for cushioning.
  • the slit paper pattern of slits advantageously has slits in the range from 0.30 to 0.45 inches (i.e., in the lengthwise dimension of the slits) and spaces between rows in the range from 0.1125 to 0.1688 inches (i.e., the distance between adjacent rows of slits). Most preferably, these embodiments are made from an extensible paper. In some preferred embodiments, the slit paper has slits wherein the slit width is 0.45 inches plus 5%, minus 33% (i.e. , here the slit width refers to the lengthwise dimension of the slits). Most preferably, again, these embodiments are also made from an extensible paper.
  • the slit pattern advantageously produces an expandable slit paper having a number of legs per square foot that is at least 20% greater than slit paper having slit (cut) widths of 0.5 inches.
  • an expanded slit paper cushioning product of the present invention has a number of legs per square foot that is at least 15% greater than slit paper that has slit (cut) widths of 0.5 inches. In some preferred embodiments, an expanded slit paper cushioning product of the present invention has such a number of legs per square foot that is in the range from 20% to 50% greater than that of slit paper having slit (cut) widths of 0.5 inches, and, in some embodiments that is in a range of more than 50% greater than that of slit paper having slit (cut) widths of 0.5 inches.
  • expanded slit sheets can be created having greatly improved cushioning characteristics.
  • the improvement in cushioning characteristics can be achieved due to one or more, or all, of the following: a) In the preferred embodiments, the use of an extensible paper enables an “easier opening” structure, which enables the creation of smaller cells, whereby the smaller cells advantageously lead to the formation of increased cell density and, hence, improved cushioning characteristics. b) In some preferred embodiments, the use of an extensible paper enables the achievement of a novel “alternating row expansion pattern” which has substantially improved cushioning characteristics over prior expansion patterns (see discussion regarding novel alternating row expansion pattern below in this document).
  • novel and previously-unviable pallet wrapping products can be created.
  • extensible papers as set forth in the above- referenced U.S. Patent No. 10,669,086 are employed. Towards that end, the following paragraphs (in quotations) under this section, quoted from the ⁇ 86 patent, set forth details of extensible papers according to some preferred embodiments that can be employed in preferred embodiments of the present invention.
  • the term “extensible” as applied to paper sheets means a paper sheet that is able to stretch in a longitudinal direction of the paper sheet upon applying a force in the longitudinal direction of the paper sheet.
  • Illustrative extensible sheets are disclosed in U.S. Patent No. 3,908,071 , U.S. Patent Application No.14/901 ,997 (U.S. Patent No. 9,945,077), International Application No. WO 1984002936, U.S. Publication Nos. 2002/0060034, 2007/0240841 (US 7,918,966), and U.S. Patent Nos.
  • extensible paper can be produced by varying the accumulation of paper fibers by essentially slowing the paper feeding process during the drying method to trap extra fibers that make the paper appear to have microscopically sized rows of paper that you would see if one were to pleat the paper. The difference is that extensible paper's microscopic rows are adhered to each other through the use of binders and other types of adhesives in conjunction with the drying process.
  • patent U.S. Application No. 2007/0240841 US 7,918,966 where the purpose is to create a non-creped extensible paper that does not easily disconnect from itself. In addition, the surface of the extensible paper is still fairly flat.”
  • the extensible paper that is employed has low extensible properties as compared to other types of extensible papers.
  • an optimal extensible paper enables a smooth transition from an unexpanded to the expanded slit sheet by providing a small amount of stretching at the very start of expansion of the extensible slit sheet paper material.”
  • the force required to initiate expansion is substantially higher than the force required to continue expansion.
  • the extensible slit sheet paper substantially reduces the force required to initiate expansion.
  • the extensible paper does not substantially stretch simultaneously with the process of expanding the slit sheet paper; otherwise, the expanded sheet might not optimally be made into a cushioning wrap.”
  • Extensible paper stretches as part of an increase in paper strength.
  • the functioning of the invention involves that the extensible slit sheet paper substantially utilizes the extensible property to ease the rotating the cells into the stretched shape and to resist tearing of the slit sheet during the expansion step. This means that at the initial point at which the cell rotates (i.e. , initiating rotation between legs 38a and 38b on each side of the slit and land 20) the extensible slit sheet paper is substantially enhanced by the extensible paper's ability to stretch.
  • the functioning of the invention thus, involves that extensible papers’ properties are substantially utilized at this initial point and substantially finished as soon as the cell begins to rotate into its three-dimensional shape (i.e., after this initial point, the reliance on the extensible nature of the paper may be less substantial or even non- existent).
  • the slit pattern properties regardless of paper type, opens with greater ease to the point at which it forms a hexagon. Accordingly, in some embodiments, the extensible property substantially merely comes into play at the initial moment of expansion.
  • the extensible features of the paper can have some affect during further expansion of the paper, whereby the initial point of expansion can be substantially facilitated due to extensibility and further expansion can also be, at least, somewhat facilitated due to extensibility.”
  • preferable extensible papers that can be employed include extensible papers where the purpose of the extensible nature is to provide the type of stretching found for the use of multi-wall bags for heavy weight items like cement, or seed and the like.
  • U.S. Patent Publication No. 2016/0355985 U.S. Application No. 14/901 ,997
  • U.S. Patent Nos. 3,104,197 and 3,266,972 teach the manufacture and properties of this form of extensible paper. Further teachings can be found in “Understanding sheet extensibility”, R.S. Seth, Pulp & Paper Canada T31 , 106:2 (2005) III, pages 33-40 (T31-T38).
  • the disclosures of the foregoing patents, patent publication, and printed publication are incorporated herein by reference, as though recited in full.”
  • this use of an extensible slit sheet paper advantageously provides a reduction in force required to open the slit sheet and therefore provides a faster and easier expanding process for the user of the expanded slit sheet.
  • the unexpected benefit resulting from the reduction in force at the very start of the expansion of the slit sheet provides an unexpected improvement to the slit sheet packaging product and renders the employment of the extensible paper highly unique.
  • the prior expanded slit sheet paper persisted in and was widely used in the marketplace for decades without the contemplation of the present invention or the potential advantages therefrom.”
  • the extensible slit sheet imparts an ease of expansion that greatly reduces the force required to expand the slit sheet, not based on the main purpose for extensible paper which is to increase its tensile strength but, rather, its capability to stretch. Since extensible paper is higher in cost and Kraft paper was strong enough, it was not previously known that extensible paper could be of benefit for making slit paper sheets of the types found in, e.g., U.S. Patent Nos. 5,538,778, 5,667,871 , 5,688,578, and 5,782,735, and U.S. Non-Provisional Application No. 15/428,144.
  • an extensible slit sheet could have provided an equivalent strength to light weight, thin papers that previously had no applicability as a wrapping product.
  • the extensible paper enables the use of the lighter weight expanded slit-sheet papers that also advantageously provide gentler cushioning required by fragile items when a slit sheet is expanded, in contrast to the more rigid cushioning provided by heavier weight expanded slit-sheet papers.”
  • machine direction extensibility ranges of the extendible slit sheet paper can have ranges of: a) from 1.5%-9%, or more preferably from 1.5% to 6% preferred, or even more preferably from 1.5% to 4%; or b) from 2%-9%, or more preferably from 2% to 6% preferred, or even more preferably from 2% to 4%; or c) from 3%-9%, or more preferably from 3% to 6% preferred, or even more preferably from 3% to 4%.”
  • cross direction extensible ranges from 1 %-5% provides an adequate extensibility with 1% to 4% preferred, and 1% to 3% most highly preferred.
  • cross direction extensibility ranges of the extendible slit sheet paper can have ranges of: a) from 1.5%-5%, or more preferably from 1.5% to 4%, or even more preferably from 1.5% to 3%; or b) from 2 %-5%, or more preferably from 2% to 4%, or even more preferably from 2% to 3%.”
  • a smaller, lighter weight, and recyclable version of an expander can be employed (such as, e.g., made entirely or substantially entirely with recyclable cardboard in some illustrative embodiments).
  • This expands the market to customers that use a very small amount of wrap as compared to the industrial market. It also provides for a less expensive expansion device to be employed for expanding the slit paper. Additionally, it enhances the ease of use by the packer by providing for less ripping during the wrapping process that occurs when the tension is not properly set. This occurs as the roll, during its continued use, becomes smaller and lighter in weight. As the roll of expanded slit sheet becomes lighter the tension required increases. Thus, there need for a varying tensioning method.
  • the tension required is significantly decreased and the strength of the paper is increased. Both benefit the person wrapping by making the tensioning required much less precise to the point at which, a single tension setting can be used with little or no adjustment. If the tension is set higher than necessary, the increase in strength from the extensible paper keeps the product from tearing and therefore makes it easier for the packer to use. Therefore, the packer can make fewer adjustments as the slit sheet roll becomes smaller and smaller.”
  • Heavy-duty Clupak paper having a basis weight of 84.9 g/m2 was made using a gap-former paper-making machine equipped with a Clupak system, at a paper-making speed of 480 m/min and using, as material, 100% unbleached softwood Kraft pulp that had been beaten at high concentration of 28%.
  • the negative draw on the Clupak was set to -4.5%.”
  • Heavy-duty Clupak paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 76.1 g/m 2 and the negative draw on the Clupak was set to -6.0%.”
  • Heavy-duty Clupak paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 73.4 g/m 2 and the negative draw on the Clupak was set to -4.0%.”
  • Heavy-duty Clupak paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 85.0 g/m 2 , the negative draw on the Clupak was set to -4.0%, and the pulp blend consisted of 90% unbleached softwood Kraft pulp and 10% unbleached hardwood Kraft pulp.”
  • Heavy-duty Clupak paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 71.9 g/m 2 and the negative draw on the Clupak was set to -10.0%.”
  • Comparative Example 2 Heavy-duty Clupak paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 85.4 g/m 2 and the negative draw on the Clupak was set to -1.0%.”
  • Heavy-duty Kraft paper was made in the same manner as in Example 1 , except that the paper had a basis weight of 76.0 g/m2 and the Clupak process was not performed.”
  • Tensile strength and extensibility or stretch are two important failure properties of paper. They are defined by the end-point of the sheet’s load-elongation curve (Fig. 1). Individually and together, they are important for many product performance properties. For example, TEA, the tensile energy absorbed by the sheet before failure is proportional to the area under the load-elongation curve. Thus, it depends on both the tensile strength and extensibility of the sheet.
  • a high TEA is desired in sack papers [1]
  • the bursting strength of paper has been shown to be proportional to the product of tensile strength and the square-root of stretch [2]
  • the fracture toughness of paper has been found to depend strongly on the sheet’s tensile strength and stretch [3, 4]
  • Sheet stretch has also been regarded as important for paper runnability both at the paper machine’s dry-end and in the pressroom [5-8] Papers with high stretch also seem to have a somewhat higher tearing resistance [9], and folding endurance; they are found to be more dimensionally unstable as well [10]
  • the factors that control sheet tensile strength are fairly well understood [4]
  • the tensile strength is high if fibres are strong, long, fine and thin-walled.
  • the fibres should be conformable and have a high fibre-fibre bond strength.
  • the sheet tensile strength is also high if fibres are straight, free from deformations and the sheets are well formed. Otherwise, the stress is unevenly distributed when the sheet is strained, leading to premature failure.”
  • the sheet stretch of a furnish generally increases with increased fibre-fibre bonding. This is observed for almost all papermaking fibres -- chemical, mechanical, wood, non-wood, or recycled. The reasons are as follows. Fibres have a certain “stretch-potential”. Flowever, this potential is realized in paper only when fibres form a bonded network. If the bonding is weak, the network fails before the stretch- potential is realized; the sheet stretch is low. As bonding in the network is increased, the stretch-potential of fibres is increasingly realized, the sheet stretch increases.
  • Extensible paper is a known paper which, because of special treatment during its production, presents considerable extensibility both in the longitudinal direction (i.e. in the direction of its advancement along the production line) and in the transverse direction (i.e. in the direction perpendicular to the preceding).
  • This treatment consists essentially of passing the paper web not yet formed and presenting a moisture content of about 35%/45% between two rollers rotating at different speeds.
  • One of these rollers generally the lower roller, is made of rubber and is rotated at lower speed, while the upper roller is made of steel and comprises in its cylindrical surface a continuous spiral-shaped groove.
  • the different material nature and the different speed of the two rollers results in a sort of longitudinal accumulation of the paper forming material and prepares it for longitudinal extensibility, by an amount which can reach 15-20%.
  • the spiral groove performs a double function: on the one hand it causes a sort of transverse accumulation of the material forming the paper to prepare it for transverse extensibility. By an amount which can reach 10-15%.
  • the spiral groove contributes to maintaining longitudinal advancement of the processed paper web along the machine.”
  • the tensile test is used for measuring force versus percent elongation properties. The tests are performed on a Thwing Albert Intellect ll-STD Model No. 1451-24PGB, available from the Thwing-Albert Co. of Philadelphia, Pa.”
  • the samples used for this test are 1“ wide x 6“ long with the long axis of the sample cut parallel to the direction of maximum extensibility of the sample.
  • the sample should be cut With a sharp Exacto knife or some suitably sharp cutting device design to cut a precise 1“ wide sample. (If there is more than one direction of extensibility of the material, samples should be taken parallel to representative direction of elongation).
  • the sample should be cut so that an area representative of the symmetry of the overall pattern of the deformed region is represented. There will be cases (due to variations in either the size of the deformed portion or the relative geometries of regions 1 and 2) in which it will be necessary to cut either larger or smaller samples than is suggested herein. In this case, it is very important to note (along with any data reported) the size of the sample, which area of the deformed region it was taken from and preferably include a schematic of the representative area used for the sample. Three samples of a given material are tested.”
  • Elongation T457 By the expression “extensible papers” is meant a paper having an increased elongation (generally a minimum of about 6%) in the machine direction.
  • rosin size (0.3% by weight based on the weight of pi up) is added at the beater and the pH is adjusted to 4.5 with alum.
  • the stock, having a consistency of 3.6% is dropped to the beater chest and is then pumped to a second chest, passed through a Jordan and continuously diluted with "white water” at the Fourdrinier headbox to a consistency of 0.3%.
  • Properties measured on the various papers is reported in Table III. Each paper has a basis weight of from 49.4 to 50.3 pounds per ream.”
  • a multilayer papery material comprising at least one first three dimensional structure sheet exhibiting reliefs having maximum sizes which are lower than the width of the original sheet, said reliefs being obtained through localized stretching of said first sheet which has an original degree of extensibility of not less than 5% in all the directions, and at least one second sheet made of papery material coupled to said first structure sheet and defining empty spaces with the reliefs thereof.”
  • the multilayer material of the invention consists of two layers 2, 4 of paper presenting extensibility characteristics of not less than 5% both in a longitudinal and in a transverse direction, and preferably not less than 15%.”
  • Compacted paper has improved tensile energy absorption (TEA) burst and tear characteristics which are highly desirable for such end uses as the manufacture of paper sacks.”
  • TAA tensile energy absorption
  • the following is a direct quote of the Abstract of U.S. Patent No. 6,024,832 incorporated by reference in the preceding paragraph: “A method for producing extensible paper, comprising the following stages: feeding a mix of vegetable fibres to a kneader member, mixing the mix with water in the kneader, beating the fibres to obtain a pulp, transferring the beaten pulp into a flow chest, feeding the beaten pulp from the flow chest onto a paper web formation cloth with consequent reduction of the water percentage by gravity and vacuum, pressing the web, with consequent further reduction of its water content, initial drying of the paper web to a substantially constant moisture content of between 15% and 65%, compacting, final drying to a moisture content of between 15% > and 4% > , preferably 10% > -8% > , glazing, wherein: the beating stage
  • the compacting stage is carried out between at least a pair of rollers of which one is of hard material comprising circumferential surface ribs and driven at greater speed, and the other is of soft material with a smooth surface and driven at lesser speed.”
  • one is of hard material comprising circumferential surface ribs and driven at greater speed
  • the other is of soft material with a smooth surface and driven at lesser speed.
  • Clupak refers to equipment that inserts a paper web between a roll and an endless rubber blanket to compress the paper web with a nip bar and the rubber blanket, while at the same time the pre-stretched blanket shrinks to cause the paper web to also shrink and thereby increase its breaking elongation, and this equipment is used to provide increased breaking elongation to kraft paper used in heavy packaging applications as mentioned above.”
  • Clupak refers to equipment that inserts a paper web between a roll and an endless rubber blanket to compress the paper web with a nip bar and the rubber blanket, while at the same time the pre-stretched blanket shrinks to cause the paper web to also shrink and thereby increase its breaking elongation, and this equipment is used to provide increased breaking elongation to kraft paper used in heavy packaging applications as mentioned above.”
  • Clupak refers to equipment that inserts a paper web between a roll and an endless rubber blanket to compress the paper web with a nip bar and the rubber blanket, while at the same time the pre
  • Clupak refers to equipment that inserts a paper web between a roll and an endless rubber blanket to compress the paper web with a nip bar and the rubber blanket, while at the same time the pre-stretched blanket shrinks to cause the paper web to also shrink and thereby increase its breaking elongation, and this equipment is used to provide increased breaking elongation to kraft paper used in heavy packaging applications as mentioned above;" and “[0028]
  • the manufacturing method using this Clupak system is such that a paper web is inserted between a roll and an endless rubber blanket to compress the paper web with a nip bar and the rubber blanket, while at the same time the pre-stretched blanket shrinks to cause the paper web to also shrink and thereby increase its breaking elongation.
  • the Clupak system allows for adjustment of the breaking elongation of kraft paper in the longitudinal direction according to the ratio of the manufacturing speed on the inlet side of the Clupak system and manufacturing speed on the outlet side of the Clupak system, and also according to the pressurization force applied by the nip bar.”
  • extensible paper employed can involve one or more of the following Example features, as set forth in the ⁇ 86 patent.
  • Example 1 An extensible slit sheet paper cushioning product, comprising: a roll of slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, said roll resisting pulling of a length of slit sheet paper along the machine direction to enable expansion of the length of slit sheet paper in the machine direction, said slit sheet paper being formed from a paper that is extensible in the machine direction and the cross direction prior to providing said slit pattern, said extensible paper having an extensible range of 3 to 20% in the machine direction prior to providing said slit pattern.
  • Example 2 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible range is not less than 5% in both the machine direction and cross direction.
  • Example 3 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible range is 3-15% in the machine direction; or, in some embodiments, wherein said extensible range is 3-9% in the machine direction.
  • Example 4 The extensible slit sheet paper cushioning product of example 1 , wherein said slit sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form said open cells.
  • Example 5 The extensible slit sheet paper cushioning product of example 2, wherein said slit sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form said open cells.
  • Example 6 The extensible slit sheet paper cushioning product of example 5, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 7 The extensible slit sheet paper cushioning product of example 1 , wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 8 A shipping package comprising: a wrapped object, said wrapped object being wrapped in at least two layers of an expanded slit sheet paper wrap having interlocking hexagonal cells, said slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of hexagonal cells upon expansion in a machine direction and being expanded by applying an expansion force and wrapped to form said at least two layers of expanded slit sheet paper wrap having interlocking hexagonal cells, said slit sheet paper being formed from a paper that is extensible in the machine direction and the cross direction prior to providing said slit pattern, said extensible paper having an extensible range of 3 to 20% in the machine direction prior to providing said slit pattern.
  • Example 9 The shipping package of example 8, wherein said extensible range is not less than 5% in both the machine direction and cross direction.
  • Example 10 The shipping package of claim 8, wherein said extensible range is 3-15% in the machine direction.
  • Example 11 The shipping package of example 8, wherein said slit sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form said hexagonal cells.
  • Example 12 The shipping package of example 11 , wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 13 The shipping package of example 8, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 14 A method of expanding and wrapping a slit sheet paper that upon expansion and wrapping forms two or more layers of interlocking hexagonal cells, comprising the steps of: providing said slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of hexagonal cells upon expansion in a machine direction, wherein said slit sheet paper being formed from a paper that is extensible in the machine direction and the cross direction prior to providing said slit pattern, said extensible paper having an extensible range of 3 to 20% in the machine direction prior to providing said slit pattern, expanding said slit sheet paper, and wrapping said expanded slit sheet paper to form adjacent layers, said adjacent layers being in interlocking contact, whereby expanded layers resist contraction and tearing.
  • Example 15 The method of example 14, wherein said extensible range is not less than 5% in both the machine direction and cross direction.
  • Example 16 The method of example 14, wherein said extensible range is 3-15% in the machine direction.
  • Example 17 The method of example 14, wherein said step of expanding comprises applying an expansion force of 0.15 to 0.22 pounds per inch to form said hexagonal cells.
  • Example 18 The method of example 17, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 19 The method of example 14, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 20 The method of example 14, wherein the step of wrapping said slit sheet paper to form said adjacent layers, comprises: wrapping the expanded slit sheet paper around an object and forming said two or more layers of overlying interlocking hexagonal cells around said object, said overlying interlocking hexagonal cells being in direct contact substantially across the width of the layers.
  • Example 21 The method of example 20, wherein said extensible range is 3-15% in the machine direction and not less than 5% in the cross direction.
  • Example 22 The method of example 20, wherein said extensible range is 3-9% in the machine direction and not less than 5% in the cross direction.
  • Example 23 The method of example 20, wherein said step of expanding comprises applying an expansion force of 0.15 to 0.22 pounds per inch to form said hexagonal cells.
  • Example 24 The method of example 21, wherein said step of expanding comprises applying an expansion force of 0.15 to 0.22 pounds per inch to form said hexagonal cells.
  • Example 26 The method of above examples, wherein said extensible range is 3- 15% in the machine direction and not less than 5% in the cross direction.
  • Example 27 The method of above examples, wherein said extensible range is 3- 9% in the machine direction and not less than 5% in the cross direction.
  • Example 28 The method of above examples, wherein said step of expanding a length of said expandable sheet material comprises applying an expansion force of 0.15 to 0.22 pounds per inch.
  • Example 29 The method of example 26, wherein said step of expanding a length of said expandable sheet material comprises applying an expansion force of 0.15 to 0.22 pounds per inch.
  • Example 30 The method of above examples, wherein the slit extensible paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 31 The method of example 28, wherein the slit extensible paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 32 The extensible slit sheet paper cushioning product of example 1, wherein said extensible range is 3-11.1% in the machine direction.
  • Example 33 The shipping package of example 8, wherein said extensible range is 3-11.1 % in the machine direction.
  • Example 34 The method of example 14, wherein said extensible range is 3-11.1% in the machine direction.
  • Example: 35 The method of above examples, wherein said extensible range is 3- 11.1% in the machine direction.
  • Example 36 The extensible slit sheet paper cushioning product of example 1, wherein said extensible range is 3.3-10.6% in the machine direction.
  • Example 37 The shipping package of example 8, wherein said extensible range is 3.3-10.6% in the machine direction.
  • Example 38 The method of example 14, wherein said extensible range is 3.3- 10.6% in the machine direction.
  • Example 39 The method of above examples, wherein said extensible range is 3.3-10.6% in the machine direction.
  • Example 40 The extensible slit sheet paper cushioning product of example 1, wherein said extensible range is 9.7-11.1% in the machine direction.
  • Example 41 The shipping package of example 8, wherein said extensible range is 9.7-11.1% in the machine direction.
  • Example 42 The method of example 14, wherein said extensible range is 9.7- 11.1 % in the machine direction.
  • Example 43 The method of above examples, wherein said extensible range is 9.7-11.1% in the machine direction.
  • Example 44 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible paper is formed by imparting a treatment prior to providing the slit pattern comprising inserting said paper between a roll and an endless pre-stretched blanket to compress the paper with a nip bar and the blanket (or otherwise compressing the paper between two different (e.g., differently moving) surfaces, such as between two different rollers).
  • Example 45 The shipping package of example 8, wherein said extensible paper is formed by imparting a treatment prior to providing the slit pattern comprising inserting said paper between a roll and an endless pre-stretched blanket to compress the paper with a nip bar and the blanket (or otherwise compressing the paper between two different (e.g., differently moving) surfaces, such as between two different rollers).
  • Example 46 The method of example 14, wherein said extensible paper is formed by imparting a treatment prior to providing the slit pattern comprising inserting said paper between a roll and an endless pre-stretched blanket to compress the paper with a nip bar and the blanket (or otherwise compressing the paper between two different (e.g., differently moving) surfaces, such as between two different rollers).
  • Example 47 The method of example 25, wherein said extensible paper is formed by imparting a treatment prior to providing the slits comprising inserting said paper between a roll and an endless pre-stretched blanket to compress the paper with a nip bar and the blanket (or otherwise compressing the paper between two different (e.g., differently moving) surfaces, such as between two different rollers).
  • Example 51 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible paper is a nonwoven fibrous material with fibre-to-fibre bonding that resists tearing upon 3-15% expansion in the machine direction as measured prior to providing the slit pattern.
  • Example 52 The shipping package of example 8, wherein said extensible paper is a nonwoven fibrous material with fibre-to-fibre bonding that resists tearing upon 3-15% expansion in the machine direction as measured prior to providing the slit pattern.
  • Example 53 The method of example 14, wherein said extensible paper is a nonwoven fibrous material with fibre-to-fibre bonding that resists tearing upon 3-15% expansion in the machine direction as measured prior to providing the slit pattern.
  • Example 54 The method of above examples, wherein said nonwoven fibrous material comprises fibre-to-fibre bonding that resists tearing upon 3-15% expansion in the machine direction as measured prior to providing the slits.
  • Example 55 The extensible slit sheet paper cushioning product of example 1 , wherein said roll of slit sheet paper is wound on a cylindrical core, and said length of slit sheet paper extends from said roll of slit sheet paper.
  • Example 56 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible range is 5-15% in a cross-direction.
  • Example 57 The extensible slit sheet paper cushioning product of example 1 , wherein said extensible range is 7.1-15% in a cross-direction.
  • Example 58 An extensible slit sheet paper cushioning product, comprising: a length of slit sheet paper having a slit pattern including a plurality of slits extending in a cross direction that forms a plurality of open cells upon expansion in a machine direction, said slit sheet paper being formed from a paper that is extensible in the machine direction and the cross direction prior to providing the slit pattern, said extensible paper having an extensible range of 3 to 20% in the machine direction prior to providing the slit pattern.
  • Example 59 The extensible slit sheet paper cushioning product of example 58, further including a resister that resists pulling of the length of slit sheet paper along the machine direction to enable expansion of the length of slit sheet paper in the machine direction.
  • Example 60 The extensible slit sheet paper cushioning product of example 59, wherein said resister is a roll of slit sheet paper from which said length of slit sheet paper extends.
  • Example 61 The extensible slit sheet paper cushioning product of example 58, wherein said extensible range is not less than 5% in both the machine direction and cross direction.
  • Example 62 The extensible slit sheet paper cushioning product of example 58, wherein said extensible range is 3-15% in the machine direction.
  • Example 63 The extensible slit sheet paper cushioning product of example 58, wherein said slit sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form said open cells.
  • Example 64 The extensible slit sheet paper cushioning product of example 58, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 50 pounds per 3,000 sq. ft.
  • Example 69 The extensible slit sheet paper cushioning product of example 1 , wherein said a slit pattern is configured to form a plurality of hexagonal cells upon expansion in a machine direction.
  • Example 70 The extensible slit sheet paper cushioning product of example 69, wherein said hexagonal cells are three-dimensional hexagonal cells with substantially rectangular land portions situated at an inclined angle transverse to an original plane of the slit sheet paper, and leg portions connecting the land portions.
  • Example 71 The extensible slit sheet paper cushioning product of example 58, wherein said a slit pattern is configured to form a plurality of hexagonal cells upon expansion in a machine direction.
  • Example 72 The extensible slit sheet paper cushioning product of example 71 , wherein said hexagonal cells are three-dimensional hexagonal cells with substantially rectangular land portions situated at an inclined angle transverse to an original plane of the slit sheet paper, and leg portions connecting the land portions.
  • FIG. 2(A) shows a top plan view of a sample expanded slit sheet paper employing Kraft paper, which opens in a manner substantially similar to that shown in FIG. 1 (B), discussed above.
  • this paper includes, in an unexpanded state, an array of rows similar to that shown in FIG. 1 (A), and, when expanded, the paper assumes the expansion pattern as shown in FIG. 2(A).
  • the expansion pattern includes the formation of substantially flat land portions 20 which tilt at an angle, and which extend across a width of the expanded sheet, along with leg portions 21 , with each land portion having four respective leg portions 21 extending therefrom.
  • FIG. 2(B) shows a top view of the same expanded slit sheet paper shown in FIG. 2(A) taken at an angle to the plane of the expanded paper, such as to look directly into the expanded cells of the paper (i.e., taken at an angle substantially parallel to the angle of tilt of the land portions 20. As shown, at this angle, the expansion pattern forms substantially hexagonal cells.
  • FIG. 2(C) shows a top view of the same expanded slit sheet paper shown in FIGS. 2(A) and 2(B), but taken at an angle to the plane of the expanded paper opposite to that of the angle shown in FIG. 2(B), such that the cell openings are obstructed from view by the broad sides of the land portions 20 and the leg portions 21 .
  • FIG. 2(D) shows a top view of the same expanded slit sheet paper shown in FIGS. 2(A)-2(C), but taken from an angle to the plane of the expanded paper from a position lower to the plane of the paper proximate the lower end of FIG. 2(D).
  • This view helps to demonstrate how the land portions 20 extend at a consistent angle, with the left edge of each land portion being at a lowest position and the right edge of each land portion being at a highest position, such as to extend upward at an inclination from left to right sides of the land portion as shown in FIG. 2(D).
  • this expansion pattern creates an array of open cell openings 26, each having a high side FIS at a left side of the open cell and a low side LS at a right of the open cell as shown in FIG. 2(D).
  • an expansion pattern similar to that shown in FIGS. 2(A)-2(D) can be employed.
  • the slit sheet paper can be configured to assume an expansion pattern similar to that shown in FIGS. 2(A)-2(D), referred to herein as a “normal expansion pattern.”
  • FIG. 3(A) shows a novel expansion pattern according to some preferred embodiments of the present invention, referred to herein as an “alternating row expansion pattern.” Although some of the preferred embodiments of the present invention will include such a novel “alternating row expansion pattern,” this type of expansion pattern is not required to be employed in all embodiments of the invention.
  • this alternating row expansion pattern can be employed in some preferred embodiments of the invention that include novel reduced-sized slit patterns described herein, this alternating row expansion pattern provides a new and advantageous inventive feature that can be implemented in the context of any desired slit size patterns, such as, e.g., slit size patterns with 0.5 inch slit lengths or even larger in some preferred embodiments.
  • this type of previously unknown alternating row expansion pattern can be achieved by employing an extensible slit sheet paper from an extensible paper that has sufficient extensibility characteristics.
  • the extensibility preferably is adjusted to have sufficient extensibility in both the machine direction and the cross direction to achieve such an alternating row expansion pattern.
  • this type of alternating row expansion pattern has been achieved by employing extensible paper having an extensibility of both i) 8.8% in the machine direction and ii) 8.8% in the cross direction.
  • this expansion pattern can be achieved employing 30#, 40#, 50#, 60#, 70# extensible paper sheets having such a slit arrangement.
  • extensibility of at least about 6% in both the machine direction and the cross direction can advantageously achieve such an alternating row expansion pattern.
  • such an alternating row expansion pattern can be achieved with slit patterns employing extensible paper that is extensible in a machine direction in a range of at least 5% and in a cross direction in a range of at least 5%, or, in some more preferred embodiments, that is extensible in a machine direction in a range of at least 6% and in a cross direction in a range of at least 6%, or, in some more preferred embodiments, that is extensible in a machine direction in a range of at least 7% and in a cross direction in a range of at least 7%, or, in some more preferred embodiments, that is extensible in a machine direction in a range of at least 8% and in a cross direction in a range of at least 8%.
  • this novel alternating row expansion pattern can be created by implementation of extensible paper even with the same original slit pattern of an unexpanded sheet.
  • the present inventor discovered that the expansion pattern can be adjusted so as to achieve an alternating row expansion pattern by, e.g., modifying the paper to comprise an extensible paper as discussed above.
  • the alternating row expansion pattern includes alternating rows (rows R-a and rows R-b) with bottom-side cell openings a26 and top- side cell openings b26.
  • the cell openings a26 in the rows R-a are situated on the bottom side of the expanded paper sheet (i.e. , on the opposite side or the far side from the point of view of FIG. 3(A), or, downward into the page view), and the cell openings b26 in the rows R-b are situated on the top side of the expanded paper sheet (i.e., on the near or close side to the point of view of FIG. 3(A)).
  • each land portion includes a portion that extends upward, and a portion that extends downward.
  • the land portions in rows R-a include a first portion 20a1 that extends from an edge of an open cell a26 at a left side of the land portion upwardly to the creased or angled portion at the center of the land portion, and a second portion 20a2 that extends from the creased or angled portion at the center of the land portion downwardly to an edge of an open cell a26 at a right side of the land portion.
  • a first portion 20a1 that extends from an edge of an open cell a26 at a left side of the land portion upwardly to the creased or angled portion at the center of the land portion
  • a second portion 20a2 that extends from the creased or angled portion at the center of the land portion downwardly to an edge of an open cell a26 at a right side of the land portion.
  • all of the land portions within the row R-a include a similar up-and-down configuration as shown in the figure, in which the creased or angle portion at the center of the land portion forms an apex or top ridge of the land portion that is at a highest point of the land portion in a direction towards the top side of the expanded paper sheet (i.e. , closest to the close side to the point of view of FIG. 3(A)).
  • all of the land portions within the row R-b include an opposite “down-and-up” configuration as shown in the figure, in which a creased or angle portion at the center of the land portion forms a bottom ridge of the land portion that is at a lowest point of the land portion in a direction towards the bottom side of the expanded paper sheet (i.e., farthest from the close side to the point of view of FIG. 3(A)).
  • a creased or angle portion at the center of the land portion forms a bottom ridge of the land portion that is at a lowest point of the land portion in a direction towards the bottom side of the expanded paper sheet (i.e., farthest from the close side to the point of view of FIG. 3(A)).
  • the land portions in rows R-b include a first portion 20b1 that extends from an edge of an open cell b26 at a left side of the land portion downwardly to the creased or angled portion at the center of the land portion, and a second portion 20b2 that extends from the creased or angled portion at the center of the land portion upwardly to an edge of an open cell b26 at a right side of the land portion.
  • all of the land portions within the row R-b include a similar down- and-up configuration as shown in the figure.
  • the leg portions extending from a first side of the land portion extend in different directions.
  • this includes first legs extending from a top edge of the land portion extending upwards towards a close side of the expanded paper (e.g., in a direction towards the top left of FIG. 2(A), and second legs extending from that top edge of the land portion extending downwards towards a far side of the expanded paper (e.g., in a direction towards the top right of FIG. 2(A)).
  • this also includes third legs extending from a bottom edge of the land portion extending upwards towards a close side of the expanded paper (e.g., in a direction towards the bottom left of FIG. 2(A), and forth legs extending from that bottom edge of the land portion extending downwards towards a far side of the expanded paper (e.g., in a direction towards the lower right of FIG. 2(A)).
  • the leg portions extending from a first side of the land portion extend in similar directions.
  • the leg portions extend in a manner to create the alternating rows R-a and R-b, wherein these alternating rows R-a and R-b are located at opposing sides of the expanded slit sheet in a width direction of the sheet - that is, with the rows R-a being at a far side of the expanded slit sheet in the width direction as viewed in FIG. 3(A) and with the rows R-b being at a close side of the expanded slit sheet in the width direction of the sheet.
  • the legs include: a) first legs 21a extending from a top edge of a land portion 20b2 downwardly to a land portion 20a1 ; b) second legs 20b extending from a top edge of a land portion 20b1 downwardly to a land portion 20a2; c) third legs 21c extending from a bottom edge of a land portion 20b2 downwardly to another land portion 20a1 ; and d) fourth legs 20d extending from a bottom edge of a land portion 20b1 downwardly to another land portion 20a2.
  • this alternating row expansion pattern has a number of substantial advantages and benefits over the expansion pattern shown in FIG. 2(A).
  • the alternating row expansion pattern has substantial aesthetic benefits and is more aesthetically appealing and interesting.
  • the alternating row expansion pattern creates an expansion pattern that is more visually obstructive at a variety of angles.
  • the alternating row expansion pattern creates an expansion pattern that has improved cushioning and operational characteristics.
  • the open cells 26 of the example shown in FIG. 2(A) creates cells having a high side FIS at a close side of the expanded paper and a low side LS at a far side of the expanded paper (as shown in FIG. 2(A))
  • the open cells a26 and b26 shown in FIG. 3(A) create cells having both sides at similar heights (i.e., either at a high side such as, e.g., cells b26 or at a low side such as, e.g., cells a26).
  • forces applied to the periphery of the open cells a26 and b26 are, thus, generally applied more evenly on opposite sides of the open cells, rather than being applied at a single side of the open cells of the opens cells 26 shown in FIG. 2(A).
  • FIGS. 4(A) to 4(C) provide an explanatory diagram demonstrating the formation of the alternating row expansion pattern according to the preferred embodiments of the invention.
  • FIG. 4(A) shows an illustrative slit pattern formed within a sheet of paper.
  • the slit pattern is generally similar to that shown in FIG. 5(A), discussed above.
  • the slit pattern has novel and advantageous slit and slit pattern dimensions and relationships as discussed further below.
  • the slits include a plurality of rows of slits extending substantially horizontally across the page of view of the figure. Although only 7 slits S are depicted (for explanatory purposes), it should be appreciated that in preferred embodiments the product would include rows of slits extending entirely or substantially entirely across the paper sheet.
  • the slits preferably have a common slit length SL (i.e., all slits preferably have a like slit length), a common slit spacing SS between ends of the slits in the same row of slits (i.e., all slit spacings preferably have a like length), and a common row spacing RS between adjacent rows of slits (i.e., all spacings between rows preferably have a like distance).
  • the extent of overlap between slits of adjacent rows preferably includes equal sized spacings OL1 and OL2 (i.e., the slits in adjacent rows are preferably symmetrically aligned such as to create symmetrical cells upon expansion).
  • FIG. 4(B) shows the slit pattern of FIG. 4(A) with regions of the paper prior to expansion highlighted for reference. Towards that end, the regions A1 , A2, B1 , B2, C1 , C2, D1 and D2 are shaded in the figure to facilitate reference. Flowever, it should be appreciated that in this unexpanded state shown in FIG. 4(B), these regions are, e.g., all flat or planar regions along the plane of the original unexpanded sheet of paper.
  • the slits S are caused to open and create open cells a26 and b26. Additionally, as depicted in FIG. 4(C), the regions A1 are caused to assume the orientations of legs 21a discussed above, the regions A2 are caused to assume the orientations of legs 21 b discussed above, the regions B1 are caused to assume the orientations of legs 21c discussed above, the regions B2 are caused to assume the orientations of claim 21 d discussed above, the regions C1 are caused to assume the orientations of land portions 20a1 discussed above, the regions C2 are caused to assume the orientations of land portions 20a2 discussed above, the regions D1 are caused to assume the orientations of land portions 20b2 discussed above, and the regions D2 are caused to assume the orientations of land portions 20b1 discussed above.
  • the open cells a26 and b26 form substantially hexagonal peripheries that are “bent” at a central region such as to not form a regular hexagon (i.e. , both equilateral and equiangular), but, rather, to form, e.g., a substantially hexagonal shape in which the opposing land portions 20b2 and 20b1 are closer to one another.
  • the prior expansion pattern leads to substantially regular hexagons.
  • the hexagonal open cells a26 and b26 include a first half that extends along substantially a first plane with edges along one of the land portions and two of the leg portions and a second half that extends along substantially a second plane with edges along another of the land portions and two of the leg portions.
  • an open cell b26 includes a first half along a first plane delineated by an edge of the leg 21c, an edge of the land portion 20b2, and an edge of the leg 21a, and a second half along a second plane delineated by an edge of the leg 21 d, an edge of the land portion 20b1 , and an edge of the leg 21 b.
  • such a substantially hexagon shape that is bent between two planes is referred to as a “bent hexagon.”
  • the bent hexagons of the cells b26 are formed so as to open upwardly (i.e., such that the angle between both of the planes opens upwardly) while the bent hexagons of the cells a26 are formed so as to open downwardly (i.e., such that the angle between both of the planes opens downwardly and oppositely to that of the angle of the bent hexagons of the cells b26).
  • the present inventor has also discovered that this decrease enables further slit pattern opportunities that can provide greater resiliency and a reduced thickness, as desired, while, in the past, such would have been too difficult to stretch manually and provide a burden to the automated expanding equipment.
  • the present inventor has discovered that, by way of example, a 10% reduction in slit, land, and row size increases the number of supporting legs by 23.7% - a more than doubling of the strength of the material. This provides cushioning solutions where greater resiliency of the same or smaller leg height can be accomplished.
  • leg height impacts stiffness. As the leg height is reduced, the leg becomes stiffen This is due to the fiber length that becomes more difficult to bow or flex as the height becomes shorter. According to preferred embodiments of the present invention, the leg height, the number of legs per square foot, and the paper weight is balanced to provide optimal cushioning while providing the least amount of pulling strength to open.
  • the crush strength for the current commercial pattern using a 0.5” slit is 2.2 pounds per square inch of strength.
  • a preferred reduced slit pattern utilizing 50# Kraft paper with a slit pattern of 0.45” slit (i.e. , length of slit), 0.1688” land (i.e., distance between adjacent slits in a lengthwise direction of the slits), 0.1125” row width (i.e., distance between adjacent rows of slits) is provided.
  • such a configuration yields 2.72-2.92 pounds of per inch of crush strength, which yields a 27% increase in strength with a 10% decrease in thickness from 0.1875” to 0.16875”.
  • the paper employed is an extensible paper.
  • another preferred slit pattern is 0.40” slit, 0.15” land, 0.1125” row width.
  • this latter configuration yields 3.1-3.3 pounds per inch crush strength, which yields a 40% increase in crush strength with a 10% decrease in thickness from 0.1875” to 0.16875.”
  • the paper employed is an extensible paper.
  • this increase in strength can advantageously be used to allow for a reduced thickness of the expanded slit sheet paper, which can, thus, provide, e.g., an equivalent crush strength while providing for a reduction in overall height.
  • a reduced thickness of the expanded slit sheet paper which can, thus, provide, e.g., an equivalent crush strength while providing for a reduction in overall height.
  • the use of 40# paper would reduce the leg stiffness, but would reduce the cost of the paper.
  • an expandable slit paper sheet includes a pattern of slits having slit lengths in the range from 0.30 to 0.45 inches and spaces between rows of slits in the range from 0.1125 to 0.1688.
  • the paper employed is an extensible paper.
  • an expandable slit paper sheet includes a pattern of slits having slit lengths in the range of 0.45 inches plus 5% (e.g., 0.4725 inches) to 0.45 inches minus 33% (e.g., 0.30 inches).
  • the paper employed is an extensible paper.
  • an expandable slit paper sheet includes a pattern of slits that upon expansion produces an expandable slit paper having a number of legs per square foot that is at least 20% greater than a slit paper sheet with slit lengths of 0.5 inches which is configured to create hexagonal cells (e.g., with equilateral hexagons).
  • an expandable slit paper sheet includes a pattern of slits that upon expansion produces an expandable slit paper having a number of legs per square foot that is at least 15% greater than a slit paper sheet with slit lengths of 0.5 inches which is configured to create hexagonal cells (e.g., with equilateral hexagons), and, more preferably, in the range from 20% to 50% greater than such slit paper with slit lengths of 0.5 inches which is configured to create hexagonal cells (e.g., with equilateral hexagons), and, in some embodiments more than 50% greater than such slit paper with slit lengths of 0.5 inches which is configured to create hexagonal cells (e.g., with equilateral hexagons).
  • the paper employed is an extensible paper as described herein-above.
  • the use of such extensible paper highly advantageously enables a reduced slit pattern size in comparison to prior slit patterns.
  • non- extensible paper has limitations in relation to the viable sizes and dimensions of the slits, and such non-extensible paper does not enable reduction in sizes to that of preferred embodiments described herein because such prior papers would be inoperable and would not adequately or properly expand if such small sizes were attempted to be employed.
  • the present inventor discovered means by which smaller slit patterns can be achieved (e.g., via the use of the extensible paper) and that such smaller slit patterns with such extensible papers can, in fact, provide enhance cushioning despite the losses in cushioning due to the reduced “width” of the expandable slit sheet paper. Additionally, the present inventor also discovered other desirable applications and uses of such novel expandable slit sheet paper.
  • a slit pattern is provided which includes slit lengths of 0.35” slits (i.e. , the lengths of the slits), 0.13125” lands (i.e., the distances between adjacent slits in the same row of slits in a lengthwise direction of the slits), and 0.0875” row width (i.e., the distances between adjacent rows of slits).
  • such a slit pattern is preferably implemented within a pattern of slits similar to that shown in, e.g., FIG. 4(A), in which all of the slits of the expandable slit sheet have the same lengths, the distances between adjacent rows is consistently the same, in which the distance between slits in the same row is consistently the same, and in which the locations of the slits in adjacent rows is arranged with equal overlap to form symmetrical cells.
  • an extensible slit sheet paper is preferably employed; notably, a non-extensible paper cannot be used to viably operationally function with such a slit pattern.
  • the expanded slit sheet paper would include a same slit pattern throughout the sheet, in some embodiments such a pattern can be employed within a portion or region of the paper and/or some regions of the paper may potentially include some differences in the pattern. Additionally, although the slit lengths and dimensions are preferably consistently the same as indicated above, in some embodiments, there can be some variations in sizes, positions of the slits as long as operation of the product is not impeded.
  • a slit pattern having 0.35” slits, 0.13125” lands, and 0.0875” row width can yield 3.52-3.82 pounds per inch crush strength which yields a 60% increase in crush strength with a 30% decrease in thickness from 0.1875” to 0.1125.”
  • the lands distance i.e., the distance SS shown in FIG. 4(A) between the slits
  • the distance SS is approximately 1/3 the length of the slits (i.e., the distance SL shown in FIG. 4(A)).
  • the distance SS is about 1/3 the length of the slits, the lengths of the perimeter sides of the created cell openings a26 and b26 are substantially equal.
  • the distance of the lands i.e., SS
  • the distance of the lands is preferably slightly greater than 1/3 the length of the slits.
  • the ratio is approximately 0.375. Accordingly, in this example, the length of the lands are approximate 12.5% larger than 1/3 the length of the slits.
  • the lengths of the lands would be about 1/3 the length of the slits plus or minus about 25%. In some other preferred embodiments, the lengths of the lands would be about 1/3 the length of the slits plus or minus about 20%. In some preferred embodiments, the lengths of the lands would be about 1/3 the length of the slits plus or minus about 15%. In some other preferred embodiments, the lengths of the lands would be about 1/3 the length of the slits plus or minus about 10%.
  • the lengths of the lands would be between about 1/3 the length of the slits to 25% greater than 1/3 the length of the slits. In some other preferred embodiments, the lengths of the lands would be between about 1/3 the length of the slits to 20% greater than 1/3 the length of the slits. In some other preferred embodiments, the lengths of the lands would be between about 1/3 the length of the slits to 15% greater than 1/3 the length of the slits. In some other preferred embodiments, the lengths of the lands would be between about 1/3 the length of the slits to 10 % greater than 1/3 the length of the slits.
  • the dimensions of the expandable slit sheet paper are proportionally reduced from an expandable slit sheet paper having a 0.5” slit length, a 1/8” (0.125 inch) spacing between rows, and a spacing between slits within the same row (i.e. , land length) of 3/16” (0.1875 inch) as follows: a) the row spacing is proportionally reduced by a ratio SL(new)/0.5 and b) the slit spacing is set at SL(new) divided by 2.6667.
  • some preferred embodiments include dimensions as set forth below Table A:
  • the corresponding row spacings of the Examples A to L in the above Table A are substantially as shown in Table A.
  • the row spacings of Examples A to L can be substantially as shown in Table A plus or minus 20%, or, more preferably, substantially as shown in Table A plus or minus 15%, or, more preferably, substantially as shown in Table A plus or minus 10%, or, more preferably, substantially as shown in Table A plus or minus 5%.
  • the corresponding row spacings of the Examples A to L in the above Table A are, more preferably, within a range that is the same or lower than the row spacings shown in Table A for the respective slit lengths; notably, with reduced slit length, there can be increased difficulty to open the cells, which difficulty is increased with larger row spacings. Accordingly, as the slit lengths are decreased, in some preferred embodiments, the row spacing decreases an extent that is proportionally the same or more than the proportional decrease in the slit length.
  • slit lengths can be viably decreased by the use of extensible papers as described herein, the present inventor also noted that even with extensible papers reduction in slit lengths can increase difficulty to open cells in the event that row spacings are proportionally too large.
  • the preceding Table A shows row spacings that are substantially reduced well below the 1/8” (0.125 inch) row spacing of the background art
  • the row spacings for various embodiments of the invention can still be larger. That is, while the present invention very advantageously enables such a reduced row spacing due to the greatly improved cushioning characteristics that enable the row spacing to be reduced (e.g., the reduction in cushioning resultant from reduced row spacing can be offset by the improved cushioning characteristics of the present invention), such a substantial reduction is not necessarily required, as long as the cell structure can be opened for expansion.
  • any of the embodiments of the invention having slit lengths within a range of 0.40 to 0.25 can employ row spacings that are less than that of the existing art, such as, e.g., less than 0.125 inches, or, more preferably, less than 0.12 inches, or, more preferably, less than 0.115 inches, or, more preferably, less than 0.1125 inches, or, more preferably, less than 0.0875 inches, or, in some embodiments more preferably, less than 0.08 inches.
  • the slit paper pattern of slits advantageously has slits in the range from 0.2 to 0.3 inches (i.e., in the lengthwise dimension of the slits) and spaces between rows in the range from 0.05 to 0.075 inches (i.e., the distance between adjacent rows of slits).
  • the slit paper pattern of slits advantageously has slits of about 0.25 inches (i.e., in the lengthwise dimension of the slits) and spaces between rows of about 0.06 to about 0.065 inches (i.e., the distance between adjacent rows of slits) and most preferably spaces between rows of about 0.0625 inches.
  • the space between the slits of each row is preferably in the range from about 0.1 to about 0.09 inches and most preferably, the space between the slits of each row is about 0.094 inches.
  • the foregoing dimensions can produce a slit pattern that creates more cells per square foot, provides crush resistance and resiliency for cushioning, and provides substantially improved tensile strength.
  • the paper is, most preferably, an extensible paper.
  • the extensible paper is an extensible paper according to any of the embodiments or examples of extensible paper disclosed herein.
  • any of the various extensible papers described herein in relation to the various patents and documents described herein can be employed.
  • the extendable paper can employ extensibility according to any of the embodiments described herein, including, e.g., any of the Example 1 to Example 72 described above.
  • the extendable paper can include features of any of the extensible papers described herein in relation to, e.g., opening forces required, paper weight or type, etc.
  • the extensibility is adapted to achieve the alternating row expansion pattern as described herein.
  • an extensible paper is employed having an extensible range of 3 to 20% in the machine direction, or, in some embodiments, 3 to 9% in the machine direction.
  • an extensible paper is employed having an extensible range of 3 to 20% in the cross direction, or, in some embodiments, 3 to 9% in the cross direction. In some illustrative examples, in some embodiments, an extensible paper is employed having an extensible range of 3 to 15% in the machine direction. In some illustrative examples, in some embodiments, an extensible paper is employed having an extensible range of 3 to 15% in the cross direction. In some illustrative examples, in some embodiments, an extensible paper is employed having an extensible range of 7 to 15% in the machine direction. In some illustrative examples, in some embodiments, an extensible paper is employed having an extensible range of 7 to 15% in the cross direction. In some illustrative examples, the extensible range is not less than 5% in both the machine direction and cross direction.
  • the slit sheet paper is an extensible slit sheet configured such that expansion is performed by applying an expansion force of 0.10 to 0.40 pounds per inch, or, preferably, of 0.125 to .33 pounds per inch, or, in some embodiments, of 0.15 to 0.22 pounds per inch, to form said open cells.
  • the slit sheet paper is an extensible slit sheet, wherein said slit sheet paper has a weight, prior to expansion, from about 30 to 70 pounds per 3,000 sq. ft.
  • all of the embodiments of the invention described herein e.g., the various slit patterns, including slit lengths, slit spacings, row spacings, etc.
  • papers with weights within this range can be employed in various implementations of papers with weights within this range in some embodiments, such as, e.g., on 30# paper, 40# paper, 50# paper, 60# paper, 65# paper, and on any papers within this range.
  • papers can be employed lower than this range of 30# to 70#, such as, e.g., 20# or less, or larger than this range, such as, e.g., 60# or more.
  • weight in pounds e.g., #
  • weight in pounds indicates the listed number of pounds as per 3,000 square feet (e.g., sq. ft.).
  • a 50# paper should be understood as corresponding to 50 pounds per 3,000 square feet.
  • Expandable Slit Sheet Paper Pallet Wrap w/o Support Wrap As indicated above, while some preferred embodiments include a support wrap that provides enhanced support along with an expandable slit sheet paper, in some of the more preferred embodiments, a support wrap is not required. Thus, some of the preferred embodiments provide an expandable slit sheet material that is specially and uniquely configured to operate as a pallet wrap without a required support wrap. Although a support wrap (e.g., any of the types of support wraps described herein) can be included (if desired) in the context of such novel expandable slit sheet material that does not require a support wrap, such support wraps can be advantageously omitted in some preferred embodiments.
  • a support wrap e.g., any of the types of support wraps described herein
  • any of the embodiments of the expandable slit sheet material described herein can be employed without the use of a support wrap in some embodiments for the wrapping pallets, due to the high load requirements in the context of wrapping of many common pallets, in some of the most preferred embodiments, a specially configured and designed expandable slit sheet paper is created for implementation as a pallet wrap without a required support wrap (for example, employing paper with substantial extensibility and/or smaller slit lengths, etc., according to various embodiments described herein).
  • an expandable slit sheet paper that has a substantially reduced slit pattern in comparison to expandable slit sheet papers that are commonly employed for wrapping of products placed within shipping packages or the like (such as, e.g., hand-wrapped products).
  • expandable slit sheet papers have been created having slit lengths of generally about 0.5 inches long for the purposes of hand-wrapping of individual products that are stored in shipping packages.
  • the existing expandable slit sheet papers are relatively easily expanded and relatively easily torn.
  • expandable slit sheet paper can be made with slit lengths SL of significantly less than 0.5 inches, including, for example, embodiments of Examples A-L in Table A.
  • the present inventor has been able to achieve expandable slit sheet paper with slit lengths of substantially less than 0.5 inches, including, by way of example, Example I having 0.25 inch slit lengths.
  • an expandable slit sheet paper with substantially reduced slit pattern sizes can be achieved, while previously expandable slit paper could not be made with smaller slit pattern sizes, as, for example, the forces required to expand the prior expandable slit paper would be too great in comparison to the tensile strength of the expandable slit paper if such smaller slit pattern sizes were employed.
  • the present inventor discovered that by providing expandable slit sheet paper with substantially reduced slit pattern sizes, the tensile forces achievable by the expandable slit sheet paper can be greatly increased. As a result, as discovered by the present inventor, an expandable slit sheet paper can be achieved that provides sufficient tensile forces to operate as a pallet wrap without any required support wrap surrounding the expandable slit sheet paper.
  • an expandable slit sheet paper having 0.5 inch slit lengths can require a force of about 2-3 lbs to open the cells (i.e. , to expand the cells to an open state) and a force of about 6-8 lbs to tear the expandable slit sheet paper
  • a similar expandable slit sheet paper having 0.25 slit lengths can require a force of about 6-8 lbs to open the cells (i.e., to expand the cells to an open state) and a force of about 16-20 lbs to tear the expandable slit sheet paper.
  • an expandable slit sheet paper can be created that has vastly superior tensile strength (e.g.
  • expandable slit sheet papers having reduced slit pattern sizes also achieved other novel and advantageous features having particular utility and advantages in the context of pallet wrapping.
  • the expansion thickness of the expanded slit sheet paper is substantially reduced.
  • the overall diameter of the wrapped pallet is more minimally increased due to the added layering of the expandable slit sheet paper surrounding the pallet.
  • the row spacing of 0.0625 inches i.e. , 1/16 inch
  • pallets have common dimensions with a supporting surface area of about 3 foot by 3 foot or greater, such as, e.g., in some examples, approximately 40 inches x 48 inches, or in some examples of approximately 42 inches by 48 inches.
  • pallet assemblies are stacked at a height of about 3 foot or greater, such as, e.g., being stacked at a maximum height of about 40 inches high, or, in some examples, at a maximum of about 50 inches high, or, in some examples, at a maximum of about 70 inches high. Accordingly, minimization of the added thickness caused by wrapping of expanded slit sheet paper can facilitate meeting and maintaining appropriate sizes requirements.
  • expandable slit sheet papers having reduced slit pattern sizes can achieve unique expansion characteristics having advantages in the context of wrapping pallets.
  • the reduced sized slit patterns enables the expandable slit sheet paper to hyper expand, such that the overall length of expansion can be significantly increased.
  • an existing expandable slit sheet paper having a pattern of 0.5 inch long slits generally increases in length by about 67% to full expansion
  • expandable slit sheet papers having reduced slit pattern sizes can be hyper expanded beyond such 67% expansion.
  • expandable slit sheet papers having reduced pattern sizes can be created that can be hyper expanded by at least 10% more than the 67% expansion of existing expandable slit sheet paper.
  • expandable slit sheet papers having reduced pattern sizes can be created that can be hyper expanded by at least 15% more than the 67% expansion of existing expandable slit sheet paper. Moreover, the present inventor discovered that expandable slit sheet papers having reduced pattern sizes can be created that can be hyper expanded by at least 20% more than the 67% expansion of existing expandable slit sheet paper. Moreover, the present inventor discovered that expandable slit sheet papers having reduced pattern sizes can be created that can be hyper expanded by at least 25% more than the 67% expansion of existing expandable slit sheet paper.
  • the present inventor also discovered that such additional expansion is highly advantageous in the context of wrapping of pallets.
  • the present inventor discovered that when pallets having substantially rectangular configurations are relatively rotated, as schematically shown in FIG. 13, the perimeter of the rectangular pallet rotates between positions 10-1 of the pallet 10’ and positions 10-2 of the pallet 10’, wherein the expandable slit sheet paper 510’ fed from the roll 210’ similarly oscillates between angular positions 510-1 and 510-2.
  • such rotation can lead to increased expansion of the expandable slit sheet paper as it wraps around the pallet (e.g., due to the increased lateral distance of the lower corner of the pallet in position 10-2).
  • the present inventor’s novel expandable slit sheet paper’s enhanced ability to expand and to hyper expand is highly advantageous in the context of pallet wrapping.
  • the present inventor discovered that the reduced sized slit patterns enable the expandable slit sheet paper to hyper expand to an expansion state in which the expandable slit sheet paper does not retract or minimally retracts from an expanded state.
  • the expanded paper exerts a retractive force seeking to cause the expanded slit sheet paper to retract from the fully expanded state.
  • the cushioning afforded by the expandable slit sheet paper wrap around the pallet can be well maintained even in the even tensile forces are alleviated along a region of the wrapped expandable slit sheet paper around the pallet (such as, e.g., due to shifting of the wrapped items, such as, e.g., boxes, on the pallet).
  • a pallet wrap system similar to that shown in Figs. 5 or 6 can be employed to wrap an expanded slit sheet paper without a mechanism for wrapping a support wrap 520. That is, in the embodiments shown in Figs. 5 and 6, the systems can omit the support wraps 520, 520a and the corresponding rolls 220, 220a, such that the systems are configured to wrap the pallet wrap 510, 510a without any required support wrap.
  • systems and methods for wrapping pallets with stretch wrap film can be retrofitted to replace stretch wrap film applied with such systems with expandable slit sheet paper according to embodiments of the present invention.
  • systems and methods described in the patents and publications incorporated herein by reference above can be retrofitted to replace the shrink wrap rolls of plastics or elastomeric materials with expandable slit sheet material according to be embodiments of the present invention.
  • a resistance breaking mechanism can be added to adjust a breaking or resistance to rotation of the roll (e.g., similar to the below-described breaking mechanism in the pallet wrap device 200e shown in FIG. 14) to facilitate expansion.
  • one or more guiding rollers can be added to facilitate feeding or expanding of the expandable slit sheet paper material.
  • FIG. 15 is a schematic perspective view showing an illustrative embodiment of retrofitting an existing pallet wrap machine that does not dispense expandable slit sheet paper to become a pallet wrap machine that dispenses expandable slit sheet paper according to an embodiment of the present invention.
  • an existing automated pallet wrap machine which includes a rotated platform for rotatably supporting a pallet assembly, a vertical support frame that supports a vertically reciprocated roll supporter (e.g., movable up and down along a vertical track or shaft), can be retrofitted to support a roll of expandable slit sheet paper and to include enhanced controls to facilitate dispensing and expansion of the roll of expandable slit sheet paper.
  • a vertically reciprocated roll supporter e.g., movable up and down along a vertical track or shaft
  • the control unit can be upgraded to include an add on control for a brake (e.g., a pneumatic or other type of control), which brake can be employed to enhance the control of the braking or rotation resistance of the roll of expandable slit sheet paper, such that the paper can be pulled under sufficient tensile force to ensure expansion of the expandable slit sheet paper as it is fed to the periphery of the pallet assembly, while limiting the tensile forces to below the tearing strength of the expandable slit sheet paper.
  • the control for the brake should apply a tension that is in between the force required to open the cells of the expandable slit sheet paper and the force at which the expandable slit sheet paper would tear.
  • expandable slit sheet papers are created that have substantially greater tensile strengths than that of prior expandable slit sheet papers, enabling the ability to retrofit pallet wrap machines for the dispensing of expandable slit sheet paper as a pallet wrap in some advantageous embodiments. Accordingly, by retrofitting of existing pallet wrap machines and devices that do not dispense expandable slit sheet paper, not only can environmentally safe and beneficial pallet wrap according to embodiments of the present invention be employed, but existing machines and devices can be retained rather than creating waste due to obsolete/discarded machinery. Additionally, substantial cost savings can be achieved in upgrading to healthier and more environmentally friendly systems and methods, which can greatly facilitate and incentivize conversion to new environmentally safe and beneficial pallet wrap systems and methods according to embodiments of the present invention.
  • FIGS. 5 and 6 depict automated pallet wrapping equipment
  • pallet wrap materials of the present invention can be implemented with manually operated pallet wrapping devices.
  • a manually operated pallet wrap device 200e can be provided that supports a roll 21 Oe of expandable slit sheet paper according to embodiments of the present invention.
  • such a manually operated pallet wrap device 200e can essentially have two handles on opposite ends of the roll 21 Oe (as shown), and the device can include an internal breaking mechanism that resists rotation of the of the roll 21 Oe such that upon manually pulling of the expandable slit sheet material 51 Oe, the cells of the expandable slit sheet material are caused to expand into an open state.
  • a user U can manually wrap a pallet assembly 10e on a pallet 110e as shown.
  • the pallet 110e can be stationary upon a floor or support.
  • the pallet 110e can be rotated via a rotational device or mechanism similar to that shown in FIGS. 5 or 6.
  • existing manually operated pallet wrapping devices which are known in the art for wrapping of shrink wrap rolls of plastics or elastomeric materials can be retrofitted with expandable slit sheet paper according to be embodiments of the present invention.
  • a resistance breaking mechanism can be added to adjust a breaking or resistance to rotation of the roll to facilitate expansion.
  • one or more of the systems and methods can be retrofitted to dispense expandable slit sheet paper according to embodiments of the present invention described herein-above: U.S. Patent Publication No. 2015/0183542 (Hand Dispenser for Stretch Wrap); U.S. Patent No. 4,477,037 (Stretch-Wrap Film Dispenser); U.S. Patent No. 7,937,915 (Hand Dispenser for Stretch Wrap); U.S. Patent No. 7,357,349 (Stretch Film Dispenser with Auxiliary Stand Device); U.S. Patent No.
  • a sheet of extensible paper can be employed that does not include an array of slits that open into expanded cells.
  • the sheet of extensible paper can have extensibility values (i.e. , % extensibility values) similar to any of the exemplary embodiments described herein.
  • the sheet of extensible paper has a high level of extensibility, such that a level of extensibility of embodiments described herein with a greater extensibility can be employed in some embodiments.
  • the extensibility can be greater than 6% in a machine direction, and, in some embodiments, the extensibility can be greater than 7% in a machine direction, and, in some embodiments, the extensibility can be greater than 8% in a machine direction, and, in some embodiments, the extensibility can be greater than 9% in a machine direction, and, in some embodiments, the extensibility can be greater than 10% in a machine direction, and, in some embodiments, the extensibility can be greater than 11 % in a machine direction, and, in some embodiments, the extensibility can be greater than 12% in a machine direction, and, in some embodiments, the extensibility can be greater than 13% in a machine direction, and, in some embodiments, the extensibility can be greater than 14% in a machine direction, and, in some embodiments, the extensibility can be greater than 15% in a machine direction.
  • a support wrap according to one of more of the embodiments herein can also be provided; by way of example, in some embodiments, supporting fibers or filaments similar to the support filaments 520c shown in FIG. 9 can be employed.
  • a slit- sheet material is advantageously employed for the structure of the pallet wrap.
  • various embodiments of the present invention can employ any of the various extensible papers and methods for manufacture thereof described herein-above and in the numerous patents and publications incorporated herein-above by reference. Additionally, various embodiments of the present invention can employ any of the various extensible papers and methods for manufacture thereof described in the following additional patents and publications, which are all incorporated herein by reference in their entireties:
  • extensibility can be determined employing various methods well known in the paper industry. As described herein-above, in some embodiments, extensibility % values can be determined according to Technical Association of the Pulp and Paper Industry (TAPPI) standards. With respect to the above- noted TAPPI T-457 standard, it should be appreciated that TAPPI 457 has since been combined into TAPPI T-404 by TAPPI. In some embodiments, extensibility %’s correspond to elongation % at rupture. For reference, tensile breaking strength is determined to be the maximum value of stress that occurs when the paper ruptures or tears. Elongation at rupture is the measure of the maximum percentage of stretch, or the maximum strain, that the paper can achieve before failure.
  • Tensile strength can be described by stress-strain graphs and measured by TAPPI tests T-404 and T-494. Stress- strain curves provide a fundamental engineering description of the mechanical behavior of paper when subjected to tensile stress.
  • TAPPI method T-404 measures tensile breaking strength end elongation of paper and paperboard using a pendulum-type tester, and T-494 measures tensile breaking properties of paper and paperboard using constant rate of elongation apparatus.
  • TAPPI tensile strength tests of paper TAPPI tests T-404 and T-494 are useful in evaluating the tensile properties of paper.
  • TAPPI T-494 enables the simultaneous evaluation of three properties for the same test specimen: tensile breaking strength, stretch or elongation at break, and TEA (tensile energy absorption)
  • extensibility can be determined according to ISO 1924 of the International Organization for Standardization (www.iso.org), which specifies a method for measuring the tensile strength, strain at break and tensile energy absorption of paper and board, using a testing machine operating at a constant rate of elongation (20 mm/min).
  • This part of ISO 1924 also specifies equations for calculating the tensile index, the tensile energy absorption index and the modulus of elasticity.
  • the %’s of extensibility in various embodiments described herein correspond to extensibility values as determined under one or more of the TAPPI tests. According to some embodiments, the %’s of extensibility in various embodiments described herein correspond to extensibility values as determined under one or more of the ISO tests.
  • an extensible paper is provided that is formed with or from hemp in view of hemp’s natural extensibility.
  • Hemp paper can be made exclusively or with a significant amount of pulp obtained from fibers of industrial hemp. Hemp fibers can be substantially longer than wood pulp fibers, and have a higher tear resistance and tensile strength. See Wikipedia, Hemp Paper. Additionally, hemp fibers have significant resistance to decomposition, are highly recyclable, and is advantageously a fast crop to yield.
  • extensible papers can be made with virgin fibers, such as, e.g., virgin wood fibers, such as, e.g., virgin fibers from Pine and/or Spruce or other woods. In some embodiments, extensible papers can be made with recycled fibers.
  • an extensible paper can be a single layer or a multi-layer paper, such as, e.g., with 2, 3 or 4 layers, or even more layers.
  • an extensible paper can be made from unbleached softwood kraft pulp.
  • a stock preparation system and paper machine are adapted such that the stock preparation system includes a high consistency refining system and the paper machine includes a Clupak unit.
  • pulp from an unbleached high-density storage tower is set to the paper machine where it is thickened (e.g., from around 6% consistency to about 32- 35% in some examples). This can be done in a press (such as, e.g., a twin-wire, screw press, roll press, etc.). After the press, the fiber is sent to the high consistency refiner.
  • the refiner applies energy into the paper, without relevant changes in the fiber length, but adding many curls, kinds, and compressions in the fiber anatomy (such as, e.g., applying about 280-300 kWh/ton of energy to the paper in some examples).
  • the structural changes in the fiber make them stronger and more flexible.
  • the Clupak unit responsible to create micro-compressions in the paper to develop the stretch ability (e.g., extensibility).
  • the Clupak unit includes a chromium plated dryer cylinder heated by steam to enable slipping of the paper, an endless rubber blanket with a circuit of guide and stretch rolls, a non-rotating nip bar with an approaching and separating pneumatic system and a blanket rectifier.
  • extensible papers employed in the packaging industry as extensible sack paper can be employed.
  • various extensible sack papers in the market related to one or more of the following companies can be employed in some illustrative embodiments: Segezha Group, Stora Tru S.A., Starkraft, KapStone Paper and Packaging Corporation, BillerudKorsnas, Swedpaper, Natron- Hayat d.o.o. Maglaj, WestRock, Nordicpaper, Horizon Pulp and Paper Ltd., Primo Tedesco.
  • extensible papers provided by Mondi see www.mondigroup.com
  • Canadian Kraft Paper see www.canadiankraftpaper.com
  • slit patterns as described herein.
  • the paper products set forth in the following tables of Examples A, B and C below have been adapted by the present inventor to include slit patterns to form expandable slit sheet papers for pallet wrapping.
  • Example A Example B: Example C:
  • extensible papers can be employed having properties similar to that shown in any of Examples A-C above + or - 10% from the values shown in the tables, or, in some embodiments, + or - 25% from the values shown in the tables, or, in some embodiments, + or - 50% from the values shown in the tables. Additionally, in some other illustrative embodiments, extensible papers can be employed having properties that are the same or greater than the values shown in the tables of any of Examples A-C above.
  • the term "preferably” is non-exclusive and means “preferably, but not limited to.”
  • means-plus-function or step-plus-function limitations will only be employed where for a specific claim limitation all of the following conditions are present in that limitation: a) "means for” or “step for” is expressly recited; b) a corresponding function is expressly recited; and c) structure, material or acts that support that structure are not recited.
  • the terminology “present invention” or “invention” may be used as a reference to one or more aspect within the present disclosure.
  • the terms "about”, “substantially”, and “approximately” when referring to a numerical value shall have their plain and ordinary meanings to a person of ordinary skill in the art to which the disclosed subject matter is most closely related or the art relevant to the range or element at issue.
  • the amount of broadening from the strict numerical boundary depends upon many factors. For example, some of the factors which may be considered include the criticality of the element and/or the effect a given amount of variation will have on the performance of the claimed subject matter, as well as other considerations known to those of skill in the art.
  • any ranges, ratios and ranges of ratios that can be formed by, or derived from, any of the data disclosed herein represent further embodiments of the present disclosure and are included as part of the disclosure as though they were explicitly set forth. This includes ranges that can be formed that do or do not include a finite upper and/or lower boundary. Accordingly, a person of ordinary skill in the art most closely related to a particular range, ratio or range of ratios will appreciate that such values are unambiguously derivable from the data presented herein.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Buffer Packaging (AREA)
  • Pallets (AREA)
  • Basic Packing Technique (AREA)
  • Laminated Bodies (AREA)
  • Packages (AREA)

Abstract

Selon des modes de réalisation donnés à titre illustratif, l'invention concerne un nouvel emballage de palette. Dans certains modes de réalisation préférés, l'emballage de palette comprend : un papier en feuille à fentes extensible ayant un motif à fentes comprenant une pluralité de fentes s'étendant dans une direction transversale formant une pluralité de cellules ouvertes lors de l'extension dans un sens machine. Dans certains modes de réalisation, l'emballage de palette comprend un nouveau papier en feuille à fentes extensible conçu pour permettre l'emballage d'un ensemble palette. Dans certains modes de réalisation, l'emballage de palette comprend un papier en feuille à fentes extensible et un emballage de support, le papier en feuille à fentes extensible étant conçu pour être enroulé autour d'un ensemble palette et l'emballage de support étant conçu pour entourer au moins une partie du papier en feuille à fentes extensible enroulé autour de l'ensemble palette.
PCT/US2022/022059 2021-03-25 2022-03-25 Systèmes et procédés d'emballage de palettes et analogues avec du papier extensible Ceased WO2022204579A1 (fr)

Priority Applications (9)

Application Number Priority Date Filing Date Title
MX2023010766A MX2023010766A (es) 2021-03-25 2022-03-25 Sistemas y métodos para envolver pallets/tarimas y similares con papel expandible.
EP22776772.0A EP4313775A4 (fr) 2021-03-25 2022-03-25 Systèmes et procédés d'emballage de palettes et analogues avec du papier extensible
US17/802,012 US20230294858A1 (en) 2021-03-25 2022-03-25 Systems and Methods for Wrapping Pallets and the Like with Expandable Paper
CA3212888A CA3212888A1 (fr) 2021-03-25 2022-03-25 Systemes et procedes d'emballage de palettes et analogues avec du papier extensible
BR112023019314A BR112023019314A2 (pt) 2021-03-25 2022-03-25 Sistemas e métodos para embalagem de paletes e similares com papel expansível
AU2022246177A AU2022246177A1 (en) 2021-03-25 2022-03-25 Systems and methods for wrapping pallets and the like with expandable paper
CONC2023/0013816A CO2023013816A2 (es) 2021-03-25 2023-10-19 Sistemas y métodos para envolver palets y similares con papel expandible
US18/615,179 US20240359840A1 (en) 2021-03-25 2024-03-25 Systems and methods for wrapping pallets and the like with expandable paper
US18/792,386 US20240391622A1 (en) 2021-03-25 2024-08-01 Systems and methods for wrapping pallets and the like with expandable paper

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US202163166233P 2021-03-25 2021-03-25
US63/166,233 2021-03-25
US202163190025P 2021-05-18 2021-05-18
US63/190,025 2021-05-18

Related Child Applications (3)

Application Number Title Priority Date Filing Date
US17/802,012 A-371-Of-International US20230294858A1 (en) 2021-03-25 2022-03-25 Systems and Methods for Wrapping Pallets and the Like with Expandable Paper
US18/615,179 Continuation-In-Part US20240359840A1 (en) 2021-03-25 2024-03-25 Systems and methods for wrapping pallets and the like with expandable paper
US18/792,386 Continuation US20240391622A1 (en) 2021-03-25 2024-08-01 Systems and methods for wrapping pallets and the like with expandable paper

Publications (1)

Publication Number Publication Date
WO2022204579A1 true WO2022204579A1 (fr) 2022-09-29

Family

ID=83397964

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2022/022059 Ceased WO2022204579A1 (fr) 2021-03-25 2022-03-25 Systèmes et procédés d'emballage de palettes et analogues avec du papier extensible

Country Status (8)

Country Link
US (2) US20230294858A1 (fr)
EP (1) EP4313775A4 (fr)
AU (1) AU2022246177A1 (fr)
BR (1) BR112023019314A2 (fr)
CA (1) CA3212888A1 (fr)
CO (1) CO2023013816A2 (fr)
MX (1) MX2023010766A (fr)
WO (1) WO2022204579A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024097942A1 (fr) * 2022-11-04 2024-05-10 Domtar Paper Company, Llc Produits contenant du papier extensible
WO2024246178A1 (fr) 2023-05-30 2024-12-05 Ikea Supply Ag Procédés et dispositif d'emballage de papier de marchandises chargées sur une palette, et palette de marchandises emballée de papier

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5433058A (en) * 1993-04-22 1995-07-18 Peterson; Robert W. System, method, and apparatus for packaging bales of hay
WO2015192250A1 (fr) * 2014-06-19 2015-12-23 Crawford Packaging Inc. Dispositif de contrôle de machine d'emballage par rétraction de palettes
WO2018191012A9 (fr) * 2017-04-10 2018-11-22 Ranpak Corporation Matériau de papier à feuille fendue extensible, système de conversion en produit de calage et procédé d'extension
US20210031997A1 (en) * 2013-09-06 2021-02-04 David Paul Goodrich Expanded slit sheet cushioning products with novel slit pattern and paper properties

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4852330A (en) * 1986-05-09 1989-08-01 Carangelo Martin C Method for stabilizing stacked load
US5688578A (en) * 1992-03-16 1997-11-18 Goodrich; David P. Composite packaging material having an expanded sheet with a separator sheet
ITVE20040013A1 (it) * 2004-04-14 2004-07-14 Cartiere Cariolaro S P A Metodo di realizzazione di carta estensibile, impianto per attuare il metodo, prodotto ottenuto con il metodo e materiale cartaceo ottenuto con il prodotto.
US8637134B1 (en) * 2009-03-23 2014-01-28 Alliance Plastics, LLC Vented plastic film and method of making
US10099814B2 (en) * 2013-08-12 2018-10-16 Ryan Burk Pallet
KR102534941B1 (ko) * 2017-06-26 2023-05-26 데이비드 폴 굿리치 신장성 페이퍼, 및 확장된 슬릿 패키징 랩 제품 및 공간 충진 제품들의 제조에 있어서의 신장성 페이퍼의 용도
CN114206734A (zh) * 2019-06-26 2022-03-18 希曼纸业公司马萨诸塞股份有限公司 可拉伸的运输/托盘包裹件及其使用方法
WO2021023806A1 (fr) * 2019-08-06 2021-02-11 Société des Produits Nestlé S.A. Unité palette pourvue d'une feuille d'emballage continue s'étendant au sein de l'empilement de blocs et procédé de palettisation
WO2022087080A1 (fr) * 2020-10-20 2022-04-28 David Paul Goodrich Systèmes et procédés pour incorporer des étiquettes et analogues avec une enveloppe de matériau en feuille à fente extensible

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5433058A (en) * 1993-04-22 1995-07-18 Peterson; Robert W. System, method, and apparatus for packaging bales of hay
US20210031997A1 (en) * 2013-09-06 2021-02-04 David Paul Goodrich Expanded slit sheet cushioning products with novel slit pattern and paper properties
WO2015192250A1 (fr) * 2014-06-19 2015-12-23 Crawford Packaging Inc. Dispositif de contrôle de machine d'emballage par rétraction de palettes
WO2018191012A9 (fr) * 2017-04-10 2018-11-22 Ranpak Corporation Matériau de papier à feuille fendue extensible, système de conversion en produit de calage et procédé d'extension

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP4313775A4 *

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2024097942A1 (fr) * 2022-11-04 2024-05-10 Domtar Paper Company, Llc Produits contenant du papier extensible
WO2024246178A1 (fr) 2023-05-30 2024-12-05 Ikea Supply Ag Procédés et dispositif d'emballage de papier de marchandises chargées sur une palette, et palette de marchandises emballée de papier

Also Published As

Publication number Publication date
US20230294858A1 (en) 2023-09-21
EP4313775A1 (fr) 2024-02-07
EP4313775A4 (fr) 2025-03-19
BR112023019314A2 (pt) 2023-10-31
MX2023010766A (es) 2023-11-22
CO2023013816A2 (es) 2023-11-10
AU2022246177A1 (en) 2023-10-05
CA3212888A1 (fr) 2022-09-29
US20240391622A1 (en) 2024-11-28

Similar Documents

Publication Publication Date Title
US11760548B2 (en) Extensible paper and its use in the production of expanded slit packaging wrap and void fill products
US20240391622A1 (en) Systems and methods for wrapping pallets and the like with expandable paper
US11697536B2 (en) Expanded slit sheet cushioning products with novel slit pattern and paper properties
US11834240B2 (en) Expanded slit sheet cushioning products with novel alternating expansion patterns
US20240359840A1 (en) Systems and methods for wrapping pallets and the like with expandable paper
WO2021163453A1 (fr) Systèmes et procédés de distribution du remplissage de vides de feuilles fendues et étendues
US11905088B2 (en) Expanded slit sheet cushioning products with novel slit pattern and paper properties
US12221260B2 (en) Expanded slit sheet cushioning products with novel reduced dimension slit patterns
CN114786937B (zh) 具有新颖狭缝图案和纸张性质的改善扩展狭缝片材缓冲产品
WO2024178410A1 (fr) Systèmes et procédés d'expansion de papier en feuille fendue utilisant une ou plusieurs brosses de friction et/ou un ou plusieurs autres éléments de friction
CA3204038A1 (fr) Produits de rembourrage a feuille decoupee expansee ameliores avec de nouveaux motifs de decoupe de dimension reduite
HK40069543B (en) Improved expanded slit sheet cushioning products with novel slit pattern and paper properties
HK40069543A (en) Improved expanded slit sheet cushioning products with novel slit pattern and paper properties
HK40019891A (en) Extensible paper and its use in the production of expanded slit packaging wrap and void fill products
HK40019891B (en) Extensible paper and its use in the production of expanded slit packaging wrap and void fill products

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 22776772

Country of ref document: EP

Kind code of ref document: A1

WWE Wipo information: entry into national phase

Ref document number: MX/A/2023/010766

Country of ref document: MX

WWE Wipo information: entry into national phase

Ref document number: 2022246177

Country of ref document: AU

Ref document number: AU2022246177

Country of ref document: AU

Ref document number: 3212888

Country of ref document: CA

REG Reference to national code

Ref country code: BR

Ref legal event code: B01A

Ref document number: 112023019314

Country of ref document: BR

ENP Entry into the national phase

Ref document number: 2022246177

Country of ref document: AU

Date of ref document: 20220325

Kind code of ref document: A

WWE Wipo information: entry into national phase

Ref document number: 202317068747

Country of ref document: IN

WWE Wipo information: entry into national phase

Ref document number: NC2023/0013816

Country of ref document: CO

WWE Wipo information: entry into national phase

Ref document number: 2022776772

Country of ref document: EP

NENP Non-entry into the national phase

Ref country code: DE

ENP Entry into the national phase

Ref document number: 112023019314

Country of ref document: BR

Kind code of ref document: A2

Effective date: 20230921

ENP Entry into the national phase

Ref document number: 2022776772

Country of ref document: EP

Effective date: 20231025

WWP Wipo information: published in national office

Ref document number: NC2023/0013816

Country of ref document: CO