Note: Descriptions are shown in the official language in which they were submitted.
CA 02402882 2002-10-09
1
PACKAGING MATERIAL
BACKGROUND OF THE INVENTION
This is a div i s ion i1 appl ic;ation r:~f C:anadian Patent
Application Sc,?rial No. a', 29 ~, 71G f:i-'weed ~:m ,luly 22, 1998. The
expression "the .inv-mtic~r~" and thc~ L i ke sr~oold be understood to
encompass the s~.ibje::t matt:cer oi- both thce p~:~rent and 'the
divisional application.
1. Field of the Invention.
The present invention relates generally to cushioning
materials for packaging articles, and more particularly, but not
by way of limitation, to a packaging material comprising a
plurality of cushioning members wherein each of the cushioning
members is formed of a crumpled sheet of flexible material
having a bonding material disposed thereon for bondably
connecting overlapping portions of the crumpled sheet of
material to enhance the resiliency of the crumpled sheet of
material.
2. Brief Description of the Related Art.
In the process of shipping an article from one location to
another, the article is typically placed in a container along
with a protective packaging material to fill the voids about the
article and to cushion the article during the~shipping process.
One common protective packaging material is comprised of a
plurality of plastic: foam, peanut-shaped members, which are
commonly known as "Styrofoam peanuts." An advantage of using
Styrofoam peanuts is t:he ease with which they may be disposed
about an article positioned in a container by simply pouring the
Styrofoam peanuts from a dispenser.
Styrofoam peanuts have been widely accepted in the
packaging industry, however, they are not without disadvantages.
For example, the light weight: <~nd flowability ofd the styrofoam
peanuts results in heavier objects gravitating through the
peanuts to the bottom of the container where the object can be
damaged. Also, while the flowability of the Styrofoam peanuts
facilitates the introduction of the peanuts into a container,
the receiver of the parka<le i~~ left with having to deal with the
peanuts upon removal of t.hc~ article from t:he container in the
form of having to clean ~tp the mes s left by the peanuts which
CA 02402882 2002-10-09
2
are easily scattered upon removal of the article from the
container.
These disadvantages, as well as the environmental problems
associated with the disposal of Styrofoam peanuts, has made
paper protective packaging material a popular alternative.
Paper is biodegradable, recyclable and renewable, making it an
environmentally responsible choice. However, like Styrofoam
peanuts, paper packaging materials, such as crumpled sheets of
newsprint, are not without disadvantages in that they are
generally not very resilient, and thus, large amounts of paper
are required to provide the bulk needed to adequately cushion an
article.
An example of a paper cushioning product is disclosed in
U.S. Patent No. 5,568,867, issued to Lencoski. More
specifically, Lencoski '867 teaches a thimble shaped cushioning
product formed from a sheet of paper. The cushioning product is
formed by inserting a pr.rnch through a die with a sheet of paper
positioned therebetween so as to form the sheet of paper into
the thimble shaped cushioning product. The cushioning product
includes a closed lower' end, an open upper end, and a tubular
sidewall having a plurality of overlapping folds formed therein.
Again, the problem encountered in the use of the paper
cushioning product of hencosk:i is that the flexibility of the
paper results in the cushioning product. not being able to retain
its shape when subjected to c:ompressi.ve stresses. Thus, the
cushioning products are easily crushed and deformed whereby
voids can develop about the packed article during the shipping
process and the resiliency or cushioning effect provided by the
cushioning products can quickly deteriorate.
U.S. Patent Nos. 3,655,500, 4,109,040, and 4,717,613,
disclose cushioning dunnage products formed of a flexible,
multi-ply stock material wherein the edges of the stock material
are rolled inwardly to form pillow-like portions which are
connected together alone their engaged abutting sides by coining
or adhesive. While such dunnage products have achieved varying
degrees of success, the manufacture of such products requires
the use of specific equipment which dictates that. such products
be manufactured and then shipped to the end user rather than
formed by the end user. This in turn leads to increased costs
CA 02402882 2002-10-09
3
in the form of manufactur ing and tine~>tora<~eand shipping
of
a voluminous product.
To this end, an imp.a oved pack~~ging material is needed
which can be manually or me~Tlvan ~-owned froma sheet
ic-a=i 1 of
y
s f_le~ibie material intc r~-:~ i 1ient.shioningmem ber and
~~ cu
which can be formed just prior to . It to such a
use is
packagi rig material that h~ c~r~~ muent: is di rected.
'. sera i ion
BRIEF' SUMaIAR'r' Of THE. INDENTION
The present inventi.<}n i~; directed to a cushioning
l0 member for use as a packaging materia-1L. The cushioning
member is formed of a fl.<,xible sheet c>,= material crumpled
into a globular c:onf igurat ion such t hat the sheet. of
material. has a plurality of random folds, a plurality of
random engaged porti~-ins, <-~n<.1 a pl.ura 1i ~ y of voids . The
l~ sheet of material ha ~ an u~p~r sure ~ca and a lower surface
with at least on of the ~~pFer ~.uri a~~e arid t=he lower surf ace
having a bonding materiai_ ci~;posed thereon such that at
least a portion of the engaged portiorl:~ of the sheet of
material are bondably connect-ed thereby increasing the
20 resiliency of the folds.
The present invF~nti.c:n also providE:s a method of forming
a cushioning member for nse in packagir:g an article which
generally includes tine s!-eps of providing a sheet_ of
material. having a bor:c.in<I materia:l li:~I~osE'd on at least one
'> side thereof, anti crurnpl : ng the ~li~: ~t :,f material into a
globular configuratim s~.wh that tlne :~l,~eeU_ of material has a
plurality of random told°;, a plura~it~.~ of random engaged
CA 02402882 2002-10-09
i,1
pOrt10n;3, and e:~ f:) p' c) dS ant: .:11c.'11 tl'1at
l l;T a~. l V(:>l at= l.eaSt a
1t:
portl0n of the engaged rJY.'e b~:JC"'1<:lab Le
p :?rt l On; C:,OrneCted.
The i nvention a7_~>ofr>ro~~idE~~;a pa,.,k:age, comprising
a
container, an article in tl'I~:'e container, and
pc'.) pit a
ionE~ed
plurality of cushioning rnerrlber:;posit.i~:~ned in the container
so as to support and cus nic>n tfie art.i~:: Le, each of the
cushioning members formed of: a flexi_bl.~ sheet of material
crumpled into a c~lobnlar configuration such that the sheet
of material has ~r plural ~ t y of rarniom aolc~:>, a plurality of
l0 random c.~rzgaged pc.>rti::ins, m~.d ~-~ plczr j7. i.;:y o- voids, the
sheet
of material having a;r uf'y:~er sunfacE~ and a lower surface with
at least one of t:.he ~.zppe ~: surf~~ce and ~:.he lower ~>urface
having a bonding mat~~ria !. al. ;posed the ~eor~ such that at
least a portion of the engaged portion; are bondably
I~ connect:ed thereby in~,rear:~ing the resi.i..ienc:~,~ of: tl-re folds.
The inventic>n also y~rcvides a pa c:l:age, comprising a
container, an art.:i cle po:~itioned in t.lac:~ container, and a
plurality of cushioning Ioerr~bers positic:)ned in trl~~ container
so as to support. and c:uslvion the ant i.c:le, a~act~ of the
2o cushioning members formed of a flE=xibiE.> shE:et of material
crumpled such that tale srneet of material leas a plurality of
random folds, a pluralitu of random eruc;aged portions, and a
plurality of voids, the :;beet of material having an upper
surface and a lower surfa:~ce with at lE:ast c:ne of the upper
2~ surface and the lower sm face h-~vinc~ ~: bonding material
disposed therE:on suclu th~:~t at 1 :past a f:~ortioo of the engaged
portions are bondably cor:r~ected therei:y ir~or~easi:gig the
resiliency of t_he foals.
CA 02402882 2003-06-04
3b
The invention also provides a. package, comprising a
container, an article positioned in the container, and a
plurality of c:ushionir~ members positioned in the container
so as to substantially :surround the article and support and
cushion the az-tic:le. Each of the cushioning members is
formed of a f7.exible sheet of material crumpled into a
globular configuration :~~sc:h that the sheet c>f material has a
plurality of folds, a plurality of engaged portions and a
plurality of voids; the sheet of material having an upper
surface and a lower surface with at least one of the upper
surface and the lower :~;urface having a bonding material
disposed thereon such that at least a portion of the engaged
portions are f~ondably c~c.>nnected.
The invention also provides a package, comprising a
container, an article positioned in the container, and a
plurality of cushioning members positianed in the container
so as to substantially surround the article and resiliently
support and cushion th<~ article, each of the cushioning
members formed of a fl~.ex:ible sheet of material crumpled such
that the sheet of matea:-ial has a p:Lurality of random folds,
a plurality of random c~ngac~ed portions, and a plurality of
voids, the sheet of material having an upper surface and a
lower surface with at :Least one of the upper surface and the
lower surface having a bonding material disposed thereon
such that at least a portion of the engaged portions are
bondably connected thex:~eby increasing the resiliency of the
folds.
CA 02402882 2002-10-09
iC
'The invention also provides a rnet.hod c>f packaging an
rrticle, comprising t:he :;tees of:
(a) po..sit ior:ing they article in a c~onta~iner;
(b) providing a sheet of material having a bonding
rnatez: ia.L dispo:~eci on at ea:~t cane s~rrt <~ce t hereof ;
(c) crumpling the ~t.eei: of mat E~ciarl '~r~t.o a
substantially globular c;~~nfiguratzon :;uclo that the sheet of
materia:l_ has a plum Lity of folds, a 1~ Lur~zl qty of engaged
portions, and a plur<3lit~~- of vc.ids and suctu that at least a
l0 portion of the engaged pc>rtic~nv are bondably connected;
(d; disposing the clwmplea sheet of material into the
:.:ontainer; and
(e) repeating steps (b)-(d) until the article is
supported in the cont.ainF°r by the crumbled sheets of
i~ material.
The invention also ~:rovides a method packaging an
article, comprising t_he : tees cf:
(a) positioning the article in a container;
(b) removing th~~ sheet of material from a pad of
2(i plurality of sheets of material, each :sheet of material of
the pad of sheets of material having a bonding material
disposed on at. least one surface thereof;
(c) crumpling the rE-moved sheet of- material into a
substantially globular <_<:nfigurrric~ro sm~h that t::ze removed
2~ sheet. c:f materiarl ha:; a ~ l,.rt <~l i!: ,~ c>t f c:1:1:_:, a~ p1 zral l
t y of
engaged portions, anc_( a plurality of vem d:and such that at
least a portion of the er:gaged portior_L~ are bondably
connected;
CA 02402882 2002-10-09
(c.~-ii_ spas :ng tfae cr ~,lmf; fE~<~ ~>ht_ crt <~f rant eria L into t:he
c:va>r~ta i nE>r; <=lnc~
(e,' repeating st eps (b; - (c~) urH::i l t=he article is
supported in the coast ainE:r by t~~re crumb:led sheets of
material.
The invention also provides a method of pac:Kaging an
article, comprising t_he sterns of:
(a) posit:ic_>ning the .~rti.cl~~ ira ~~ c:ontainer;
(b) providing a sheEt of rnateri~~l having a bonding
~(I irlatarla~ (~l.spOSE:c~ Or7 at I~:='a:t. C:)IlF~ clll f~~'.'r~
t.fiE_'YE:Ot;
(c) crumpling true sPvc>_et of matE?rial such that the sheet
of material has a plurality of folds, a plurality of engaged
portions, and a plurality of voids and :such that at least a
portion of the engaged portions are bondabl.y connected;
15 (d) disposing the crumpled sheet cf material into the
container; and
(e) repeating steps (b)-(d) until the article is
supported in the coast a ine r h~y tl~c-: crl_lmpled sheets of
m~iterial.
20 The invention also provides a rrlethod of packaging an
article, comprising the steps of:
providing a plurality of sheets of material, each sheet
of material having a bonding mat=erial disposed on at least.
one surface thereof;
25 crumpling each of t:ne sheets of material into a
substantial_Ly globular configuration such that each sheet of
material teas. a p1~_rral it-y of fold,>, a plczrality of engaged
CA 02402882 2002-10-09
~ ('
portions, and a plurality of voids and sl.lch that at least a
portion of the engaga~d pcrt:ions are k~cr:darL;~.ly connected;
disposing the crw-npl~.,c-i sheets c~~: rl,aterial into a
~::ont,-ri rucr; arn:l
s pc:~itioninc:~ tile art i.:vl? in r_he c:cnt~ainer anc-~ on the
crumpled sheets of m;:vteri:al whereby t.r,e article is supported
in the ~:ontainer by the crurrlpled sheets. of material.
The invention also provides a method of packaging an
article, comprising t_he ~:teps of
(a ) removi.nc.~ a .;beet of mater i <r if rom a pad of a
plurality of sheets of m~:te.rial, each sheet of material of
the pad of sheet:> of rnateria:r:L. having a bonding m~~ters.al.
disposed on at least c~rre sut:raca t.h~~-'tie=c~f;
(b) crumpl ing the r~-moved sheet c-f material into a
I, substantia.l_7 y g:Lcbul~rr cwrrfi<~urati.c>n such that each removed
sheet of material ha:~ a f~lurality of folds, a plurality of
engaged portions, anti a f luralit:y of voids and such that at
least a portion c:f the engaged portions are bondably
connected;
'~ci (~c) disposing tLle crumpled shecit of material into a
container;
(d) repeating steps (a) - (c ) sc~ a_< to form a layer of
<:rumplea~ sheets c~f rrr~:rter;..ll in tnEe cw~rat airm~.r; and
(e) positioning the article in the container and on the
2s 7_ayer of crumpled shceets o.f materia 1. wrlerf~~by the article is
supported in the container by the Layer of crumpled sheets
of material.
CA 02402882 2002-10-09
~~
They invention a:1 so ~ rov:i.des a mE:tr~od of packaging an
article, compris-ng 1-he : teas ot=:
(a) pr~:wie_iing a slueet cat m<~teri.arl having a l:~onding
material. disposed on at 7:east one ~;urfuce thereof;
(1~) ~vrump.l.ing the sl,~eet: of rnatF~r~i<~sl toh that the sheet
of material has a plurali ~_y of i.-olds, ~: p7 urality of engaged
portions, and a pluraility c.>f- voids and such that at least a
portico. of the engaged p.c=rdons are hor~dabl.y connected;
(r. ) dispc.~sing the cmmp:l.ed shc;c~i~ c>f material. into a
Ic container;
(d) repeating sl:eps (a)-(c) sc> a:; to form a layer of
crumpled sheets c:f m< ter:: al in the uont_ainer; and
(e) positioning the article ira 1.hEe container and on the
Layer of crum~:alea shE~et~, of rn,ateri.a:1 where;roy the article is
1~ support:ed in t=he cont:ainE~r l;>y the layer of crumpled sheets
of mater:.ial.
The invent ic:n a l.so l;r~~.vides a method of packaging an
article, comprising the :steps of:
(a) positioning the article in a container;
o (b) prov:ic~ing a sheet c>f mater.ia:1 having a bonding
material disposed on at -east one surface thereof;
(c) crumpling tlne ~~loee~t of mater-~ al into a
substantially globular c~~nficturati.on such that the sheet of
material has <r plum l.ity of r-andorn fol.'s, a plurality of
''s random engaged pc:rtivns, and a ~;lr.rrality of voids and such
that at least a l:~ort i.c>n ~>f l_lne engaged pc>rt.ions are bondably
connect=ed thereby invrea:;ing the resiliency of the folds;
CA 02402882 2002-10-09
j !=
(d) disposing tL~e cr~~mpled sheet of material into the
vontainer; and
(e) repeating st e~s (b) - (d) unt=il the article is
supported in the cone a T nc r .~y i_lze~ cr mn.~vled sheets of
mat..eri<-il .
TtnF~ in~~ent ion a I s.~ L rc»r:' d<~:-~ ,~ rneetL~od c>i: packaging arl
article, cornpri~>l.rug t r~~~ ~ t F'~;:> <>1
(a) posit Toning ttm ,irt icla irn a container;
(b) removing the sheet of material from a pad of
1u plurality of sheets of m~~t_erial, eacLn s>heet of material of
the pad of sheets of material having a bonding material
disposed on at least one surface t_bereof;
(c) crumpling the rcmovE>d sheet cf material into a
substantially globul<nr cc of idur ~tic~u ~L;ch that the removed
Is sheet of mat:eri<~l ha:; :~ ~. 1~.zr a~ li:wy of m;ride~n~. fold.->, a
plurality of random E:ngac,ed pori_ions, ~.nd a plurality of
voids and such that a-~t least a norti_on of t_he engaged
portions are bondably cor:nected thereby increasing the
resiliency of the folds;
2(> (d) disposing tlue cr urrlpled sheet c~f material into the
container; and
(e) repeating st-eps (b)-(d) until the article is
supported in the cont ainF r ~~y the crumpled sheets of
material.
2~ The invention also Lrovides a method of packaging an
article, comprising the r:teps of:
(a) positioning the article in a container;
CA 02402882 2002-10-09
~I1
(b) providing a sheet c: f: material ;paving a bonding
material c~l.isposc~d on at. lea~:;t,: one strrfGc~c, thereof;
(c1 crumpling tf~e sf-eet of matc_~riUl such that the sheet
of materi<:~1 has a p1~~rarl~!:y «t rancacrm folcas, a p.lurali.ty of
random engaged portions, ~n,~l a hlura:zl_it y of voids and such
t=hat at least a portion c:t t.tne ~~ngae,~ec1 portions ~~:re bondably
connected thereby inwrea;=i ncl the resili enc:y of the folds;
( d) ~_ii.~posin~ tt;e: cr~nni:led vlm:et: cal ru3t.eri<~l into the
container; and
Ila (e) r.epeatir~g steps (b) -- (d) t~rui:. i1 t:.h<:e article is
supported i n the cone aim-r ~.::~Y~ the orum~~led sheets of
material.
The invention also ~rovidea a method of packaging an
article, comprising i:he :-.tee:>s, c:f:
I , providing a plural.it y c~>:(= ~heE:~t :~ of ma'vterial, each sheet
of material having a bon<:~~nra ma ter ial c.'i sposed on at least
one surfarce therf_c:~f ;
crumpling each of tf_r sheets of rmt..erial into a
substantially gl.obul<~r cc>nf_i.guraticr~ _;uch that each sheet of
20 material has a plurality of random folds, a plurality of
random engaged pc~rticms, anc:~ a pltzr-ali1=y c.of voids and such
that at least a portion c~f tre engaged portions are bondably
connect:ed t:hereby ina:.rea::inc~ the rws:i liE:n<.:,Y~ of the folds;
disposing the cramped sheets of material into a
?S container; and
positioning the art clc=: in tW ~ c~~r;tainer and on the
crumpled sheets ::f matc:er a1 who rc~t>~,~ ~W_ a;wticle is supported
i.n the container by the ~;rum~~lc~d sh~aet:~ of material.
CA 02402882 2002-10-09
)1
The invent: ion a_'1 so province:, a mettvod of pact~a~ging an
article, comprisi ng t he s t-_~et~>:; c:f :
(a:r) remov:ing a :.r.~E;ai ~.:~f ;rm'_E~ria~ 1 f turn _~ pad of a
plurality of sheets ct rna'.e.e.i~.rl, eac_:h sheet of material of
the pad of sheets of rnateri~:~:l. havincl a bonding material
disposed on at least one surface thereof;
(b) crumpling tine removc:eci :sheet: of m~~teerial into a
substant.ial.ly globular ccrof igurat=ion such that each removed
sheet of material ha', a L. lur.'aali.t~l,% c,:f: rar~dc>rri tolda, a
1(i plurality of random engaGe=d portions, and a pl!zrality of
voids arud such that a:~t. l~ ~a>t: ~:~ r>:~rt '~.u~r~ of the engaged
portions are bondably con-nec::t.ed thF-~rek~;= irncreasing the
t:esiliency of the folds;
(c') disposing true cz~_impled shEeet c>f material into a
I~ container;
(d) repeating steps (a)--(c) sc~ a:> to form a layer of
crumpled sheets ef= m~~terp al in the cont:ainE:r; and
(e) positioning the art::icle i n thF~ c<>rut:ainer and on t:he
layer of crumpled sheets of matserial c~!here~>y the article is
20 supported in the c: ont:ainerv toy the laym oi- c.~rumpled sheet s
of material.
The invention a l_so L:rovi.dE s a rnc~t.luod cnf packaging an
article, comprising t=he r:teps of:
(a) providing a shec:-t of rr~at:er:ial having a bonding
s material disposed on at ;east c>ne si_rrface thereof;
(b) crumpli:~g the sheet: of mat..~~ri<~l r~uch that the sheet
of material has a pl~.arali t;~ c~f rarwiom folds, a plurality of
random engaged port. i..c~ns, anal a pll r.v~ I i ~_y c:~f:~ voids and sl.rch
CA 02402882 2002-10-09
that at least a portson of the engaged portions are bondably
connected thereby increasing the re;i7_ienc:y of the folds;
(c) disposing the cz~zmp.Led she<~t: of material into a
container;
((:~1 reEJea~7.rl~:~ :~t E':OS (,l) _. (~.~ sci <1~ t ii f:CYIT'~ a layer Of
''Llmple~d silo-L-~t~ C?f mi:t~~T.; ~i i Lr? '.:flf? c-';:or,t,-711.E~I: ;
~1T1C~
(e) positioning the ;art-icle in the <~<;ntainer and on the
layer of crumpled sheets of materialwr~ereby the article is
supported in the cont:ai.ner ~y thf-~ layer of crumpled sheets
1(I of material.
In one errlbodiment, t lue sheet of: IT~ater ial is provided in
a pad of a plurality of sizeets of m~~t.erial whereby the sheet
of material is removed from the pad prior to crumpling the
sheet of material.
iv A plura.l:it~,~ of the c:'ushioning rlern~~f r.. may be
incorporated into a ~.>a~k~;ge whiriz a<~dit.ionally includes a
container_ and an article oositioned within the container.
The cushioning members may be positioned into the container
to substantially sur_rounc? the article positioned within the
2t? container. In this manner, t:he cusruioning members will
function as a protective packaging raatE=rial which cushions
the article during a shi~pinc~ proces.=~.
CA 02402882 2002-10-09
The objects, features and advantages o.f the present
invention will become apparent from the following detailed
description when read in conjunction with the. accompanying
drawings and appended claims.
BRIEF DESCRIPTION c)F THE SEVERAL VIEWS OF THE DRAWING
FIG. 1 is a perspective view of a cushioning member
constructed in accordance with the present invention.
FIG. 2 is an enlaa-ged sectional view of a portion of the
cushioning member of F1G. 1.
FIG. 3 is a perspective view of a sheet of material for use
in forming the cushioning member of the present invention.
FIG. 4 is a perspective view of ;mother sheet of material
for use in forming t:he cu;~hioning member of the present
invention.
FIG. 5 is a perspective view of a pad of a plurality of the
sheets of material of fIG. 3.
FIG. 6 is a perspective view of a package incorporating a
plurality of cushioning members constructed in accordance with
the present invention.
CA 02402882 2002-10-09
DETAILED DF;SCRIPTION OF THE INVENTION
Referring now to the drawings, and more particularly to
FIGS. 1 and 2, a cushioning member 10 constructed in accordance
with the present invention is illustrated. The cushioning
5 member l0 is formed from a flexib:Le sheet of material 12
crumpled into a cubical, rectangular, spherical, or otherwise
globular configuration having a plurality of random folds 14, a
plurality of random engaged portions 16, and a plurality of
voids 18. The sheet of material 12 can be crumpled to form the
cushioning member 10 manually or with a suitable apparatus, such
as that disclosed in 1J.3. Patent. No. 2,924,154, issued to
Russell et al. on February 9, 1960, which is hereby expressly
incorporated herein by reference.
Referring now to FIG. 3,, the sheet of material 12 is a
substantially square or- rectangle sheet of material having a
length of approximately two to four feet and a width of
approximately two to four feet. However, it will be appreciated
that the dimensions of the sheet of material 12 may be varied.
The sheet of material 12 can be any flexible sheet of material,
2o including paper, crepe paper, polymeric film, laminated
polymeric film, and waxed paper, for example. The sheet of
material 12 may have printed matter and/or embossed pattern on
at least one side thereof, and the embossed pattern can be
either in register or out of register with the printed pattern.
Different colors can be employed to provide the printed pattern
on the sheet of material 12.
The sheet of material 12 can also be embossed so as to
provide the sheet of material 12 with an embossed pattern.
Further, the sheet of material 12 can be provided with an
embossed pattern as well as a printed pattern, and the embossed
pattern can be either in register or out of register with the
printed material and/or printed design.
The sheet of material 12 may be constructed of a single
layer of material or a plurality of layers of the same or
different types of materials. Ln addition, any thickness of the
sheet of material 72 may be utilized with the present invention
so long as the sheet of material 1:?. is shapeable into the
cushioning member 10.
Although the sheet of material 12 shown in FIG. 3 is
CA 02402882 2002-10-09
square, the sheet of material 1:p may be any shape. For example,
the sheet of material 12 may be square, rectangular, circular or
any other geometric shape. they shape of the sheet of material
12 may even have an irregular, capricious or decorative shape.
The cushioning effect provided by the cushioning member l0
results from the resiliency of the folds 14 and the volume
provided by the voids 18, However, as mentioned above, crumpled
sheets of material, particularly crumpled sheets of paper, are
generally not very resilie.nt., and t=hus, large amounts of
material are required to provide the bulk needed to adequately
cushion an article. In an effort to overcome these drawbacks,
the present invention contemplates bondably connecting the
engaged portions 16 of the sheet of material 12 thereby
imparting an additional degree of stiffness to 'the cushioning
member 10 so as to enhance the resiliency of the cushioning
member l0, and at the same time, provide the opportunity to
reduce the weight of packaging material through the use of
thinner and fewer sheets of material.
To achieve these desired effects, the sheet of material 12
is coated with a bonding material such as an adhesive or
cohesive whereby at least a portion of the engaged portions 16
of the sheet of material 12 are caused to bond together when the
sheet of material 12 is crumpled into the cushioning member 10
illustrated in FIG. 1. More specifically, the sheet of material
12, illustrated in FIG. 3, has an upper surface 20, a lower
surface 22, and a bonding material 2,4 disposed on the upper
surface 20 and the l.owf~r surface 22. In FIG. 3, the sheet of
material 12 is illustrated as being strip coated with the
bonding material 24 on the upper surface 20 and the lower
surface 22 wherein the bonding material 24 is disposed in the
form of a plurality of parallel, spaced apart strips 26 on the
upper surface 20 and a plurality of parallel, spaced apart
strips 28 on the lower surface 22. The strips 28 of bonding
material 24 on the lower surf<~ce 22 of the sheet of material 12
are preferably in a staggered relationship relative to the
strips 26 of bonding material 24 on the upper surface 20 of the
sheet of material 12. However, it will be appreciated that the
strips 28 of bonding material 24 on the lower surface 22 of the
sheet of material 12 can be aligned with the strips 26 of
CA 02402882 2002-10-09
bonding material 24 on the upper surface 20, formed in a
diagonal or perpendicular relationship, or strips of bonding
material 24 may be disposed on only one of the upper surface 20
or the lower surface 22.
Alternatively, as illustrated in FIG. 4, the bonding
material 24 may be applied in such a manner as to substantially
coat both of the upper' surface 20 and the lower surface 2.2 of
the sheet of material 12. It will be further appreciated that
the bonding material 24 may be disposed on only one of the upper
l0 surface 20 or the lower surface 22 or disposed in any of a
variety of other patterns such as circles, dots or any other
geometric or biomorphic shape, including decorative designs, so
long as the bonding material 24 is positioned to function in
accordance with the present invention.
The term "bonding material" as used herein can mean an
adhesive, frequently a pre~;sure sensitive adhesive, or a
cohesive or any adhesive/cohesive combination, having adhesive
qualities (i.e., qualities of adhesion or adhesion/cohesion,
respectively) sufficient to effect the connection between
portions of the sheet of material 12 brought into engagement
with one another. Lt will be appreciated that both adhesives
and cohesives suitable for the purposes described herein are
well known in the art, and both are commercially available.
Referring again t:o FIG. 2, the engaged portions 16 of the
cushioning member 10 are formed by overlapping portions of the
sheet of material 12 and bringing such overlapping portions into
engagement or contact with one another during the crumpling
process. In this manner, the engaged portions 16 that are
coated with the bonding material 24 <~re fixed to one another.
By bondably connecting portions of the cushioning member
10, the degree of resiliency of the cushioning member 10 can be
controlled. That is, depending on the surface of the sheet of
material 12 the bonding material 24 is applied to, the pattern
in which the bonding material 24 i.s applied, and the tackiness
of the bonding materi<31 24 used, t:he cushioning member 10 will
be formed with a variety of degrees of voids and rigidity. For
example, if the bonding material 24 is applied to the upper
surface 20 of the sheet: of material 12 so as to coat the entire
upper surface 20, as shown in FIG. 4, and the sheet of material
CA 02402882 2002-10-09
12 is formed into the cushioning member 10 so that the upper
surface 20 of the sheet of material 12 is predominately within
the interior of the cushioning member .10, opposing portions of
the cushioning member 10 defining the voids 18 may have a
tendency to bond when aw compressive force is applied to the
cushioning member 10, thereby reducing the resiliency of the
cushioning member l0. The use of bonding materials with a
lesser degree of tarok can alleviate the bonding of the portions
defining the voids 18, as well as the application of the bonding
1.0 material to less than the entire upper surface 20 of the sheet
of material 12, such a;~ in the form of_ strips, spots, and the
like. Also, the use of a stiffer bonding material can increase
the rigidity of the sheet of material 12 and thus increase the
resiliency of the cushioning member 10.
If the bonding material 24 is applied to the lower surface
22 of the sheet of material 12 so as to coat the entire lower
surface 22, and the sheet. of material 12 is formed into the
cushioning member 10 so that the lower surface 22 of the sheet
of material 12 predomin~itely forms the exterior surface of the
cushioning member 10, adjacent cushioning members 10 may have a
tendency to bond or stick together. Again, the use of bonding
materials with a~ lesser degree of tack, as well as the
application of the bonding material to less than the entire
lower surface 22 of thE: sheet of material 12, such as in the
form of strips, spots, and the like, can alleviate this
condition if it is undesirable. In some instances, however, it
may be desirable for tree cushioning members 10 to adhere to one
another to form a cohesive cushioning unit. The formation of
such a cohesive unit can reduce the mess associated with
scattering of loose or flowable packing material and prevent an
article surrounded by the cohe:~ive unit from gravitating through
the cushioning members l0, as can be experienced with the use of
loose packing materials.
As illustrated in FIG. 5, the present invention further
:35 contemplates a plurality of sheets of material 12 connected
together to form a pad 30 of sheets of material 12. The pad 30
comprises a pli.aral ity c.~f sheets of material 12 stacked one on
top of the other and pos itioned so that the periphery of the
sheets of material 12 in t:he x>ad 30 are generally aligned. The
CA 02402882 2002-10-09
~3
pad 30 is characterized has having a top sheet of material 32
and a next sheet of material 34 disposed thereunder, the other
sheets of material being disposed under the next sheet of
material 34 in the pad ~0 of sheets of material 12.
'rhe top sheet of material 32 is capable of being
disconnected from the pad 30 of sheets of material 12. When the
top sheet of material 32 is di.sconnect;ed from the pad 30, the
next sheet of material B4 forms the new top sheet of material,
and tire sheet of material lying under the new top sheet of
l0 material forms a new next sheet of material.
In a general method of use, the top sheet of material 32
is removed or disconnected from the pad 30 of sheets of material
12. The removed sheet: of material is then crumpled into a
cushioning member 12, as described above, such that the
cushioning member 12 has a plurality of random folds, a
plurality of random engaged portions, and a plurality of voids
and such that at least a port:.ion of the engaged portions are
bondably connected.
Referring now to FIG. 6, a plurality of tire cushioning
members 10 are shown incorporated into a package 35. The
package 35 includes a container 36 and an article 38 positioned
within the container 36. The cushioning members 10 may be
positioned in the container 36 so as to substantially surround
the article 38 positioned within the container 36. In this
manner, the cushioning members 10 will function as a protective
packaging material filling voids about the article 38 and
supporting and cushioning th,e article 38 during a shipping
process.
From the above description it is clear that the present
invention is well adapted to carry out the objects and to attain
the advantages mentioned herein as well as those inherent in the
invention. While presently preferred embodiments of the
invention have been described for purposes of this disclosure,
it will be understood that numerous <;hanges may be made which
will readily suggest. themselves to those skilled in the art and
which are accomplished within the spirit of the invention
disclosed and as defined in the appended claims.
