# US 12,005,685 B2 · Method of forming a cushioning sheet

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- Number: US 12,005,685 B2
- Document ID: US12005685B2
- Status: Granted
- Kind: B2
- Application number: 18/146,244
- Filed: 2022-12-23
- Published: 2023-04-27
- Granted: 2024-06-11
- Earliest claimed: 2020-07-30
- Assignees: Pratt Corrugated Holdings, Inc.
- Applicants: Pratt Corrugated Holdings, Inc.
- Inventors: Greg Sollie; Christopher M. Stanton
- Web page: https://patentgrep.com/patent/US12005685B2

## CPC

- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- B32B 3/30: characterised by a layer formed with recesses or projections, e.g. {hollows, grooves, protuberances, ribs (apertured layer B32B3/266; layer with cavities or internal voids B32B3/26)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 29/005: {next to another layer of paper or cardboard layer}
- B32B 37/0053: {Constructional details of laminating machines comprising rollers; Constructional features of the rollers}
- B32B 37/10: characterised by the pressing technique, e.g. using action of vacuum or fluid pressure
- B65D 27/14: using adhesive applied to integral parts, e.g. flaps
- B65D 81/02: specially adapted to protect contents from mechanical damage {(containers of polygonal cross-section provided with internal protecting elements for contents B65D5/50; devices to locate articles in containers B65D25/10)}
- B65D 81/03: Wrappers or envelopes with shock-absorbing properties, e.g. bubble films {(for thermal insulating purposes B65D81/3888)}
- B32B 2307/558: Impact strength, toughness
- B32B 2439/40: Closed containers
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- 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

## Abstract

A method of forming a cushioning sheet includes forming a plurality of first sockets in a first layer; forming a plurality of second sockets in a second layer, each of the second sockets aligned with a corresponding one of the first sockets; positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets; and coupling the first layer to the second layer to retain the plurality of cushioning inserts within the voids.

## Claims

### Claim 1

A method of forming a cushioning sheet comprising:
forming a plurality of first sockets in a first layer;
forming a plurality of second sockets in a second layer, each of the second sockets aligned with a corresponding one of the first sockets;
positioning a cushioning insert within a void defined between each corresponding pair of the first and second sockets; and
coupling the first layer to the second layer to retain the plurality of cushioning inserts within the voids;
wherein:
positioning the cushioning insert within the void comprises:
picking up the cushioning insert;
releasing the cushioning insert onto the first layer;
locating the cushioning insert in one of the first sockets; and
covering the first layer with the second layer;
picking up the cushioning insert comprises picking up the cushioning insert with a vacuum roller, the vacuum roller defining an insert indentation and a vacuum port formed in the insert indentation; and
releasing the cushioning insert onto the first layer comprises releasing the cushioning insert from the insert indentation of the vacuum roller.

### Claim 2 (depends on 1)

The method of claim 1, wherein:
the first layer is substantially planar prior to forming the plurality of the first sockets; and
forming each of the plurality of first sockets comprises pressing a socket projection of a forming machine against the first layer and into a socket indentation of the forming machine.

### Claim 3 (depends on 2)

The method of claim 2, wherein:
the forming machine is a layer rolling device;
the layer rolling device comprises a first female layer roller defining a plurality of the socket indentations and a first male layer roller defining a plurality of the socket projections;
the plurality of the socket projections are configured to engage the plurality of the socket indentations; and
forming the plurality of the first sockets in the first layer comprises passing the first layer between the first female layer roller and the first male layer roller.

### Claim 4 (depends on 3)

The method of claim 3, wherein:
the second layer is substantially planar prior to forming the plurality of second sockets;
the layer rolling device comprises a second female layer roller defining a second plurality of the socket indentations and a second male layer roller defining a second plurality of the socket projections;
the second plurality of the socket projections are configured to engage the second plurality of the socket indentations; and
forming the plurality of the second sockets in the second layer comprises passing the second layer between the second female layer roller and the second male layer roller.

### Claim 5 (depends on 4)

The method of claim 4, wherein coupling the first layer to the second layer comprises feeding the first layer and the second layer simultaneously through a sheet rolling device, the sheet rolling device comprising a first female sheet roller and a second female sheet roller.

### Claim 6 (depends on 5)

The method of claim 5, wherein the first female sheet roller is the first female layer roller of the layer rolling device, and the second female sheet roller is the second female layer roller of the layer rolling device.

### Claim 7 (depends on 5)

The method of claim 5, wherein coupling the first layer to the second layer comprises:
applying an adhesive to an upper surface of the second layer prior to feeding the first layer and the second layer simultaneously through the sheet rolling device; and
pressing a lower surface of the first layer against the upper surface of the second layer between the first and second female sheet rollers.

### Claim 8 (depends on 7)

The method of claim 7, wherein a pool of the adhesive is received within an adhesive pan, and wherein applying the adhesive to the upper surface of the second layer comprises dipping an adhesive roller into the pool of the adhesive and rotating the adhesive roller into contact with the upper surface of the second layer.

### Claim 9 (depends on 1)

The method of claim 1, wherein picking up the cushioning insert with the vacuum roller comprises agitating the cushioning insert on a vibrating conveyor belt and depositing the agitated cushioning insert in the insert indentation of the vacuum roller.