Systems and Methods for Wrapping Pallets and the Like with Expandable Paper

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.

In combination:

• a) 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.

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 making a pallet wrap system, comprising:

• providing a pallet wrap dispenser;
• mounting a roll of expandable slit sheet paper on said pallet wrap dispenser.

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.

Any of the preceding claims, wherein the expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 0.8 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein the expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 0.9 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein the expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.0 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein the expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.1 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein said expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.2 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein said expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.3 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein said expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.4 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein said expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.5 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein said expandable slit sheet paper is wrapped around said pallet assembly in an expanded state and supports a maximum tensile load in a machine direction of at least 1.6 pounds per inch across the width of the expandable slit sheet paper.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein said 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein 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.

Any of the preceding claims, wherein said expandable slit sheet paper flexibly contours around corners of boxes or containers within said pallet assembly by expansion of said open cells and/or lateral twisting enabled by said open cells.

Any of the preceding claims having a support wrap, wherein said support wrap is configured to add tensile strength to the pallet wrap beyond the tensile strength of the expandable slit sheet paper.

Any of the preceding claims having a support wrap, wherein said support wrap includes:

• reinforcing fibers or filaments extending within a lengthwise direction.

Any of the preceding claims having a support wrap, wherein said support wrap includes:

• reinforcing fibers or filaments in combination reinforcing a tape or paper material.

Any of the preceding claims having a support wrap, wherein said support wrap includes:

• reinforcing fibers extending within a lengthwise direction, wherein the reinforcing fibers include synthetic fibers.

Any of the preceding claims having a support wrap, wherein said support wrap includes:

• reinforcing fibers extending within a lengthwise direction, wherein the reinforcing fibers include glass fibers or plastic fibers.

Any of the preceding claims having a support wrap, wherein said support wrap includes a non-slit paper.

Any of the preceding claims having a support wrap, wherein said support wrap includes a heavy weight non-slit paper.

Any of the preceding claims having a support wrap, wherein 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.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of at least 30#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of at least 35#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of at least 40#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of greater than 45#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of greater than 50#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of greater than 55#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of greater than 60#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of between 30# to 70#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of between 40# to 70#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of between 45# to 70#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of between 40# to 60#.

Any of the preceding claims, wherein said expandable slit sheet paper is a paper having a weight of between 45# to 60#.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is made with an extensible paper.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has slits with a slit length of between 0.15 inches to 0.45 inches.

Any of the preceding claims, wherein:

• 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%.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.45 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.40 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.35 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.30 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.25 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of less than 0.20 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of between 0.15 to 0.35 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of between 0.20 to 0.30 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of about 0.225 to 0.275 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit length of about 0.25 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper has a slit pattern of slits extending in a widthwise direction, wherein a slit spacing (SS) relates to slit length (SL) based on the formula SL = K x SS, where K is a value between 2.4 to 3.3, or, more preferably, where K is a value between 2.5 to 3.0, or, more preferably, where K is a value between 2.6 and 2.8, or, more preferably, where K is about 2.6667.

Any of the preceding claims, wherein:

• 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 ⅛″ (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).

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• when said slit sheet paper is in an expanded state, said plurality of open cells form an alternating row expansion pattern.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is made with an extensible paper.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 3% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 4% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 5% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 6% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 7% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 8% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 9% in the machine direction.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is formed from an extensible paper having an extensibility of greater than 10% in the machine direction.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 3%.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 4%.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 5%.

Any of the preceding claims, wherein 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%.

Any of the preceding claims, wherein 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%.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 8%.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 9%.

Any of the preceding claims, wherein said expandable slit sheet paper is made with an extensible paper that is extensible in a cross direction in a range of at least 10%.

Any of the preceding claims, wherein said 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%.

Any of the preceding claims, wherein said 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%.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is configured to be wrapped concurrently with said support wrap.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is configured to be wrapped independently with respect to said support wrap.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 5 lbs to expand the cells into any open state.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 6 lbs to expand the cells into any open state.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 10 lbs to expand the cells into any open state.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 12 lbs to expand the cells into any open state.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 12 lbs to tear the expandable slit sheet paper.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 18 lbs to tear the expandable slit sheet paper.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 20 lbs to tear the expandable slit sheet paper.

Any of the preceding claims, wherein:

• said expandable slit sheet paper requires a tensile load or force in a machine direction of greater than 22 lbs to tear the expandable slit sheet paper.

Any of the preceding claims, wherein:

• 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).

Any of the preceding claims, wherein:

• said pallet assembly includes stacked items, boxes or containers extending to a height of at least 3 feet (i.e., 36 inches).

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable greater in length than a common expandable slit sheet paper.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable beyond 67% expansion.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable at least 10% more than 67% expansion.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable at least 15% more than 67% expansion.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable at least 20% more than 67% expansion.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is hyper expandable at least 25% more than 67% expansion.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is configured to not retract from a fully expanded state.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is configured to not retract or to minimally retract from a fully expanded state.

Any of the preceding claims, wherein:

• 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%.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided in a roll of expandable slit sheet paper in an unexpanded state.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 10 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 15 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided 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.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided in a roll of expandable slit sheet paper in an unexpanded state having a width in an unexpanded state of greater than 20 inches.

Any of the preceding claims, wherein:

• said expandable slit sheet paper is provided 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%.

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%.