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US 2023/0356493 A1Published application
Expanded Slit Sheet Packaging Material That Interlocks When Layered and Expanded
OwnerDavid Paul Goodrichinventor
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OwnerDavid Paul Goodrichinventor
Estimating the term…
In accordance with a broad embodiment of the invention, a novel paper product is comprised of two or more slit sheet packing material layers, each layer having its own slit pattern design to create interlocking layers of expansion sheet packaging materials. Each layer expands to create a three dimensional open netting of cells of hexagons, and the like, and is designed to have limited nesting with its opposing layer, thereby maximizing the thickness of the combined layers as compared to nested layers. Adjacent layers have differing slit patterns and can be expanded through expander type machinery such that the expansion rates of the differing slit pattern layers can be varied to deliver the same width of exiting expanded material from each layer. Preferably the differing slit pattern produce when expanded, inclined land areas that have the same number of rows per inch, but different angles of inclination of the land areas, such that adjacent layers can interlock, that is, have a restricted amount of nesting.
1- The method of producing at least a pair of interlocking adjacent layers of a paper packaging product,
2- The method of claim 1, wherein said slitting of said first sheet and said second sheet forms a substantially straight line cut along one edge of the slit and an angled cut along the other edge of the slit, thus forming a wedge shape that is wider on a first side of the blade entry point that on the other side of the blade entry point.
3- The method of claim 1, wherein said expanding of said first sheet and said second sheet is in the range from about 10 to 20% less than the maximum expansion of each of said first sheet and said second sheet.
4- The method of claim 1, wherein said expanding of said first sheet and said second sheet is in the range from about 100 to 110% of the maximum expansion of each of said first sheet and said second sheet.
5- The method of claim 1, wherein said slitting of said first sheet and said second sheet forms a straight line cut along one edge of the slit and an angled cut along the other edge of the slit.
6- The method of claim 1, wherein said angle of inclination of said first sheet and said angle of inclination of said second sheet are consistent along the length of said first sheet and said second sheet.
7- The method of claim 1, wherein said angle of inclination of said first sheet and said angle of inclination of said second sheet along the length of said first sheet and said second sheet have less than about 20% switch back effect.
8- The method of claim 1, wherein said angle of inclination of said first sheet and said angle of inclination of said second sheet along the length of said first sheet and said second sheet have less than about 10% switch back effect.
9- The method of claim 1, further comprising the step of forming slits in said first and said second sheet of slit paper using a beveled blade having an included angle in the range from 1 to 6 degrees.
10- The method of claim 9, wherein said beveled blade has a first side that forms an angle of about 90 degrees with respect to the plane of the paper being slit.
The method of claim 1, wherein upon expansion, said angle of inclination of said first sheet is in the range from 55 to 75 degrees, and said angle of inclination of said second sheet is in the range from 105 to 125 degrees.
12- The method of claim 1, further comprising the steps of;
13- The method of claim 1, further comprising the step of forming slits in said first and said second sheet of slit paper using a beveled blade against a rotating anvil, said beveled blade having an included angle in the range from 1 to 6 degrees.
14- The method of claim 1, wherein upon expansion, said angle of inclination of said first sheet is in the range from 55 to 70 degrees, and said angle of inclination of said second sheet is in the range from 125 to 110 degrees.
15- The method of claim 1, further comprising forming said first slit pattern and said second slit pattern by slitting with a blade against a rotating anvil, said blade having an angle included angle in the range from 1 to 3 degrees, and wherein said paper is recycled paper, thereby producing an inclination of said first sheet and an angle of inclination of said second sheet that is substantially consistent along the length of said first sheet and said second sheet.
16- The method of claim 15, wherein said anvil is a soft anvil and said blade cuts through said paper and into said anvil.
17- The method of claim 1, wherein one of said first sheet of slit paper and said second sheet of slit paper is Kraft paper, and the other of said first sheet of slit paper and said second sheet of slit paper is soft paper.
18- An apparatus for producing at least a pair of non-nesting adjacent layers of a paper packaging product, first means for forming in a plurality of rolls of sheet material, slits having a pattern which upon expansion of said roll of sheet material having slits, yields cells having land regions, said land regions having an inclination angle in the range from ab out 50 to 85 degrees,
19- A paper packaging product comprising:
20- The paper packaging product of claim 19, further comprising a second sheet of slit paper layered on said first sheet of slit paper, said first sheet and said second sheet being expanded to form a pair of interlocking adjacent expanded sheets of slit packaging material,
Dependencies are inferred from the claim text.