Embossed paper used in combination with paper cushioning layers for transport envelopes

Abstract

According to some demonstrative embodiments, a protective product is provided, comprising: at least one expandable slit paper sheet, the at least one expandable slit paper sheet being expanded between opposite ends of the slit paper sheet; a first embossed paper sheet facing the expanded slit paper sheet and a second paper sheet facing an opposite side of the at least one expanded slit paper sheet, at least one of the first embossed paper sheet and the second paper sheet being fixed to the expanded slit paper sheet at opposite ends of the expanded slit paper sheet to maintain the expanded paper in its expanded state, the first embossed paper sheet having a plurality of embossments that increase the rigidity of the embossed paper sheet to prevent deformation of the embossed paper sheet fixed to the expanded slit paper sheet.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 62 / 845293, filed on May 8, 2019, entitled “Embossed Paper and Paper Sheet Cushioning Combination for Shipping Envelopes” and U.S. Provisional Application No. 62 / 982,662, filed on February 27, 2020, entitled “Expanded Slit Sheet Envelope Crushing and Stretching System”, the entire disclosures of these two provisional applications are incorporated herein by reference in their entirety as part of the present specification.

[0003] In addition, this application is a partial continuation application of U.S. non-provisional patent application No. 16 / 531,017, filed on August 3, 2019, entitled "Protective product, such as an envelope, having a unique combination of unfolded slit paper liner and embossed paper outer liner", and the entire disclosure of the non-provisional patent application is also incorporated herein by reference as part of the specification of the present invention.

[0004] In addition, this application is a partial continuation application of U.S. non-provisional patent application 16 / 018,702 (published on December 27, 2018 as U.S. publication number 2018 / 0370702) entitled "Expandable paper and its use in the production of expanded slit packaging packages and gap filling products" filed on June 26, 2018, and the entire disclosure of the U.S. non-provisional patent application is also incorporated herein by reference as part of the specification of the present invention. Technical Field

[0005] Preferred embodiments of the present invention relate to the manufacture and / or use of paper cushioned shipping envelopes or bags. Background Art

[0006] Background Art in Manufacturing Shipping Envelopes Plastic bubbles, plastic bubble-paper combinations, shredded newsprint, kraft paper, etc. have been manufactured. Plastic materials are fairly flexible and provide adequate initial cushioning in some cases, while kraft paper is somewhat less flexible. Background art paper alternatives are more expensive to manufacture and have higher shipping costs to the end user due to their increased weight compared to plastics.

[0007] Background Art Cushion envelopes have been manufactured using a guillotine start-stop non-rotating manufacturing process. However, the inventors have now determined that this background design is not suitable for manufacturing envelopes that utilize expanded slit sheet cushioning. Summary of the invention

[0008] The preferred embodiments overcome the above-mentioned and / or other shortcomings in the background art.

[0009] According to some illustrative broad embodiments of the present invention, the use of paper sheets transformed into various shapes, including, for example, creped paper, unfolded slit sheets and / or embossed paper, etc., as an inner cushioning layer in combination with an outer paper sheet having an embossing (e.g., embossed or serrated kraft paper) as an outer material provides a lightweight, extremely protective product that eliminates the need for plastic or heavier weight paper alternatives.

[0010] 1. According to some preferred embodiments, the protective product comprises:

[0011] at least one expandable slit paper sheet, the at least one expandable slit paper expanding between opposite ends of the slit paper;

[0012] a first embossed paper sheet facing the unfolded slit paper sheet, and

[0013] a second paper sheet facing an opposite side of the at least one unfolded slit paper sheet,

[0014] At least one of the first embossed paper sheet and the second paper sheet is fixed to the unfolded slit paper sheet at opposite ends of the unfolded slit paper sheet to maintain the unfolded paper sheet in its unfolded state, the first embossed paper sheet having a plurality of embossments which increase the rigidity of the embossed paper sheet to suppress deformation of the embossed paper sheet fixed to the unfolded slit paper sheet.

[0015] 2. In some embodiments according to 1 above:

[0016] The plurality of embossments in the embossed paper sheet comprises an array of embossment shapes distributed across a surface of the embossed paper sheet.

[0017] 3. In some embodiments according to any one of 1-2 above, the embossed shape array comprises a polygon array, and adjacent polygons share a common edge.

[0018] 4. In some embodiments according to any one of 1-3 above, the embossed shape array includes a hexagonal array, and adjacent hexagons share a side.

[0019] 5. In some embodiments according to any one of 1-4 above:

[0020] The plurality of embossments include a plurality of ribs extending across a majority of a face of the embossed sheet.

[0021] 6. In some embodiments according to any one of 1-5 above, the embossing comprises serrations extending inwardly toward the unfolded slit paper sheet.

[0022] 7. In some embodiments according to any one of 1-6 above, the embossing extends inward from the plane of the embossed paper sheet by a distance that increases the rigidity of the embossed paper sheet and is less than 0.1 inches, thereby inhibiting deformation of the embossed paper sheet fixed to the unfolded slit paper sheet.

[0023] 8. In some embodiments according to any one of 1-7 above: the first embossed paper sheet, the unfolded slit paper and the second paper sheet are folded along a folding line and fixed together to form a bag area.

[0024] 9. In some embodiments according to any one of 1-8 above, the first embossed paper sheet, the unfolded slit paper and the second paper sheet are folded along a folding line and fixed together to form a bag area.

[0025] 10. In some embodiments according to any one of 1-9 above, the protective product is an envelope having a flap area, and the flap area can be folded to close the pocket area.

[0026] 11. In some embodiments according to any one of 1-10 above, the first embossed paper sheet, the unfolded slit paper and the second paper sheet are fixed together with an adhesive in the flap area, and the flap is crushed at least in the flap area containing the adhesive.

[0027] 12. In some embodiments according to any one of 1-11 above, there is no adhesive in the area of ​​the folding line.

[0028] 13. In some embodiments according to any one of 1 to 12 above, the second paper sheet is embossed.

[0029] 14. In some embodiments according to any one of 1 to 13 above, the second paper sheet has embossing alternating between depressions and protrusions.

[0030] 15. In some embodiments according to any one of 1-14 above, the embossing of the first embossed paper sheet extends inward from the plane of the embossed paper sheet by a distance that is less than 0.1 inches from the plane of the embossing, and the distance is sufficient to increase the rigidity of the embossed paper sheet and inhibit deformation of the embossed paper sheet fixed to the unfolded slit paper sheet.

[0031] 16. In some embodiments according to any one of 1-15 above, the distance is less than 0.05 inches.

[0032] 17. In some embodiments according to any one of 1-16 above, the distance is less than 0.03 inches.

[0033] 18. In some embodiments according to any one of 1 to 17 above, the slit paper sheet is expandable paper, and the expansion range of the expandable paper measured in the pre-slit structure in the machine direction is 1% to 20%.

[0034] 19. In some embodiments according to any one of 1 to 18 above, the slit paper sheet is expandable paper, and the expansion range of the expandable paper measured in the pre-slit structure in the machine direction is 3% to 20%.

[0035] 20. In some embodiments according to any one of 1 to 19 above, the slit paper sheet is expandable paper, and the expansion range of the expandable paper measured in the pre-slit structure in the machine direction is 3% to 9%.

[0036] 21. In some embodiments according to any one of 1-20 above, the slit paper sheet is a paper having a weight ranging from about 30 to 50 pounds per 3000 square feet.

[0037] 22. In some embodiments according to any one of 1-21 above:

[0038] The first embossed paper sheet and the second paper sheet are not secured to the unfolded slit paper sheet over a majority of the area of ​​the unfolded slit paper sheet.

[0039] 23. In some embodiments according to any one of 1-22 above:

[0040] The embossed paper sheet contacts the unfolded slit paper sheet at the side of the first embossed paper sheet but is not connected to the unfolded slit paper sheet.

[0041] 24. In some embodiments according to any one of 1-23 above, the protective product is a recyclable paper product.

[0042] 25. In some embodiments according to any one of 1-24 above,

[0043] The protective product is an envelope having a bag, the bag comprising the embossed paper sheet and the unfolded slit paper sheet, the embossed paper sheet and the unfolded slit paper sheet being folded together to form the front and rear walls of the bag and being secured together at the sides of the bag, wherein the embossed paper sheet contacts the unfolded slit paper sheet at the sides of the bag but is not connected to the unfolded slit paper sheet, and

[0044] The embossed paper sheet is fixed to the unfolded slit paper sheet at the outer peripheral end of the unfolded slit paper sheet, thereby maintaining the unfolded paper in its unfolded state.

[0045] 26. In some embodiments according to any one of 1-25 above: the embossed paper sheet and the unfolded slit paper are folded together to form the front wall and the rear wall of the bag, and are fixed together with an adhesive at the sides of the bag.

[0046] 27. In some embodiments according to any one of 1-26 above:

[0047] The at least one unfolded slit paper sheet in the unfolded state includes a plurality of unfolded slit paper sheets stacked side by side with each other in the unfolded state.

[0048] 28. In some embodiments according to any one of 1-27 above:

[0049] The plurality of unfolded slit sheets include two unfolded slit sheets, and further include a second embossed sheet facing opposite sides of the two unfolded slit sheets.

[0050] 29. In some embodiments according to any one of 1-28 above:

[0051] The embossing of the embossed paper sheet is recessed toward the at least one unfolded slit paper sheet.

[0052] 30. In some embodiments according to any one of 1-29 above, it also includes: an address label, wherein the address label is fixed to the envelope.

[0053] 31. In some embodiments according to any one of 1-30 above, the protective product is a sleeve; and

[0054] The embossing of the embossed paper sheet projects outwardly from the at least one unfolded slit paper sheet and faces toward the interior of a pocket of the envelope, whereby the embossing helps to limit the friction applied to an article inserted into the pocket.

[0055] 32. In some embodiments according to any one of 1-31 above, the embossing is hexagonal.

[0056] 33. In some embodiments according to any one of 1-32 above, adjacent hexagons share one edge, thereby the hexagons are connected.

[0057] 34. In some embodiments according to any one of 1-33 above, the plurality of embossments are sufficient to counteract the inherent shrinkage tendency of the unfolded slit paper and thereby inhibit wrinkling of the embossed paper.

[0058] 35. In some preferred embodiments, the method comprises:

[0059] Providing a protective product according to any one of 1-34 above; and

[0060] An article is placed within a bag of the protective product, wherein the unfolded slit paper sheet provides cushioning to protect the article within the bag, and wherein the embossed paper inhibits deformation of the embossed paper sheet secured to the unfolded slit paper sheet.

[0061] 36. In some preferred embodiments, the method comprises:

[0062] Providing a protective product according to any one of 1-34 above; and

[0063] An article is placed in the envelope, wherein the expanded slit paper sheet provides cushioning to protect the article in the envelope, and the embossed paper inhibits deformation of the embossed paper secured to the expanded slit paper sheet.

[0064] 37. In some preferred embodiments, the envelope comprises:

[0065] at least one unfolded slit paper sheet in an unfolded state;

[0066] a first paper sheet facing a first side of the at least one unfolded slit paper sheet and fixed relative to the at least one unfolded slit paper sheet along at least two opposing peripheral ends of the at least one unfolded slit paper sheet;

[0067] a second paper sheet, the second paper sheet facing the at least one unfolded slit paper sheet on a surface of the at least one unfolded slit paper sheet opposite to the first paper sheet, and the second paper sheet being fixed relative to the at least one unfolded slit paper sheet at least along at least two opposite peripheral ends of the at least one unfolded slit paper sheet;

[0068] Wherein a) the first paper sheet and the second paper sheet are embossed sheets having a plurality of embossments, and the embossments suppress deformation of the first paper sheet and the second paper sheet due to the contraction force of the at least one unfolded slit paper sheet, or b) the first paper sheet and the second paper sheet are non-embossed sheets, and the non-embossed sheets have a heavier weight than the weight of the at least one unfolded slit paper sheet, and the non-embossed sheets suppress deformation of the first paper sheet and the second paper sheet due to the contraction force of the at least one unfolded slit paper sheet.

[0069] 38. In some embodiments according to 37 above, one of the first paper sheet and the second paper sheet is an unembossed kraft paper sheet having a weight of 40# paper or greater under the TAPPI standard paper weight specification of 3000 square feet, and the second paper sheet is embossed.

[0070] 39. In some embodiments according to any one of 37-38 above, the at least one unfolded slit paper sheet is at least one substantially rectangular paper sheet, and the at least one substantially rectangular paper sheet is fixed to at least one of the first paper sheet and the second paper sheet only at two opposite end areas of the at least one unfolded slit paper sheet.

[0071] 40. In some embodiments according to any one of the above 37-39, the two opposite end regions of the at least one unfolded slit paper sheet are opposite ends of the at least one unfolded slit paper sheet in the unfolding direction of the at least one unfolded slit paper sheet.

[0072] 41. In some embodiments according to any one of the above 37-40, the at least one unfolded slit paper sheet includes two unfolded slit paper sheets that are side by side and directly contact each other.

[0073] 42. In some embodiments according to any one of items 37-41 above, one of the first paper sheet and the second paper sheet is a non-embossed kraft paper sheet having a weight of 60# paper or greater under TAPPI standard paper weight specifications of 3000 square feet.

[0074] 43. In some embodiments according to any one of 37-42 above:

[0075] The first sheet and the second sheet contact the at least one unfolded slit sheet over a majority of the area of ​​the at least one unfolded slit sheet but are not connected to the at least one unfolded slit sheet over a majority of the area of ​​the at least one unfolded slit sheet.

[0076] 44. In some embodiments according to any one of the above 37-43, the envelope has a bag including a buffer wall, wherein the second paper sheet is an inner layer forming an inner wall of the bag, the first paper sheet is an outer layer forming an outer wall of the bag, and the at least one unfolded slit paper sheet is located between the inner layer and the outer layer.

[0077] 45. In some embodiments according to any one of items 37-44 above, the buffer wall of the bag is folded along a folding line so that the buffer wall forms the front wall and the rear wall of the bag, and the first paper sheet is the outer layer on the front surface and the rear surface of the front wall and the rear wall of the bag, wherein an adhesive is applied to at least one of the first paper sheet and the second paper sheet along the folding line.

[0078] 46. ​​In some embodiments according to any one of 37-45, the rear wall of the bag is longer than the front wall of the bag, and wherein the portion of the first paper sheet extending beyond one end of the front wall has an adhesive tape fixed thereto, the adhesive tape having a removable release liner for adhesively closing the envelope by removing the release liner and adhering the adhesive tape to the front wall.

[0079] 47. In some embodiments according to any one of 37-46, the rear wall of the bag is longer than the front wall of the bag and forms a flap area, wherein a portion of the first paper sheet and the second paper sheet contact the at least one unfolded slit paper sheet and are fixed together with an adhesive, and at least the portion is crushed to flatten the at least one unfolded slit paper sheet and reinforce at least a portion of the flap area.

[0080] 48. In some embodiments according to any one of items 37-47 above, the envelope has a bag including a buffer wall, wherein the buffer wall has four layers, wherein the first paper sheet forms the first layer of the four layers and is the outer layer forming the outer wall of the bag, the two unfolded slit paper sheets form the second and third layers of the four layers, the second and third layers are between the first and fourth layers and are in direct contact with each other, and the second paper sheet forms the fourth layer of the four layers and is the inner layer forming the inner wall of the bag.

[0081] 49. In some preferred embodiments, the method comprises:

[0082] Providing the envelope of any one of 37-48 above; and

[0083] An article is placed within a pocket of the envelope, wherein the at least one expanded slit paper sheet provides cushioning to protect the article within the pocket.

[0084] 50. In some preferred embodiments, the method of manufacturing the envelope comprises:

[0085] providing at least one expandable slit paper sheet;

[0086] providing a first paper sheet, the first paper sheet being configured to face a first side of the at least one expandable slit paper sheet;

[0087] providing a second paper sheet, the second paper sheet being used to face the at least one unfolded slit paper sheet on a side of the at least one unfolded slit paper sheet opposite to the first paper sheet;

[0088] Expanding the at least one expanded slit paper sheet to an expanded state, and fixing the at least one expanded slit paper sheet to at least the opposite portion of the outer periphery of the at least one expanded slit paper sheet that is opposite to the first paper sheet and the second paper sheet;

[0089] Deformation of the first and second paper sheets in response to the contraction force of the at least one unfolded slit paper sheet is suppressed by either: a) providing the first and second paper sheets with a plurality of embossments or b) providing the first and second paper sheets as non-embossed sheets having a weight heavier than that of the at least one unfolded slit paper sheet, the weight being sufficient to suppress deformation of the first and second paper sheets.

[0090] 51. In some embodiments according to the above 50, the step of suppressing deformation of the first and second paper sheets in response to the contraction force of the at least one unfolded slit paper sheet includes: setting each of the first paper sheet and the second paper sheet as a non-embossed sheet and having a weight of 40# or greater under the TAPPI standard paper sheet weight specification of 3000 square feet.

[0091] 52. In some embodiments according to any one of the above 50-51, it also includes providing the at least one unfolded slit paper sheet as at least one substantially rectangular sheet, and fixing the at least one unfolded slit paper sheet to at least one of the first paper sheet and the second paper sheet only at two opposite end areas of the at least one unfolded slit paper sheet.

[0092] 53. In some embodiments according to any one of 50-52 above, fixing two opposite end regions of the at least one unfolded slit paper sheet includes fixing opposite ends of the at least one unfolded slit paper sheet along an unfolding direction of the at least one unfolded slit paper sheet.

[0093] 54. In some embodiments according to any one of the above 50-53, it also includes providing the at least one unfolded slit paper sheet as two unfolded slit paper sheets, and the two unfolded slit paper sheets are placed side by side and directly contact each other.

[0094] 55. In some embodiments according to any one of items 37-48 above, the at least one unfolded slit paper sheet in the unfolded state is made of an expandable paper, which is made to be expandable in the machine direction and the cross direction without the slit pattern, and the expandable paper has an expandability in the machine direction in the range of 3% to 20%.

[0095] 56. In some embodiments according to 55 above, the expandability is in the range of 3-15% in the machine direction.

[0096] 57. In some embodiments according to any one of the above 37-48, the weight of the slit paper sheet before unfolding is about 30 to 50 pounds per 3000 square feet.

[0097] 58. In some embodiments, the method comprises the following steps:

[0098] a series of envelope units are passed continuously in a straight-line flow between the rotary die-cutting and crushing tool and the rotating mandrel, thereby applying back pressure, wherein the envelope unit is a combination of the first paper sheet, the at least one unfolded paper sheet and the second paper sheet that have been fixed together,

[0099] The rotating tool has a crushing part and a cutting part, the crushing part crushes a part of the combined wing-forming area, and the cutting part cuts the envelope unit from the series of envelope units to form a single envelope unit,

[0100] The rotary die cutting tool has an outer circumference equal to the overall length of the envelope being produced.

[0101] 59. In some embodiments, the protective product comprises:

[0102] at least one buffer paper sheet, the at least one buffer paper sheet being an expandable slit paper, a fan-folded paper or a double-sided embossed paper sheet,

[0103] a first embossed paper sheet, said first embossed paper sheet facing said at least one buffer paper sheet, and

[0104] a second sheet of paper, the second sheet of paper facing an opposite side of the at least one buffer sheet of paper,

[0105] At least one of the first embossed paper sheet and the second paper sheet is fixed to the buffer paper sheet, the first embossed paper sheet having a plurality of embossments which increase rigidity of the embossed paper sheet to suppress deformation of the embossed paper sheet fixed to the unfolded slit paper sheet.

[0106] In conjunction with the accompanying drawings, the above and / or other aspects, features and / or advantages of various embodiments will be further understood according to the following description. Where applicable, various embodiments may include and / or exclude different aspects, features and / or advantages. In addition, where applicable, various embodiments may combine one or more aspects or features of other embodiments. The description of the aspects, features and / or advantages of a particular embodiment should not be construed as limiting other embodiments or claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0107] Several preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, in which:

[0108] Figure 1 is a side view of a composite material of an unfolded slit sheet enclosed by a serrated kraft paper sheet;

[0109] Figure 2is a perspective view of a composite material of an unfolded slit sheet enclosed by a serrated kraft paper sheet;

[0110] Figure 3 is a schematic side view of the manufacturing process;

[0111] Figure 4 is a top view of the composite material;

[0112] Figure 5 is a top view of a composite material having fold lines and double-sided adhesive;

[0113] Figure 6 is a top view of a composite material folded into an unclosed envelope shape;

[0114] Figure 7 is a perspective view of a composite unenclosed envelope with a release liner wherein a pocket region is formed by side bonding side extruded regions at extruded / folded regions;

[0115] Figure 8 It is a perspective view of the composite closed envelope;

[0116] Fig. 9 is a perspective view showing a cutout area for tearing open a sealed envelope;

[0117] Fig.10 is a side view of a single outer embossed layer of kraft paper, a double layer of unfolded paper, and an inner layer of raised and depressed embossed paper;

[0118] Fig.11 , 11A , 11B, 11C and 11D are schematic diagrams of various patterns and sizes of hexagonal embossing;

[0119] Fig.12 is a side view of a single-sided embossed layer, a flat kraft paper layer, and a double-layer unfolded paper between the embossed layer and the flat layer;

[0120] Fig.13 is a side view of the embossed sheet;

[0121] Fig.14 is a side view of the double-sided embossed paper used as a cushioning inner layer;

[0122] Fig.15 It is combined with inner and outer layers of single-sided embossed kraft paper Fig.14 A side view of a double-sided embossed layer;

[0123] Fig.16 yes Fig.15 A perspective view of the combination;

[0124] Fig.17 is a perspective view of a fan-folded cushioning layer combined with an embossed layer;

[0125] Fig.18 is a perspective view of the wavy double-sided pattern combined with the embossed layer;

[0126] Fig.19 is a plan view of two continuous envelope liners which have been extruded in the folding regions and die cut in the envelope end extrusion regions while being held under tension in the manufacturing direction in the side extrusion regions;

[0127] Fig. 20 is a side view of an upper rotary tool that provides extrusion and cutting for making a gasketed envelope;

[0128] Fig.21 is a side view of a die-cut extrusion rotary system; and

[0129] Fig. 22 is a perspective view of the rotary liner envelope liner manufacturing portion. DETAILED DESCRIPTION

[0130] Definition of the Preferred Embodiments

[0131] In a preferred embodiment, the term "envelope" is a package with an opening into which one or more items can be inserted for storage and / or transportation. In some preferred embodiments, the opening of the "envelope" is closable and sealable after inserting one or more items for storage and / or transportation (e.g., transportation by a transportation service).

[0132] In preferred embodiments, the term "pocket" refers to an area within an envelope in which one or more items for storage and / or transport are placed. In some preferred embodiments, the filled envelope may be placed within a shipping container.

[0133] In some preferred embodiments, the term "in-box shipping" of envelopes refers to the case where the envelopes are shipped within a box or container (e.g., within a corrugated box). For example, such a box or container may be used to ship multiple envelopes contained therein and / or one or more envelopes together with any other number of items. In the case of in-box shipping of envelopes, the material of the envelope may be modified, for example, to use a lighter paper and / or not use a durable and / or tear-resistant outer layer, and it may be required to ship the envelope without the protection of a surrounding box during in-box shipping.

[0134] In a preferred embodiment, the term "outer layer" with respect to an envelope refers to the outermost layer of the envelope.

[0135] In a preferred embodiment, the term "inner layer" refers to the layer of the envelope that forms the inner surface of the envelope. For example, an item placed in the envelope will usually come into contact with the inner surface of the envelope.

[0136] In a preferred embodiment, the term "mailing envelope" refers to an envelope designed for shipment by USPS, UPS, FedEx, and / or similar companies, rather than being contained within a box or container as is the case with in-box shipment. In a preferred embodiment, the mailing envelope preferably has a durable outer layer to compensate for shipping by itself without the external protection of a box or container (e.g., to avoid tearing or ripping).

[0137] In a preferred embodiment, the term "uniformly opened slits" refers to slits as disclosed and / or claimed in PCT / US2014 / 054615.

[0138] In preferred embodiments, the term "randomly opened slits" refers to slits as disclosed and / or claimed in U.S. Patent Application Publication 2017 / 0203866, published on July 20, 2017. In some examples of the latter publication '866, at least some adjacent layers have different contact surface tilt angles to resist shrinkage and / or nesting.

[0139] In a preferred embodiment, the term "expandable" as applied to a sheet refers to a sheet having a slit pattern that enables the sheet to be expanded, for example, as disclosed in U.S. Patent Nos. (a) 5,538,778, (b) 5,667,871, (c) 5,688,578, and (d) 5,782,735 and PCT Application No. PCT / US2014 / 054615, the entire disclosures of which are incorporated herein by reference as if fully set forth. In a preferred embodiment, the slit pattern is configured to enable the sheet to be expanded longitudinally with a corresponding reduction in width. In some embodiments, the slit pattern produces paper pieces that have increased length due to the slit pattern when processed in an unroller, for example, unrollers of the type described in the following U.S. and PCT applications (a) 2017 / 0203866, (b) 2018 / 022266, (c) 2018 / 0127197, and (d) PCT / US2014 / 054615, the entire contents of which are incorporated herein by reference.

[0140] In a preferred embodiment, the term "slit sheet" refers to an expandable paper sheet having a slit pattern, such as disclosed in U.S. application publications (a) 2017 / 0203866, (b) 2018 / 0222665 and (c) 2018 / 0127197 and PCT application PCT / US2014 / 054615, the entire contents of which are incorporated herein by reference.

[0141] In preferred embodiments, the term "envelope liner" includes a liner incorporated into an envelope to protect one or more items contained within the envelope. In some preferred embodiments, the envelope refers to an intermediate manufacturing process, where the envelope has been cut and crushed to enable the next step of folding and gluing to its final envelope form.

[0142] In preferred embodiments, the term "cushion wrapper" refers to the final wrapper product design that provides a cushioned, flexible shipping package.

[0143] In a preferred embodiment, the term "mouth" refers to the portion of the envelope that allows one or more items to be placed within the envelope. In some embodiments, the mouth is formed when the envelope liner is glued into the shape of the liner envelope to produce a bag.

[0144] In a preferred embodiment, the term "expandable" as applied to a paper sheet refers to the paper sheet described in co-pending U.S. Patent Application No. 16 / 018,702, entitled "Expandable Paper and Its Use in Producing Expandable Slit Packaging Packages and Void Filling Products", the entire disclosure of which is incorporated herein by reference. In addition, the term "expandable" as applied to a paper sheet also includes paper that has been treated so that the paper sheet can be stretched, including the expandable paper described in the following U.S. patents, patent publications and pending applications: (a) U.S. Patent No. 3,908,071, (b) U.S. Patent Application No. 14 / 901,977 (U.S. Patent No. 9,945,077), (c) PCT Publication No. WO1984002936, (d) U.S. Application Publication No. US2002 / 0060034, (e) U.S. Application Publication No. US2007 / 0240841 (U.S. Patent No. 1 No. 7,918,966), (f) U.S. Patent No. 3,104,197, (g) U.S. Patent No. 3,220,116, (h) U.S. Patent No. 3,266,972, (i) U.S. Patent No. 3,269,393, (g) U.S. Patent No. 3,908,071, (k) U.S. Patent No. 6,024,832, (l) U.S. Patent No. 6,458,447 and (m) U.S. Patent No. 6,712,930, the entire disclosures of which are incorporated herein by reference as if fully set forth.

[0145] In some illustrative preferred embodiments, the expandable paper used has an expansion range of 3% to 20% in the machine direction, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expansion range of 3% to 15% in the machine direction, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expansion range of not less than 5% in both the machine and transverse directions, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expansion range of 3% to 20% in the machine direction, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expansion range of 1-9% in the machine direction, and an expansion range of 1-5% in the transverse direction, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expansion range of 3-9% in the machine direction, and an expansion range of not less than 5% in the transverse direction, as measured in a pre-slit configuration. In some illustrative preferred embodiments, the expandable paper used has an expandability range of 3-11.1% in the machine direction, or in some embodiments, 3.3-10.6% in the machine direction, as measured in a pre-slit configuration.

[0146] In some preferred embodiments, the expandable paper is a nonwoven fibrous material having fiber-to-fiber bonds that resist tearing when expanded 3-15% in the machine direction as measured in a non-slit configuration.

[0147] In some preferred embodiments, the expandable paper is formed by pre-compression between two different members that contact opposite sides of the paper web. For example, in some embodiments, the expandable paper is formed by pre-compressing the paper web between two different rollers having different roller surfaces and / or rotations, or the expandable paper is formed by inserting the paper web between rollers and an endless pre-stretching rubber blanket to compress the paper web with a clamp bar and the rubber blanket. In some preferred embodiments, the expandable paper is formed by pre-compression, thereby producing an expandable paper of a nonwoven fibrous material having enhanced inter-fiber bonding.

[0148] In a preferred embodiment, the term "stretching direction" refers to the direction in which the slit paper sheet is subjected to tension or stretching force. In a preferred embodiment, the stretching direction is transverse to the direction of the slits of the slit sheet. In some preferred embodiments, the stretching direction is the machine direction.

[0149] In some preferred embodiments, expandable paper can be formed using a method as described in U.S. Pat. No. 3,908,071, which is incorporated herein by reference in its entirety. For reference, the following is a direct quote from the paragraph of column 1, lines 4-19 of U.S. Pat. No. 3,908,071: "Expandable (compacted) paper produced, for example, according to the apparatus and process disclosed in U.S. Pat. No. 2,624,245 has certain known advantages and commercial uses. When placed under partially wet conditions, such paper is subjected to compression in the direction of web travel (machine direction or MD) between pressure nip rolls, thereby compacting and forcing the fibers together to produce inherent stretchability without wrinkling. Compacted paper has improved tensile energy absorption (TEA) rupture and tear characteristics, which are highly desirable for such end use as paper bag manufacturing."

[0150] In some preferred embodiments, the expandable paper may be formed using the method described in US Pat. No. 6,024,832, which is incorporated herein by reference in its entirety. For the sake of citation, here is a direct quote from the abstract of U.S. Patent No. 6,024,832: "A method for producing expandable paper comprising the following stages: supplying a mixture of plant fibers to a kneading machine member, mixing the mixture with water in the kneading machine, beating the fibers to obtain pulp, transferring the beaten pulp to a flow trough, supplying the beaten pulp from the flow trough to a web forming cloth, as a result of which the percentage of water is reduced due to gravity and vacuum, pressing the web, as a result of which its water content is further reduced, initial drying of the web to a constant moisture content substantially between 15% and 65%, compacting, final drying to a moisture content between 15% and 4%, preferably 10%-8%, glazing, wherein: the beating stage is performed by rubbing the fibers in a multi-stage unit to obtain a pulp with a freeness of at least 30 degrees. SR, the compacting stage is performed between at least one pair of rollers, wherein one pair of rollers is of a hard material comprising circumferential surface ribs and is driven at a greater speed, while the other pair of rollers is of a soft material having a smooth surface and is driven at a lesser speed".

[0151] In some preferred embodiments, expandable paper may be formed using a method as described in U.S. Patent No. 9,945,077, which is incorporated herein by reference in its entirety. The following is a direct quote from the second paragraph of the background section of U.S. Patent No. 9,945,077: "On the other hand, Clupak relates to an apparatus for inserting a paper web between a roller and an endless rubber cloth to compress the paper web with a clamp rod and a rubber cloth, while the pre-stretched rubber cloth is contracted to cause the paper web to also contract, thereby increasing its elongation at break, and the apparatus is used to provide increased elongation at break to kraft paper used in heavy packaging applications as mentioned above." The following is a direct quote from the first paragraph of column 6 of U.S. Patent No. 9,945,077: The manufacturing method using the Clupak system causes a paper web to be inserted between a roller and an endless rubber cloth to compress the paper web with a clamp rod and a rubber cloth, while the pre-stretched rubber cloth is contracted to cause the paper web to also contract, thereby increasing its elongation at break. The Clupak system allows the elongation at break of the kraft paper in the machine direction to be adjusted depending on the ratio of the production speed on the entry side of the Clupak system to the production speed on the exit side of the Clupak system and also depending on the pressing force applied by the clamp bars.

[0152] In some preferred embodiments, the extensible paper may be formed using a method as described in U.S. Pat. No. 3,104,197, the entire contents of which are incorporated herein by reference. For reference, the following is a direct quote from the paragraph at column 2, lines 41-56 of U.S. Pat. No. 3,104,197: "The use of rubber or rubber materials in the manner described in combination with a hard surface is known in the treatment of paper and fabrics, but only in a general manner, and the present invention involves the use of a much softer and more resilient rubber than has heretofore been used. In producing extensible paper by creping it in this manner, the difference in speed of the drive rollers is important. If a suitable combination of hard and soft surfaces is provided, the semi-dry web passing through the nip of the rollers will be carried by the shrinking rubber, traveling opposite the direction of travel of the web toward the nip and on the surface of the hard roller. This produces a uniformly compressed crepe in the web, providing toughness, flexibility and extensibility."

[0153] In a preferred embodiment, the term "expandable slit paper sheet" refers to an expandable and unfoldable paper as disclosed in U.S. patent application 16 / 018,702 (published in U.S. patent application publication No. US2018 / 0370702 on December 27, 2018), the entire disclosure of which is incorporated herein by reference.

[0154] In preferred embodiments, the term "embossing" refers to an area of ​​a paper sheet that is raised and / or lowered. Most preferably, the embossing comprises raised and / or lowered areas of the paper sheet that are raised and / or lowered by the application of a force so as to press the paper sheet into an embossed shape, wherein the pressure causes the paper sheet to deform so as to have a shape that includes such raised and / or lowered areas. In some preferred embodiments, the paper sheet is initially substantially planar and does not have embossed raised and / or lowered areas in the initial state, and then the paper sheet is pressed to cause the paper sheet to deform including raised and / or lowered areas. In the most preferred embodiments, these raised and / or lowered areas from the original plane of the originally planar paper sheet are referred to as "embossed" areas or "embossments". By way of example, in a most preferred embodiment, the embossing is produced by pressing an initial sheet (e.g., a planar or substantially planar sheet) between opposing pressing surfaces, such as (1) between templates that reciprocate relative to one another to press the surface of the planar sheet, wherein the template has a pattern of raised and lowered areas (e.g., protrusions and recesses) that produce lateral pressure on the face of the planar sheet to cause the sheet to deform and form the embossing, and / or (2) between two rollers (e.g., such as Figure 3 embossing. In some embodiments, embossing may include pressure applied by a single reciprocating template having a raised / lowered embossing pattern pressed against a first surface of the sheet of paper, while the opposite side of the sheet of paper is pressed or supported by a resilient (e.g., rubber) member that resiliently receives the raised and / or lowered portions to cooperatively cause embossing in the sheet of paper. Similarly, in some embodiments, embossing may include pressure applied by a single roller die having a raised / lowered embossing pattern pressed against a first surface of the sheet of paper, while the opposite side of the sheet of paper is pressed or supported by a resilient (e.g., rubber) roller member or other surface member (e.g., a conveyor or other member) that flexibly receives the raised and / or lowered portions to cooperatively cause embossing in the sheet of paper.

[0155] In some preferred embodiments, the embossing is formed in a repeating pattern along the paper sheet as it is conveyed from an initial roller. In some preferred embodiments, the embossing defines discrete shapes that are displaced (e.g., raised and / or lowered) from the original plane of the paper sheet in separate areas along the face of the paper sheet. In some preferred embodiments, these discrete areas may have irregular shapes, and in some embodiments, these discrete areas may have circular shapes, elliptical shapes, oval shapes, polygonal shapes, triangular shapes, square shapes, pentagonal shapes, hexagonal shapes, octagonal shapes, and / or other shapes. In the most preferred embodiment, the embossing has a hexagonal shape. Here, the term "shape" of the embossing in the above paragraph refers to the shape of the embossing viewed downward toward the face of the paper sheet. It should be understood that, as in a side view (e.g., similar to a Fig.10 and Figure 12-15 Such embossing has different shapes, as can be seen in the side view shown in FIG.

[0156] In some preferred embodiments, the embossing may have a substantially flat or uniform peak height or displacement height from the original plane of the paper sheet. Fig.10 and 12 -15, the peak height of the embossing is substantially uniform. In this regard, in a preferred embodiment, the peak height of the embossing is preferably substantially uniform along each individual embossing and within each individual embossing. In addition, in a preferred embodiment, the peak height of the embossing is preferably substantially uniform between multiple embossings, so that the embossing extending in a specific direction (e.g., an ascending direction or a descending direction) has a substantially uniform peak height along the face of the sheet. In some embodiments, the embossing can extend in an ascending and descending manner, and the peak height can be different on each opposite side of the sheet, but is preferably substantially uniform on the corresponding sides of the sheet.

[0157] Furthermore, in some preferred embodiments, the peaks of the embossing are substantially planar or include a substantially planar central region that may taper or be rounded at the edges of the embossing peaks. Furthermore, in some preferred embodiments, the perimeter of the embossing preferably extends substantially transversely from the original plane of the paper sheet. This structure may be, for example, in the above Fig.10 and 12 -15. In addition, in some embodiments, the perimeter of the embossing extending substantially transversely to the original plane of the paper sheet extends substantially perpendicular to the plane of the paper sheet. In some other embodiments, similar to Figure 13-15In the embodiment shown in the figure, the periphery of the embossing extends at an angle to the original plane of the paper sheet and tilts toward the embossed area. In certain embodiments, the angle of inclination can be shown in the various embossings in the figure. In certain embodiments, the angle of inclination can be between about 45-90 degrees, or between 60-90 degrees, or between 70-90 degrees, or between 80-90 degrees. Some illustrative embodiments will have an angle between about 65-85 degrees.

[0158] In some embodiments, the embossings may be a pattern (eg, an array) of embossings in which at least some of the embossings are discretely located at separate locations on the paper sheet (eg, such that the discrete embossings are surrounded by portions having an originally flat surface of the paper sheet).

[0159] In some embodiments, the embossing can be an embossing pattern (e.g., an array) in which at least some of the embossings are not completely discretely located at separate locations on the paper sheet. For example, in some embodiments, the embossings can be located adjacent to each other, or can be connected together. For example, in some embodiments, thin or elongated or linear embossings (e.g., elevated track-shaped embossings or lowered groove-shaped embossings). However, in the most preferred embodiments, at least some, preferably most, of the embossings will have a perimeter that is primarily surrounded by portions having the original plane of the paper sheet. For example, in many cases, the perimeter of the embossing will be primarily surrounded by portions having the original plane of the paper sheet.

[0160] In a preferred embodiment, embossing is applied to a separate sheet of paper so as to form an embossed pattern within the separate sheet of paper. In a preferred embodiment, embossing does not adhere multiple sheets of paper together. In a preferred embodiment, embossing forms elevated and / or depressed areas that, in fact, contribute to separating adjacent layers (e.g., adjacent paper layers) by displacing the original plane of the embossed sheet from adjacent sheets due to the increased peak height of the embossing. In some embodiments, where the embossed sheet will be attached to an adjacent sheet, this attachment can be attached to the adjacent sheet by gluing and / or otherwise. This contrasts with the use of techniques such as embossing, which can be used to connect adjacent sheets.

[0161] In some preferred embodiments, the term embossing includes raising and / or lowering the surface of a paper sheet (eg, kraft paper), and includes recessed embossing, raised embossing, and both raised and recessed embossing.

[0162] In some preferred embodiments, the term "debossed embossing" refers to lowering the surface of a paper sheet (eg, kraft paper) relative to adjacent layers (sunken relief).

[0163] In some preferred embodiments, the term "raised embossing" refers to raising the surface of a paper sheet (eg, kraft paper) relative to adjacent plies.

[0164] In some preferred embodiments, an "embossed" area of ​​the sheet comprises an area where the plane of the embossed area of ​​the sheet is offset from the plane of non-embossed areas of the sheet adjacent to the embossed area of ​​the sheet.

[0165] Description of the Preferred Embodiments of the Invention

[0166] While the present invention may be embodied in many different forms, the illustrative embodiments described herein should be understood that the present disclosure should be considered to provide examples of the principles of the invention and that such examples are not intended to limit the invention to the preferred embodiments described and / or illustrated herein.

[0167] In the most preferred embodiment of the present invention, the present invention uses an "expanded slit sheet" material in combination with an outer layer of "embossed" paper to produce a cushioning envelope having cushioning properties. In addition to other patents and other publications incorporated herein by reference in this application, the entire disclosures of U.S. Patent No. 2,856,323 describing the manufacture of "embossed" paper and U.S. Patent No. 10,226,907 describing the manufacture and design of "expanded slit sheet", U.S. Application Publication No. 2018 / 0222665, U.S. Application Publication No. 2018 / 0127197, and U.S. Application Publication No. 2018 / 0370702 are all incorporated herein by reference as if fully described herein.

[0168] like Figure 1 As shown, the embodiment shown uses four layers of composite material, starting with a first layer of embossed paper 104, which is embossed at all edges (such as Figure 4 10,226,907, with a fourth top layer of embossed paper. This creates a fully recyclable paper pad, and the paper pad can be made primarily of recycled paper.

[0169] In a preferred embodiment, after the paper pad is constructed, two additional steps are used to manufacture the envelope. The first step is as follows Figure 7 The liner is shown folded so that when the laminated sides 703 are bonded together a pocket area 704 is formed. Optionally, the sides 703 can be crushed to provide rigidity and flatten the side areas.

[0170] In a preferred embodiment, the double-sided adhesive tape 502 (such as Figure 6 ) is provided with a release liner 701 (as shown Figure 7 ), the release liner 701 covers the adhesive strip 502 and can be removed to expose the adhesive strip 502 for closing the envelope.

[0171] Reference Figure 44. In the top view of the paper, the middle area 401 is where the unfolded slit sheet will be placed and will be further placed on area 403, and area 403 will be laminated with a layer of paper that can be embossed as taught below.

[0172] refer to Figure 2 In a preferred embodiment, as shown, the expanded slit sheets 102 and 103 are the full length of the embossed papers 101 and 104 instead of the full width. The expanded layers do not have to be fully expanded in width. However, in a preferred embodiment, the expanded layers are fully expanded in length. Figure 4 , the adhesive area 403 sandwiches the unfolded slit paper sheet between the embossed outer layer and the inner layer to hold and maintain the unfolded slit sheet, thereby providing the cushioning and overall thickness that the unfolded slit sheet must provide. The inner layer can be flat or embossed, as described below.

[0173] although Figure 1 Two layers of unfolded slit sheets are shown in the figure, but other embodiments may use slit sheets with different numbers of layers. The envelope of the preferred embodiment of the present invention can be made of a single layer, two layers (as shown in the figure), or even three or more layers of unfolded slit sheets. In addition, in some embodiments, one or more layers or all layers of unfolded slit sheets can adopt an unfolded slit sheet of a disordered unit structure as disclosed in U.S. Application Publication No. 2018 / 0127197, the entire disclosure of which is incorporated herein by reference.

[0174] In a preferred embodiment, by placing items or articles for transport in the bag area 704 (e.g. Figure 7 Then, after the item or article is contained within the pocket region, the envelope is closed by removing the release liner 701 (e.g., by manually grasping the extension tabs 708 and pulling the release liner laterally across the width of the envelope), and then folding the top of the liner at the fold location 707 (e.g., fold line) to place the top of the liner on the pocket region and enable the adhesive strip 502 to seal the envelope 600 by adhering to the outer surface of the pocket region 704.

[0175] In some preferred embodiments, the embossed paper can be an embossed paper found in the art (e.g., as described in all patents and publications discussed in this application, the entire contents of which are incorporated herein by reference), and in a preferred embodiment, the embossed paper is made of kraft paper having a weight in the range of about 40 to about 60 pounds according to the TAPPI standard paper weight specification for 3,000 square feet. Advantageously, a paper weight equal to a basis weight of 50 pounds plus or minus 10% allows the envelope to function in a manner not previously anticipated.

[0176] exist Figure 1 and Figure 2In the illustrative embodiment shown in , the embossed paper 101 is formed with embossments made by using matching male and female dies that are pressed together to press or punch the embossments into the paper, for example, as described in U.S. Pat. No. 2,856,323 (the entire disclosure of which is incorporated herein by reference), which shows circular embossments. The embossments are preferably distributed so as to produce unique reinforcing properties while still achieving the flexibility required for placing items within the bag. In the most preferred embodiment, a plurality of hexagonal embossments are provided. Figure 1 and Figure 2 In the embodiment shown in , the embossing is formed in the outer layer 101 of the envelope. Figure 1 and Figure 2 In the embodiment shown in , the embossing is also formed in the inner layer 104 of the envelope. As described herein, in some preferred embodiments, the embossing is provided only in the outer layer 101 of the envelope and not in the inner layer 104 of the envelope. In addition, while the preferred embodiment includes the embossing in the outer layer 101, some embodiments may omit the embossing in the outer layer 101 while including the embossing in the inner layer 104, while still other embodiments may omit the embossing in both the outer layer 101 and the inner layer 104.

[0177] refer to Fig.11 , which shows an illustrative embossing pattern that can be used in some illustrative embodiments. In some embodiments, Fig.11 An embossing pattern similar to that shown in FIG. 1 can be formed into a layer (eg, outer layer 101 and / or inner layer 104) by extruding a die configured to produce a series of hexagonal embossings. Fig. 11C In some embodiments, each hexagonal region 1403 (e.g., Fig. 11C Five such regions 1403 are shown for illustrative purposes in FIG. 1403 ) may be formed by a hexagonal extrusion member configured to be pressed into a paper sheet to produce a hexagonal embossing having a substantially or approximately flat surface. To this end, Fig. 11C The shaded area in (ie, in this example, within the hexagonal area 1403) represents the embossing that has been pressed to be displaced from the original plane of the paper sheet. Fig. 11C In the example, the white spaces between the hexagonal embossings may be, for example, at the original plane of the paper sheet.

[0178] In some embodiments, each hexagonal region 1403 is displaced from the initial plane of the paper sheet in the same direction. For example, in some embodiments, all regions 1403 are displaced downward. In some other embodiments, all regions 1403 are displaced upward. In still other and more preferred embodiments, some regions 1403 are displaced upward and some regions 1403 are displaced downward. For example, in Fig. 11C, the area 1403 shaded by the dashed array is shifted downward, as indicated by label D. On the other hand, in Fig. 11C , the region 1403 shaded with diagonal lines is shifted upward, as indicated by the label U. In some embodiments, the changes in the upward U shift and the downward D shift of the region 1403 may be random. In some embodiments, the changes in the upward U shift and the downward D shift of the region 1403 may be in an alternating manner. In some embodiments, the changes in the upward U shift and the downward D shift of the region 1403 may be in a preset pattern.

[0179] Among them, the strength and rigidity of the embossed layer can be significantly increased by adopting the area 1403 with both upward U displacement and downward D displacement. In addition, by changing the direction of the embossing, less embossing can be formed to extend to the specific upward and / or downward side of the layer. First, by extending some embossing in the opposite direction, the number of embossing is necessarily less than the number of embossing if all embossings extend in the same direction. Secondly, by extending some embossing in the opposite direction, a larger number of embossings can be arranged to extend in one direction rather than in another direction. For example, in some embodiments, one side of the layer can have a lesser number of embossings, so as to reduce the contact surface area when the article or article slides across the surface against the embossing. By way of example, by forming the inner layer 104 with a reduced number of outwardly extending embossings, a reduced contact surface area can be generated to promote the insertion and / or removal of the article in the bag, and this embodiment can be conducive to reducing friction when the article is placed in the bag of the envelope. For example, under the background of the insertion of flat articles or articles (such as, for example, paper, etc.), a significant reduction in contact friction can be achieved.

[0180] Reference Fig.11D In some embodiments, embossing may be performed around the perimeter of such region 1403, rather than across the entire area of ​​region 1403. In particular, Fig.11D As shown, in some embodiments, the peripheral boundary line 1401 around the hexagonal area can be embossed. To this end, Fig.11D The shaded perimeter boundary line 1401 represents the embossing that has been pressed so as to be displaced from the original plane of the paper sheet. Fig.11D , the white space within the interior of the hexagonal area may be, for example, at the original plane of the paper sheet.

[0181] although Fig.11D The embodiment shown may have Fig. 11C The embodiment shown has less structural rigidity, but Fig.11D The illustrated embodiment may have some substantial advantages for some purposes. For example, when Fig.11DThe "white area" shown represents the original plane of the paper sheet, which contains most of the surface and most of the surface is at a substantially uniform height or substantially horizontal. When such a substantially uniform or horizontal surface is required, this embodiment can have substantial usefulness and advantages. For example, in some preferred embodiments, the outer layer 101 is embossed as shown. Fig.11D Among other things, having this embodiment pattern on outer layer 101, the peripheral surface of the envelope (created by outer layer 101) can be advantageously adapted to be able to receive a label (e.g., an adhesive label), such as a shipping label for shipping the envelope. For example, such a label can include shipping information, such as the name and address of the intended recipient of the envelope, content information related to the items contained within the envelope, and / or other information related to the shipping or delivery of the envelope.

[0182] In some embodiments, for example, used as outer layer 101, Fig.11D The embossed peripheral boundary line 1401 preferably extends downward D (eg Fig.11D ). In this way, the embossed area will not extend upward from the surface of layer 101. Therefore, the embossing will more fully avoid interfering with the use of the outer surface of outer layer 101.

[0183] In some implementations, the hexagonal molded elements may be formed in a layer (eg, outer layer 101 and / or inner layer 104) by extruding a mold having an array of protruding hexagonal molded elements. Fig.11 The embossed pattern is similar to the embossed pattern shown, each protruding hexagonal molded member is configured to have the same Fig.11 The shape shown corresponds to hexagon 1403. In some embodiments, therefore, an array of hexagons 1403 can be produced by pressing a die against an embossed layer (i.e., by sandwiching the layer between the die and a complementary shaped receiving die member that is placed on the opposite side of the layer being embossed).

[0184] For example, in some illustrative embodiments, outer layer 101 may include Fig.11 The embossing pattern shown, in which the peripheral boundary line 1401 of the hexagon 1401 is a recessed embossing (similar to Fig.11DThe embossing pattern may be embossed in a manner that is small and has a small depth. For example, in some embodiments, the depth may be less than 0.01", and most preferably, may be about 0.005" (0.127 mm) in depth. In some illustrative embodiments, this depth value may vary within a range of about + / - 50%, or more preferably, within a range of about + / - 25%, or most preferably, within a range of about + / - 15%. Surprisingly, this small embossing pattern still provides considerable resilience to the paper and a more comfortable and protective feel, and is very advantageous as an outer layer 101. Furthermore, in this latter embodiment, by extending the embossing downward, the embossing does not substantially interfere with the use of the paper sheet for applying labels or other purposes.

[0185] like Fig.11 , Fig.11A and Fig. 11B As shown in the illustrative embossing pattern shown, in various embodiments, the size or dimensions of the hexagonal regions 1403 may vary depending on the circumstances. Fig.11 In the example shown, the diameter or distance between the opposing walls of the hexagon is about 0.93' (i.e., 0.93 inches), while Fig.11A In the example shown, the diameter or distance between the opposing walls of the hexagon is about 0.70' (i.e., 0.70 inches), while Fig. 11B In the example shown, the diameter or distance between the opposing walls of the hexagon is approximately 0.45' (i.e., 0.45 inches). Although the diameter of such hexagonal area 1403 can vary, in some embodiments, the diameter is preferably less than 2", and more preferably, less than 1.5", and more preferably, less than 1.0".

[0186] Furthermore, in some embodiments where embossing is employed on both the outer layer 101 and the inner layer 104, the diameter of the embossing may be selected differently between these layers. For example, in some preferred embodiments, the diameter of the embossing of the outer layer 101 is substantially greater than the diameter of the embossing of the inner layer 104. Among other things, the outer layer 101 may be provided with a plurality of embossings. Fig.11D The larger diameter embossing of the type shown in further reduces the interference of the embossing. Fig. 11C Smaller diameter embossments of the type shown in can further reduce the surface area of ​​the embossments to reduce friction when an article is placed in the pocket of the envelope, thereby facilitating sliding of the article into and out of the envelope.

[0187] In some most preferred embodiments, the inner layer 104 comprises Fig. 11C The embossing is of the type shown, and the diameter of each hexagon 1403 is approximately 0.25" wide. Additionally, the embossing preferably alternates between extending upward and downward (ie, convex and concave embossing).

[0188] In some most preferred embodiments, the outer layer 101 comprises Fig.11D The embossing is of the type shown, and the inner diameter of each hexagon between the inner sides of the peripheral boundary line on opposite sides of the hexagon is 0.75". In addition, in a preferred embodiment, the outer diameter of each hexagon between the outer sides of the peripheral boundary line is 0.875" (i.e., so that the width of the peripheral boundary line (i.e., the width of the embossing) is therefore 0.0625"). In other embodiments, the width of the peripheral boundary line (i.e., the width of the embossing) can be in the range of about 0.002' to 0.25".

[0189] As described above, in the most preferred embodiment of the present invention, the present invention utilizes an "expanded slit sheet" material in combination with an outer layer of "embossed" paper to create a cushioning envelope having cushioning properties. An additional advantage provided by the embossed paper in combination with the expanded slit material is that it provides the ability to maintain the expanded slit sheet material in a stretched state (i.e., where the expanded slit paper sheet has been expanded to open the unit and thus create a wider width having cushioning properties) without creating wrinkles in the outer paper.

[0190] It is noteworthy that "unfolded slit sheet" paper material not only requires a force to unfold or stretch the paper, but such paper also applies a retraction force from the fully unfolded state. In the context of the present invention, wherein the unfolded slit sheet is preferably attached face-to-face with the outer layer of paper, the retraction force may have a tendency to cause wrinkling of the outer layer of paper due to insufficient strength and rigidity to resist this retraction force of the fully unfolded expandable slit sheet. Furthermore, since the retraction force of the unfolded slit sheet is in a direction along the plane of the unfolded slit sheet, when the unfolded slit sheet is attached face-to-face with the outer layer, the retraction force will therefore extend along the plane of the outer layer. Since sheet materials such as paper have limited rigidity in this direction, the retraction force may cause wrinkling and deformation of the outer layer.

[0191] While heavier weight paper may be used in some embodiments to increase rigidity sufficiently to avoid wrinkling and deformation of the outer layer (e.g., by using an outer paper heavy enough that the rigidity of the outer paper imparts a force greater than the contraction force of the unfolded slit paper sheet), this increased weight and rigidity of the outer layer has disadvantages. For example, using an outer layer with greater weight and rigidity increases postage costs (e.g., because postage costs are based on weight) and makes loading items within the bag more difficult (e.g., because the flexibility of the envelope and therefore the ability to "open" the bag and insert items is hindered by the increased rigidity of the paper, and also because heavier envelopes may be more difficult to manipulate manually in some circumstances).

[0192] In some highly preferred embodiments, the unfolded slit paper sheet can be formed in a new way to reduce the shrinkage force of the unfolded slit paper sheet by using a novel unfolded slit paper sheet developed by the inventors involving the use of "expandable" paper. As described above, in preferred embodiments, the term "expandable" as applied to the paper sheet includes the paper described in the inventors' co-pending U.S. Patent Application No. 16 / 018,702 (U.S. Application Publication No. 2018 / 0370702), entitled "Expandable Paper and Its Use in Producing Unfolded Slit Packaging Packages and Void Filling Products," the entire disclosure of which is incorporated herein by reference. The inventors have discovered that another way to counteract the wrinkling effect that unfolded slit materials tend to produce due to the shrinkage force of the unfolded slit sheet when the unfolded slit attempts to shrink is to use expandable paper, as found in the latter '702 application.

[0193] The inventors have discovered that an expandable, deployed slit sheet requires approximately 1 / 3 of the total force required to expand the deployed slit sheet compared to a non-expandable paper of similar weight having a similar slit pattern. For example, an expandable slit sheet made of kraft paper may require approximately 6 lbs of force to expand a sheet approximately 15.5" wide, while an expandable slit sheet of similar weight and slit pattern may require only approximately 2 lbs of force to expand a sheet approximately 15.5" wide. In some preferred embodiments, an expandable paper is used for an expandable slit sheet that requires an expansion force in the range of approximately 0.15 to 0.22 pounds per inch to expand the sheet. In particular, the retraction force to retract the deployed slit sheet from a fully expanded state is related to the force required to expand the expandable slit sheet paper.

[0194] In some embodiments, where wrinkling is not a concern and / or the envelope is not used for stand-alone shipping and durability is not so of concern, a lightweight non-embossed kraft outer paper layer may be used. In the latter case, the envelope may be used, for example, in reinforced shipping requiring an outer box or container (e.g., a corrugated box) or for in-box shipping, for example, where the envelope is contained in another box or container with additional items to be shipped, or used as part of the reinforced shipping. This type of shipping does not require a durable tear-resistant layer. In the case where the envelope is used for in-box shipping, etc., a lighter weight paper may be used, such as 40# or less kraft paper for such in-box shipping, or in some embodiments, even 30# kraft paper or even less kraft paper for such in-box shipping.

[0195] In some embodiments, the outer layer may be a tear-resistant paper, such as a tear-resistant flat kraft paper including thicker papers, such as 60# or more tear-inhibited kraft paper.

[0196] The additional benefit of embossed paper combined with the unfolded slit material is the enhanced packaging protection it provides. The unfolded slit paper, although extremely protective as a wrapper, must be placed in a shell or container to provide cushioning. The volume of the embossed paper imitates a very lightly loaded corrugated box, which has a slight wavy thickness and is therefore thicker than non-embossed paper. For example, in some illustrative embodiments, the wavy thickness caused by the embossing can be about three times the thickness of the paper without such embossing. In other embodiments, the wavy thickness can be greater than 3 times the thickness of the paper, for example, 4 times the thickness, or 5 times the thickness or even greater. In a preferred embodiment, the wavy nature of the embossing can act very much like the sinusoidal waves of the inner layer found in the corrugated box. Among other aspects, this can also help provide initial impact protection that even further suppresses the tearing that may occur with smooth (non-embossed) paper.

[0197] Another benefit of using an embossed outer layer for envelopes is the increased ability to manually hold the envelope securely by hand or even by conveying equipment because the embossing increases the friction between the envelope and the user's hand or between the envelope and conveying rollers or equipment for ease of handling or processing compared to smooth (non-embossed) paper and plastic.

[0198] The accompanying drawings illustrate in detail some preferred, non-limiting embodiments of the invention.

[0199] Figure 1 is a side view of a double cross-laminated paper cushioning or padding material 100 with unfolded slit sheets according to some embodiments, as described in non-provisional patent application Ser. No. 14 / 480,319 (U.S. Pat. No. 10,226,907), the entire disclosure of which is incorporated herein by reference. In particular, Figure 1 As shown, in this example, two layers of unfolded slit paper sheets 102 and 103 are sandwiched between an outer layer of paper 101 and an inner layer of paper 104. As shown by the oblique lines within the regions 102 and 103, in this double cross-ply embodiment, the unfolded sheets have cells with walls inclined in opposite directions, for example, to help limit the nesting of the two layers 102 and 103. Specifically, as shown in FIG. Figure 1 As shown, the unfolded slit paper 102 is tilted to the right (ie, facing forward), while the unfolded slit paper 103 is tilted to the left (ie, facing backward) and sandwiched between the embossed papers 101 and 104.

[0200] although Figure 1The illustrated embodiment includes two layers of unfolded slit paper sheets, but in some embodiments, three or more layers of unfolded slit paper sheets may also be used. However, in some most preferred embodiments, only a single layer of unfolded slit paper sheets is used, and the single layer preferably includes layers 101 and 104 along opposite surfaces of the single layer of unfolded slit paper sheets. In some preferred embodiments, the unfolded slit paper sheets adjacent to layer 101 contact the layer 101, and the unfolded slit paper sheets adjacent to layer 104 contact the layer 104. Alternatively, in some embodiments, one or more intermediate layers may be inserted therebetween.

[0201] Figure 2 yes Figure 1 1 is a perspective view of a paper cushioning or padding material 100 shown in FIG. 1 with portions removed for ease of reference. As shown, layers 101 and 104 are embossed outer paper layers (also referred to as outer layers 101 and inner layers 104 in the case of forming an envelope by folding the padding material 100), and as described above, the unfolded slit sheets 102 and 103 are located between these outer layers.

[0202] While cushioning materials can be manufactured in a variety of ways, Figure 3 is a schematic side view of an illustrative and preferred liner manufacturing process, wherein kraft paper rolls 300 and 303 are fed to idler rolls 309 and 310, respectively, and then fed through embossing die pairs 301 and 304, respectively, and around idler roll 308, thereby manufacturing Figure 3 The outer layer of the liner material shown in the combination area 302 of FIG. As shown, the unexpanded slit material rolls 305 and 306 are fed between a pair of Velcro rolls 307 and stretched together using corresponding brake mechanisms 320 and 319, which slow down the unwinder to allow stretching and continue to the combination area 302.

[0203] As mentioned above, Figure 4 4 is a top view of a region of a composite of embossed and unfolded slit material 400 after opposing edges 402 and 403 are joined to form a composite structure. In some preferred embodiments, edges 402 and 403 are laminated together between laminating rollers. In preferred embodiments, the unfolded slit paper ( Figure 4 Not shown in , because it is internal (eg, obscured by an outer layer of embossed paper)) within the region of 401. As shown in FIG.

[0204] Additionally, in a preferred embodiment, the unfolded slit paper sheet is contained within the region 401, rather than being adhered or fixed to the composite material 400 along the edges 402 at the sides of the unfolded slit paper sheet material. In particular, the unfolded slit sheet is preferably adhered to the composite material 400 only at the opposite ends of the unfolded slit sheet, and preferably only at the edge regions 403. In this manner, the unfolded slit sheet preferably freely extends throughout the interior region 401 in a relatively movable manner relative to the outer layers 101 and 104, except at the ends of the unfolded slit sheet, which is fixed by being pressed and glued within the edge regions 403, and adhered to the outer layers 101 and 104 within the edge regions 403.

[0205] refer to Figure 5 , Figure 5 is a top view of composite material 400 showing dashed lines 501 representing folded areas for folding material 400 to make a bag. In a preferred embodiment, a double-sided adhesive 502 is placed on the leading edge of the liner (which will be covered by a release liner 701 discussed below), which adhesive is later used to seal the bag of the final constructed envelope during use of the envelope.

[0206] refer to Figure 6 , Figure 6 is Figure 5 4 is a top view of a padded envelope 600 after the composite material 400 shown in FIG. has been folded at a fold line. As described above, double-sided tape 502 is located within the laminated edge 403 on the leading edge to provide an adhesive for the envelope to close. Figure 6 As shown, the extension or opening area 601 is a folded flap portion, which is folded and adhered to the outer surface of the envelope by adhesive 502 for closing the envelope. In some preferred embodiments, the expanded slit sheet paper in the flap portion 601 is crushed to provide a thin and rigid flap, which is convenient for handling and use. However, in some embodiments, the flap portion 601 may include an expanded slit sheet paper in an expanded state in the region for cushioning. For example, in some embodiments, the cushioning in the flap portion 601 can be sized so that it extends completely on the crushed and laminated area 403 near the bag mouth to provide an additional length for cushioning the envelope on the crushed and laminated area 403 (i.e., since the area 403 is preferably crushed and laminated, the area 403 is flattened and does not have the cushioning properties provided by the uncrushed expanded slit sheet paper).

[0207] As described above, double-sided tape 502 may be used to adhere the folded flap portion to the outer surface of the envelope, and preferably, the adhesive of tape 502 adheres to the outer surface of the envelope, adheres to the outer surface of the envelope, and adheres to the outer surface of the envelope. Figure 6The left side of the region 403 shown (i.e., on the side of the region opposite the pocket opening). For reference, Figure 8 The sleeve is shown in a state where adhesive 502 adheres to the front of the sleeve just beyond area 403 after the flap portion has been folded over.

[0208] Reference Figure 7 , Figure 7 is in the open position Figure 6 A perspective view of the envelope 600 in which the double-sided tape 502 is covered by the release liner 701. Figure 7 , edge region 703 (i.e., along the opposite side of the envelope) corresponds to region 402, which has been folded and adhered to form edge region 703. For example, region 402 may be folded and flattened, bonded, or otherwise adhered together to form edge region 703.

[0209] refer to Figure 7 , region 705 corresponds to Figure 6 The edge region 403 is formed at the end of the extended wing portion 601 shown. In some embodiments, the adhesive or adhesive tape 502 can cover the entire area of ​​the edge region 403, or as shown in FIG. Figure 6 As shown, adhesive 502 may cover a portion of edge region 403 formed at the end of the flap portion. Figure 7 In the embodiment shown, edge 705 corresponds to Figure 6 The edge region 403 at the end of the wing portion is shown. Figure 7 , adhesive 502 and release liner 701 cover the entire edge 705.

[0210] In some embodiments, to form the bag of the envelope, Figure 5 The composite component 400 shown in FIG. Figure 5 101 . In some preferred embodiments, to facilitate folding of the composite material at fold line 501 to form a bag, a glue line extends along the fold line in width so that the expandable slit sheet is glued together with the outer layer 101 and the inner layer 104 along a narrow line along the fold line. For example, in some embodiments, a narrow bead of glue is applied to facilitate folding at fold line 501. In some alternative embodiments, the expanded slit paper sheet is not glued along fold line 501, so that the expanded slit sheet can move freely relative to the outer layers 101 and 104 near fold line 501.

[0211] In some most preferred embodiments, the expandable slit sheet material in the wing portion 601 is compressed and not in an expanded state. It is noted that in more preferred embodiments, the entire wing portion 601 may be in a compressed state. However, in some embodiments, at least some or all of the expandable slit sheet material in the wing portion 601 may be in an expanded state. For example, in some embodiments, the expanded slit sheet material may be in an expanded state in the wing portion 601 until Figure 6 , or similarly, until the edge 403 shown in Figure 7 Edge 705 shown in .

[0212] exist Figure 7 In the illustrated embodiment, the envelope includes an edge region where the squeezed glue adheres to the region 703 and the edge 705, which surrounds the bag region 704. Although the regions 703 and 705 can be formed in various ways, it is preferred that the regions are formed by pressing between relative pressing members together with gluing to keep the regions in a compressed (e.g., thin) and adhered state. For example, a pressing roller, a reciprocating pressing element and / or other mechanism can be used to form such a region. In a preferred embodiment, the glue used in the region where the squeezed glue adheres (e.g., in the regions 703 and 705) is hardened to provide increased rigidity and / or stiffness. For example, this can help produce a more rigid or harder wing portion 601.

[0213] In some embodiments, in addition to using glue in regions 703 and 705, other portions of flap portion 601 may include glue similar to regions 703 and 705 (e.g., to form a more rigid or stiffer flap). However, in a most preferred embodiment, at least region 702 (i.e., at the fold line of flap portion 601) near the mouth of bag 704 is glued. Figure 7 The embodiment shown in FIG. 1 is representatively shown in dashed lines) and does not contain adhesive or glue. Figure 7 As shown, region 700 corresponds to Figure 6 The area 403 shown is formed along the edge of the mouth of the bag and outlines the outline of the mouth. In some preferred embodiments, as shown in FIG. Figure 7 As shown, the unglued area 702 overlaps the side ends of the area 700 so as to extend partially inside the bag and partially outside the bag within the flap portion 601. Specifically, by ensuring that this area is free of glue, the flap portion 601 can be folded more surely and effectively around the fold line within the area 702 to improve the handling and function of the envelope. In some embodiments, to facilitate folding on the fold line within the area 702, a crease can be formed across the width of the area 702, which can help facilitate folding.

[0214] The inventors have found that providing a non-glue area 702 in the folding area optimizes folding without adversely affecting the advantageous rigidity of the flap. Thus, the non-glue area 702 in the folding area can facilitate the folding of the flap. In some preferred embodiments, the non-glue area 702 preferably extends across the entire width of the envelope, and preferably extends a length of less than about 1 / 2 inch in the unfolding direction of the expandable slit paper (i.e., along the length direction of the envelope perpendicular to the width of the envelope), and in some more preferred embodiments, the non-glue area 702 extends less than about 1 / 3 inch in the unfolding direction, and in a preferred embodiment, the non-glue area 702 extends in the unfolding direction about 1 / 4 inch plus or minus 15%, and in a most preferred embodiment, preferably 1 / 4 inch plus or minus 5%. In some preferred embodiments, this is approximately equal to the non-glue area 702 preferably being about 0.64 cm (plus or minus 15%), and most preferably about 0.64 cm (plus or minus 5%).

[0215] As mentioned above, reference Figure 7 , reference numeral 703 indicates the glued envelope edge. In addition, as described above, in some preferred embodiments, the slit sheet is advantageously held in place only at the ends of the expandable slit sheet, and specifically at the top region 700 and at the region 705 below the release liner 701.

[0216] like Figure 7 As shown, the release liner 701 extending over and covering the adhesive 502 preferably includes at least one extension tab 708 that extends from an end of the adhesive 502 and can be manually grasped by a user to pull the release liner from the adhesive 502. Figure 7 In the illustrated embodiment, extension tabs 708 are shown at both ends of the release liner 701. However, in some embodiments, the extension tabs 708 may be located at only one end. Additionally, in other embodiments, other mechanisms may be employed to facilitate manual removal of the release liner 701 and / or the extension tabs or portions of the release liner may extend in different directions (e.g., toward or away from the mouth of the bag, rather than transversely to the sides of the envelope as in the illustrated embodiment).

[0217] In some preferred embodiments, although the region 702 has no glue or adhesive, the unfolded slit paper in the region 702 may be in a crushed state so as to have a smaller width, thereby facilitating folding the flap portion to close the mouth of the bag. However, in some alternative embodiments, a portion of the flap portion 601 extending between the distal end of the region 702 (i.e., the end of the region 702 closest to the distal end of the flap 601) and the edge region 705 includes the unfolded slit paper in an unfolded state, so that when the flap is folded, the region 700 is covered by the cushioning created by the unfolded slit paper in an unfolded state.

[0218] However, in some most preferred embodiments, the expandable slit paper flaps are in a crushed state throughout the flap portion 601, including the expandable slit paper flaps throughout the region 702 and throughout the region between the distal end of the region 702 and the edge region 705. In this way, most advantageously, the entire flap portion 601 can be more easily manipulated during use and closure of the envelope. In addition, while the region 702 is preferably not glued to facilitate folding the flap portion, other portions of the flap portion can include glue so that the flap portion 601 can be advantageously more rigid and easier to manipulate during use.

[0219] As mentioned above, Figure 8 is a perspective view of a closed envelope 600 showing, for example, double-sided tape 502 securing the envelope in a closed configuration (i.e., after the release liner is removed and the bag is closed). Figure 8 middle, Figure 7 The crushing side (e.g., 703) shown in FIG. Figure 8 800B and top folded ends 800T, both of which provide a large amount of interior bag area (e.g., to help enable larger sized items to be placed within the envelope). Figure 8 As shown, but the bottom end 800B preferably has no crushing edge, otherwise the crushing edge will occupy or limit the internal space in the bag. Similarly, the top end 800T preferably has no crushing edge, otherwise the crushing edge will occupy or limit the internal space in the bag.

[0220] like Figure 7 and 9 As shown, in a preferred embodiment, in order to facilitate opening the sealed envelope, the top end 800T of the envelope preferably includes a tearing mechanism. Although various tearing mechanisms may be used in various embodiments, such as a tear cord that is pulled laterally across the top end 800T and / or another tearing mechanism, in some preferred embodiments, the tearing mechanism includes at least one lateral side notch 706 that is configured to facilitate manual opening or tearing of the top end 800T. Figure 7 As shown, in the preferred embodiment, two lateral side notches 706 are provided, wherein a notch is located at each lateral side of the sleeve 600 .

[0221] like Fig. 9 As shown, each notch 706 is preferably positioned on the flap portion 601 at the base end of the flap portion 601, which is directly aligned with or adjacent to the outer end of the area 700 at the mouth of the bag. In a preferred embodiment, each notch 700 is a generally V-shaped cut cut from the lateral side edge of the flap. In some preferred embodiments, the base side edge 707 of the notch is formed to extend substantially parallel to the outer end of the area 700 so as to extend through the bag in the width direction parallel to the mouth of the bag, and the front side edge 715 extends forward to the base side edge notch 700 at an acute angle and returns to the lateral side edge of the flap 601. In some preferred embodiments, the acute angle can be between about 20 and 50 degrees, and in some more preferred embodiments, the acute angle is between about 25 and 45 degrees, and in some more preferred embodiments, the acute angle is between about 30 and 40 degrees, and in some most preferred embodiments, the acute angle is about 35 degrees.

[0222] In some illustrative embodiments, the base side edge 707 of the notch has a length between about 1 / 8 inch and about 1 / 2 inch, and in some more preferred embodiments, has a length of less than about 1 / 3 inch, and in some more preferred embodiments, has a length of about 1 / 4 inch. Figure 6 and Figure 7 As best shown in FIG. 1 , in a preferred embodiment, the lateral side edges of the envelope are sealed together, for example by gluing and pressing. Thus, the lateral side edges of the envelope (including along the Figure 6 and Figure 7 In some illustrative examples, the notch 706 extends across at least 1 / 4 of the width of the lateral side edge (e.g., edge 402), or in some preferred embodiments, extends across at least 1 / 3 of the width of the lateral side edge, or in some preferred embodiments, extends across at least 1 / 2 of the width of the lateral side edge, or in some preferred embodiments, extends across at least 1 / 2 of the width of the lateral side edge, or in some preferred embodiments, almost completely or completely across the lateral side edge portion.

[0223] In a preferred embodiment, the notch 706 is located in or near the region 702. In addition, in some preferred embodiments, the region 702 includes some weakening mechanism to facilitate lateral tearing of the flap from the location of the notch 706.

[0224] Reference Fig.10 , Fig.10 Other illustrative embodiments of composite materials for forming envelopes are shown. As described above, in various embodiments, the inner and outer layers of the composite materials for forming the envelopes can include various different embossed structures. Fig.10 In the illustrative example shown, outer layer 1001 is provided with a pattern or array of downwardly extending embossments. As described above, in some preferred embodiments, these downwardly facing embossments help achieve a substantially flat outer surface that can, for example, facilitate the placement or adhesion of a label (e.g., a shipping label) to the exterior of the envelope. It is noteworthy that this embodiment is similar to the above referenced Fig.11D Description of the embodiment.

[0225] In addition, Fig.10 In this embodiment, the inner layer 1003 may include a plurality of upwardly facing protrusions 1005 and downwardly facing protrusions 1004. It is worth noting that this embodiment is similar to the above description of Fig. 11C The embodiment described above. Among other things, this embodiment can help increase strength and rigidity, and can also help reduce or inhibit friction applied to items when they are inserted into or removed from the bag (as described above). In addition, the inner layer 1003 thus provides a layer with raised sides. Among other things, this provides a thick raised layer made from a thin flat sheet of paper, and thus also advantageously provides additional cushioning.

[0226] refer to Fig.12 , Fig.12 Another exemplary embodiment of a composite material 900 for forming an envelope is shown. In this exemplary embodiment, the outer layer includes a pattern of upwardly extending embossments 101. In addition, in this embodiment, the inner layer 901 is a smooth, non-embossed layer. Among other things, providing a non-embossed or smooth inner layer can facilitate the insertion of items into or removal of items from the pockets of the envelope in some cases.

[0227] refer to Figure 13-15 , which illustrate a composite material 1200 ( Fig.15 In the exemplary embodiments shown in these figures, instead of using an expandable slit sheet (e.g., instead of using one or more layers of expandable slit sheets, such as Figure 1 102 and / or 103), which are placed between the outer layers, Figure 13-15 The embodiment shown in the embodiment uses a novel embossed cushioning layer between two outer layers. Fig.15 , wherein the outer layer 1000 has embossing extending downward, and the inner layer 1000 has embossing extending upward, and the middle layer has embossing extending upward and downward (e.g., to serve as a buffer layer), but it should be understood that the outer layer 1000 and the inner layer 1000 of this embodiment can be modified similarly to other embodiments described herein. Similarly, according to other embodiments described herein, the inner layer 1100 can be modified to include other embossing patterns.

[0228] In this exemplary embodiment, Fig.13 An exemplary embossed paper sheet 1001 is shown having a pattern of embossments 1002 extending therefrom in a single direction (e.g., an array of circular, polygonal, and / or other shaped embossments). Fig.15 As shown, in this exemplary embodiment, layer 1000 can be used to form an outer layer and an inner layer. As an example, in some preferred embodiments, a similar layer 1000 can be arranged as an outer layer with the embossed side facing downward, and a similar layer 1000 can be arranged as an inner layer with the embossed side facing upward. Fig.15 As shown, in a preferred embodiment where the embossing also provides a cushioning function, the embossing of the outer layer 1000 is distributed in such a manner that when the layer 1000 is used as an outer layer with embossing facing downward, at least some of the peaks of the embossing will contact at least some of the peaks of the embossing extending upward of the middle layer, so as to maximize the thickness. Similarly, the embossing of the outer layer 1000 is distributed in such a manner that when the layer 1000 is used as an inner layer with embossing facing upward, at least some of the peaks of the embossing will contact at least some of the peaks of the embossing extending downward of the middle layer, so as to maximize the thickness.

[0229] like Fig.14 As shown, in a preferred embodiment, at least one layer is employed which is a corrugated double-sided pattern layer 1100, which increases the final thickness of the embossed sheet.

[0230] In various embodiments described herein, the embossing can have a depth that varies depending on the environment. In some embodiments, the total thickness of the embossing can vary between about 0.01 inches and 0.19 inches. Among other potential advantages, the embossing can provide flexibility to facilitate loading of items into the envelope for shipping, and the varying thickness of the cushioning layer provides additional cushioning protection.

[0231] In various other embodiments of the present invention, other types of paper cushioning materials can be used in combination with the external embossed paper. Although these paper cushioning materials can provide less cushioning than the slit layer, some embodiments can still use such other paper cushioning materials. For example, if a thinner product is desired and / or if less cushioning is needed, such other embodiments may be desired. By being able to place more envelopes in containers of the same size, the resulting thinner envelopes reduce transportation costs. Thinner composite designs can provide tear-resistant designs that do not require cushioning. These environmentally friendly, all-paper envelopes and liners can replace plastic envelopes, which, by contrast, provide little or no cushioning. Below are examples of other paper cushioning materials that can be used in some illustrative examples.

[0232] about Fig.16 , Fig.16 An embodiment is shown that includes an outer layer 101 having a downward facing circular embossing array and an inner layer 104 also including a downward facing embossing array. In this exemplary embodiment, a middle paper layer 1300 including a corrugated paper sheet may be provided. In this way, the inner paper may be used to provide cushioning qualities similar to those employed in other embodiments described above.

[0233] about Fig.17 , Fig.17 Shown includes Fig.16 The outer layer 101 shown is similar to the outer layer 101 and Fig.16 The inner layer 104 shown is similar to the embodiment of the inner layer 104. However, Fig.17 The illustrated embodiment employs a middle paper layer 1400 that is a corrugated layer. In various embodiments, the cushioning provided by the corrugated paper varies based on the thickness of the corrugated layer as well as the corrugation leg length and corrugation height and corrugation angle. In some implementations, this can provide less flexibility when packaging thinner items without the thinner items being fragile. Fig.17 As shown, the pleated layer 1400 is high, with a vertex angle of about 90 degrees. In various embodiments, the pleated height can be reduced by increasing the vertex angle to within the range of 105-165 degrees, thereby increasing the buffer and flexibility as needed. In embodiments using composite materials similar to the composite materials of this embodiment, the envelope can be constructed to be somewhat flexible in the long direction and stronger in the direction of the envelope opening. In some exemplary embodiments, the pleated embodiment is different from the prior art of corrugated paper packaging found in U.S. Patent No. 6,871,480 and U.S. Publication Nos. 2014 / 016666A1 and 2009 / 0233023A1, all of which are incorporated herein by reference as if described in full.

[0234] U.S. Patent No. 6,871,480 teaches the use of a tissue paper with a steep stiffness angle adhered to the apex of a corrugated sheet as a wrapping product that is significantly taller to create a cushioning barrier. On the other hand, in some preferred embodiments of the present invention, a wider corrugation angle than taught in U.S. Patent No. 6,871,480 is preferably employed, and preferably it is laminated only around the edges of the embossed paper.

[0235] about Fig.18 , Fig.18 shows a similar Fig.16 , but without the inner layer 104. In particular, Fig.18 The embodiment shown in FIG. 1 comprises an outer layer 101 having a series of downwardly facing circular embossments and comprising a layer similar to Fig.16 In some embodiments, the inner layer can be provided as any specific type as described in this application. In some other embodiments, Fig.18 A similar combination of outer layer 101 and middle layer 1300 shown in FIG. 1 can be placed face up on Fig.18 to produce a composite material including two intermediate corrugated paper layers according to some other embodiments.

[0236] refer to Figure 19-22 , various exemplary methods and techniques for making envelopes according to various embodiments of the present invention are described in these figures.

[0237] In some preferred embodiments, the envelope is preferably manufactured by conveying rolls of material so as to form a composite of aligned layers conveyed parallel to each other and side by side, such as Figure 3 As shown, a composite of aligned layers is shown at 302. Various embodiments described herein may include Figure 3 A delivery device similar to that shown in the drawings can be used to deliver aligned layers of elongated composites, which can then be processed to form multiple envelopes, such as by connecting portions of the layers together (e.g., at edge regions 402, 203). In some preferred embodiments, multiple composite materials (e.g., similar to Figure 4 400) is formed in an end-to-end relationship, such as Fig.19 Then, after forming, the formed composite material can be cut from the material delivered end to end to form separate individual composite materials, such as similar to Figure 4 400. The composite material can then be folded and glued to form a closed envelope, such as Figure 5-6 shown.

[0238] like Fig.19As shown, in a preferred embodiment, the composite of the delivered alignment layer includes multiple composite materials (corresponding to multiple envelopes) connected together in an end-to-end manner. Fig.19 Two composite material portions 1900A and 1900B are shown joined together in a repeating pattern, wherein: Fig.19 The composite material shown is configured to form Figure 7 Envelope of the type shown.

[0239] like Fig.19 As shown, in the illustrated embodiment, a composite material portion 1900A (which is later folded to form a Figure 7 The area 700 at the bottom end of the bag (outer edge of the mouth of the bag) is shown in a state where it is connected to the distal end of the flap portion 601 of the composite material portion 1900B.

[0240] In this illustrated example, portions 1900A and 1900B are also shown with release liners 701 attached to portions 1900A and 1900B. While in some embodiments, adhesive 502 may be placed at region 705 and release liner 701 may be placed over the adhesive prior to separation of portions 1900A and 1900B, in some alternative embodiments, such adhesive 502 and release liner 701 may be added to the respective portions 1900A and 1900B after separation.

[0241] In some demonstrative embodiments, flap portion 601 is approximately 1.5" long (ie, in the longitudinal direction of portion 1900A / B) and edge region 700 is approximately 0.5" long (ie, in the longitudinal direction of portion 1900A / B).

[0242] In some preferred embodiments, various conveyor rollers are used to a) adhere the composite layers together, b) crush the unfolded slit paper sheets within the combined layers of the composite (or crush other buffer papers, such as folded paper, embossed paper, etc., within the combined layers of the composite in some embodiments), and c) separate the composite portions 1900A / B.

[0243] For example, Fig. 20 An illustrative conveyor roller 100 that may be employed in some embodiments is shown. In this illustrative example, the conveyor roller is disposed along a Fig. 20 The counterclockwise direction indicated by the arrow 105 is shown in FIG. Fig.21 As shown, roller 100 cooperates with opposing roller 200 and rotates together as the composite layer is conveyed between rollers 100 / 200 via the conveyor system in the direction of arrow 205. In a preferred embodiment, roller 100 rotates in the direction of arrow 105 at the same rate as it moves in direction 205.

[0244] In a preferred embodiment, roller 100 operates as a die-cutting-crushing rotary tool, wherein 101 is the outer circumference of the tool and is specifically sized to have the same circumference as the total length of the cuff liner being manufactured.

[0245] like Fig. 20 and 21 As shown, the roller 100 includes a suspended pressure member 104, which is configured to cause the composite material to be Fig.21 200). In addition, roller 100 also includes a depending pressure member 102, which includes a cutting member 103 (e.g., a cutting blade, etc.) configured to cause the composite material to become crushed in region 203 and also to be cut or separated in region 203 (e.g., by being pressed between rollers 100 and 200 when portion 102 is adjacent to roller 200, and by being cut by cutting member 103).

[0246] For reference, Fig. 22 Show Fig.21 A perspective view of the system shown. Fig.21 and Fig. 22 The unfolded paper is schematically shown at 201 as creped paper, but in a preferred embodiment, element 201 is an unfolded slit paper sheet according to the most preferred embodiment of the present invention. However, it should be understood based on this disclosure that in some less preferred embodiments, the same Fig.17 Corrugated paper similar to the embodiment shown, or any other cushioning layer described in other embodiments herein may be used as Fig.21 The internal buffer layer 201 is formed by a plurality of layers of a plurality of electrodes.

[0247] refer to Figure 20-22 , noting that these figures are schematic representations and that some dimensions of components etc. are not to scale to form some embodiments of the present invention.

[0248] refer to Fig.21 In some preferred embodiments, the crushed area 202 that may be formed by the member 104 may be used to create a narrow crushed area to facilitate folding, thereby creating an envelope bag in some preferred embodiments. For example, this may be along Figure 5 The fold line 501 in the embodiment shown is used, either in Figure 7 A narrow crushing area is created at the location of fold 709 shown in the embodiment of FIG. In this way, the composite material can be more easily folded on fold line 501 or at fold 709. Although Fig.21A wide crushed portion is schematically shown, but in some preferred embodiments, the width of the crushed area in the length direction (e.g., in the machine direction) is preferably less than 1 / 2 inch, or in some embodiments, less than 1 / 3 inch, or in some embodiments, less than 1 / 4 inch, or in some embodiments, approximately 1 / 8 inch or even less.

[0249] In some preferred embodiments, before reaching the rollers 100 and 200, the composite material passes through a device that applies glue to the area to be glued during the squeezing of the rollers 100 and 200. For example, before squeezing to produce the crushed area 202, in a preferred embodiment, a narrow tape has been applied by a glue application device. In a preferred embodiment, the width of the narrow tape in the length direction is the same as or smaller than the width of the above-mentioned crushed area in the length direction.

[0250] refer to Fig.21 In some embodiments, region 203 represents the area between adjacent portions used to form a separate envelope, for example, Fig.19 In the embodiment shown in FIG. 1900A and 1900B, adjacent portions are provided. Fig.21 The cut in the region 203 in FIG. 1 (which has been made by the cutter) and the squeezed portion shown on the right side may correspond to, for example, Fig.19 700 (as an illustrative example) of the embodiment shown in FIG. Fig.21 The squeezed portion shown to the left of the cutout in region 203 in may correspond to, for example Fig.19 The fin portion 601 is shown in FIG. 6 (as one illustrative example).

[0251] As such, it should be appreciated that in some exemplary embodiments, rollers 100 and 200 may be used to join layers together by forming transverse crushed and glued portions and separating joined composite material portions to form separate individual envelopes.

[0252] Although in Figure 20-22 Not shown, but in a preferred embodiment, the layers are delivered to Figure 3 After the combination area 302 shown, and before the layer is conveyed to rollers 100 and 200, the composite layer is preferably guided to a glue-applying device, which applies glue to the appropriate positions between the composite layers at the appropriate positions along the layers. In some embodiments, the glue-applying device includes one or more glue dispensing nozzles, which are computer-controlled to dispense glue at precise positions between the layers. In some examples, the glue-applying device can, for example, apply glue to one layer, such as the bottom layer at the position between the composite layers. Then, later, in some embodiments, when pressure is applied (e.g., between rollers 100 and 200), the applied glue can penetrate and adhere between all layers.

[0253] In addition, although not shown in the figure, while the glue is applied by the glue application device or after the glue is applied but before being conveyed to the rollers 100 and 200, in some preferred embodiments, the lateral sides of the composite layer are preferably bonded together by applying a pressure roller along the two lateral sides of the composite layer to form, for example Figure 4 In order to adhere the lateral sides, it should be understood that the glue application device should also preferably apply glue on the appropriate lateral sides to be able to form the edge area 402 and the like.

[0254] In this manner, the composite layers are preferably initially attached along their side edges before being joined together transversely across the width of the layers (ie, transverse to the machine direction) to form a generally tubular configuration prior to passing between rollers 100 and 200 .

[0255] exist Fig.21 and 22 In the schematic diagram shown, the lateral side edges of the composite layer are not shown as being bonded together. However, in a preferred embodiment, the lateral side edges are bonded before passing through rollers 100 and 200, as described above.

[0256] although Fig.19 The notch region is shown to have been formed along the fin region 601, but in a preferred embodiment, the notch region (e.g. Figure 7 The notches 706 shown in FIG. 1 and FIG. 2 are formed simultaneously by rollers 100 and 200 , and in this manner, in addition to incorporating cutting elements 103 to separate adjacent portions, roller 100 may also include additional cutting elements to form similar notches 706 .

[0257] In addition, although Figure 20-22 Not shown, but in addition to the cutting element 103, the member 102 may also include a pressing element that does not cut through the composite material, but creates a score line extending between the notches 706 to facilitate tearing to open the bag after the seal is closed.

[0258] Thus, in the illustrated embodiment, attached to the periphery of the roller 100 is a crushed area member 102 that creates a folded area for the pocket area of ​​the envelope when the roller 100 rotates in the direction of arrow 105, in combination with a cutting element 103 and a scored crushed area member 104. The die cut crushed areas 102 and 103 are in contact with the envelope liner layer that is crushed and cut at 203. Continuing the rotation, only the area 104 that was just crushed in area 202 is crushed, and repetitions of the crushing will make additional crush cuts 203 to continuously manufacture envelope liners.

[0259] Additional noteworthy aspects of some preferred embodiments

[0260] As discussed above, in the preferred embodiment, an embossed paper is used which provides flexibility and a slight cushioning protection not found in flat paper sheets.

[0261] In some preferred embodiments, the unfolded slit sheet is not adhered to the sides (e.g., not adhered to the Figure 4 The area 402 shown in Figure 7 705 etc.), but advantageously, only or substantially only to the front and rear regions. Among other things, this advantageously provides a much smaller use of adhesive and produces an excellent and more sustainable cushion envelope.

[0262] In some preferred embodiments, the present invention uses the slit sheet material that expands to combine with top and bottom outer paper to produce the cushioning envelope with cushioning properties.In order to provide this slit sheet material with consistent optimal extension on a continuous basis, preferably adopt the rotary method of die cutting and crushing.

[0263] In some preferred embodiments, a cushioned envelope is provided wherein the opening of the cushioned envelope spans the width of the machine. On the other hand, in prior systems, the manufacturing mouth is transverse to the direction of the preferred embodiments herein. In prior systems for manufacturing envelopes, there is no need to consider the simultaneous expansion of slit paper (because such paper has not been used before), and therefore, prior systems orient the envelope so that more envelopes can be manufactured per minute. In addition, with prior systems, lamination is accomplished by heating the plastic bubble, and therefore, unlike the requirements of drying paper cold glue or cooling paper hot melt glue, lamination is instantaneous. Typically, the length of the envelope is wider than the mouth or envelope width. For example, if the cushioned envelope with bubbles is 10" long and 20" wide, a guillotine cut is made every 10" to every 20", thereby doubling the manufacturing speed of the cushioned envelope.

[0264] One problem with the guillotine making system is that it separates the leading envelope from the preceding envelope and places a high burden on the stretching of the slit sheet material in the smaller number of glued square inches area that remains adjacent to the envelope.

[0265] Therefore, during the manufacturing process when the glue is drying and / or cooling, it is more susceptible to deformation and peeling from the shrinking slit sheet. To overcome this, the rotation method is the best way to maintain the maximum amount of paper-adhesive combination. If the method uses a guillotine, the web will relax during the cutting process, resulting in wrinkles and peeling.

[0266] There are additional reasons for the required rotation method for the slit sheet. The unfolded slit sheet is most conveniently stretched in the direction of manufacture. Since most cushion envelopes are longer than they are wide, manufacturing in the width direction will result in either of two situations:

[0267] First, the slit sheet that expands in the direction of manufacture, and in many cases requires multiple webs of material to be stretched, which requires more than one slit sheet die cutter and the need to handle and precisely position multiple side-by-side webs. The maximum available width for the die cutter is 30", which makes the stretched width 23.5". The envelope still requires the bag to be folded, and the fold seal of about 1.5" creates a usable bag area of ​​11". Many envelopes are longer than the 11" bag area. Again, the solution is multiple die cutters in order to manage the overall length required and the complexity of placing them side by side.

[0268] The second method is by unwinding in the cross manufacturing direction, which would require a web, but would require a holding mechanism to maintain stretch while bonding multiple layers in a step-by-step rather than continuous manufacturing process.

[0269] Either approach creates the further problem of machine cost. On the other hand, the machine of the present invention has a small footprint and can be placed near markets that are too small for width-wise equipment.

[0270] In some preferred embodiments, in order to be able to adhere a label to an outer surface (e.g., a shipping label), the outer layer of the envelope is very lightly embossed, and preferably has narrow embossing, and has embossing that does not protrude outwardly. And, at the same time, the inner layer of the envelope may preferably be more heavily embossed (e.g., on the inner surface of the envelope).

[0271] The weight of the envelope is often considered an important aspect by the customer, for example, the customer wishes to save on postage. Paper having an outer layer-expanded layer-inner layer weight of less than, for example, 50 pounds each, or less than, for example, 45 pounds each, or about 43-43-43 pounds, or about 40-40-40 pounds as the envelope weight can be used with aspects of the preferred embodiments described herein and with embossing (e.g., internal embossing) in conjunction with an expandable slit paper sheet to avoid wrinkling. The use of internal embossing makes the article easier to load and adds more flexibility.

[0272] In some preferred embodiments, the paper cushion substitute and / or the expanded slit sheet is sealed to at least one of the inner or outer layers of serrated paper, kraft / tear-proof layer, standard kraft or other non-slit sheet material. The seal may be at or near the end region 403, such as Figure 4 As shown, or may be at or near the side region 402, such as Figure 4 Although sealing can be directed to one side region and one end region, preferably, sealing is directed to opposite side and / or end regions.

[0273] Although some examples involve the use of two layers of expanded slit sheets, in some preferred embodiments, a single layer may be used. Furthermore, in some embodiments, even more than two layers of expanded slit sheets may be used. Thus, at least one layer is used in the envelope, and multiple layers may be used, for example, two, three, four, or more than four layers may be used where enhanced cushioning is desired.

[0274] In some preferred embodiments, the number of unfolded slit sheets in the latter refers to the number of unfolded paper layers between the innermost layer and the outermost layer. Therefore, when the structure shown in the above embodiment is doubled, the total number of unfolded slit sheets in the envelope is doubled, while the number of unfolded slit sheets between the innermost layer and the outermost layer remains unchanged.

[0275] In a most preferred embodiment, the various envelopes of the embodiments of the present invention can be recycled by consumers along with newspapers, magazines, and corrugated containers, etc. There are three types of paper that can be used as raw materials for making recycled paper: paper mill waste, pre-consumer waste, and post-consumer waste. Paper mill waste is paper scraps and other waste paper from papermaking, and is recycled in paper mills. Pre-consumer waste is material that leaves the paper mill but is discarded before being prepared for consumer use. Post-consumer waste is material discarded after consumer use, such as old corrugated containers (OCC), old magazines, and newspapers. Paper suitable for recycling is called "waste paper", which is commonly used to produce molded pulp packaging.

[0276] In comparison, bubble wrap and The envelopes can be recycled, but they should not be added to the consumer's recycling container. Instead, bubble wrap, Tyvek and plastic bags should be recycled at special collection points. This guidance applies not only to bubble wrap, but also to completely plastic bubble mailers and air pillows. However, bubble mailers with a paper outer side cannot be recycled as is. If feasible, they can be broken down into their separate material parts and then recycled with the paper and other recyclable paper, and then the bubble wrap and other plastic films can be placed at a deposit. Information on the recycling of plastics can be found at "How2Recycle": http: / / www.how2recycle.info / sdo.

[0277] Illustrative Examples of Embodiments of the Invention

[0278] Example A

[0279] For use in containers:

[0280] Layer 1 is jagged;

[0281] Layer 2 is the unfolded slit sheet (open evenly);

[0282] Layer 3 is an unfolded slit sheet (opened evenly) forming a cross pattern with layer 2;

[0283] Layer 4 is serrated.

[0284] Example B

[0285] For use in containers:

[0286] Layer 1 is kraft paper;

[0287] Layer 2 is an unfolded sheet of randomly opened slits;

[0288] Layer 3 is an unfolded sheet of randomly opened slits;

[0289] Layer 4 is kraft paper.

[0290] Example C

[0291] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.:

[0292] Layer 1 (outer layer) is kraft paper / tear-proof layer;

[0293] Layer 2 is an unfolded uniformly opened slit sheet;

[0294] Layer 3 is a slit sheet with uniform openings that is spread out and forms a cross pattern with layer 2;

[0295] Layer 4 is serrated.

[0296] Example D

[0297] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.:

[0298] Layer 1 (outer layer) is kraft paper / tear-proof layer;

[0299] Layer 2 is an unfolded sheet of randomly opened slits;

[0300] Layer 3 is an unfolded sheet of randomly opened slits;

[0301] Layer 4 is serrated.

[0302] Example E

[0303] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.:

[0304] Layer 1 (outer layer) is serrated;

[0305] Layer 2 is an unfolded sheet of randomly opened slits;

[0306] Layer 3 is an unfolded randomly opened slit sheet

[0307] Layer 4 is serrated.

[0308] Example F

[0309] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.:

[0310] Layer 1 (outer layer) is 50# kraft paper;

[0311] Layer 2 is an unfolded sheet of randomly opened slits;

[0312] Layer 3 is an unfolded randomly opened slit sheet

[0313] Layer 4 is 30# kraft paper.

[0314] Example G

[0315] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.:

[0316] Layer 1 (outer layer) is serrated;

[0317] Layer 2 is an unfolded sheet of randomly opened slits;

[0318] Layer 3 is an unfolded sheet of randomly opened slits;

[0319] Layer 4 is 30# kraft paper.

[0320] Example H

[0321] Mailing envelopes for mailing via UPS, FedEx, USPS, etc.;

[0322] Layer 1 (outer layer) is serrated downward;

[0323] Layer 2 is double-sided serrated.

[0324] The broad scope of the invention

[0325] The use of individual numerical values ​​is expressed as an approximation, as if the value was preceded by the word "about", "substantially" or "approximately". Similarly, the numerical values ​​within the various ranges specified in this application, unless otherwise expressly stated, are considered approximations, as if the minimum and maximum values ​​within the range were preceded by the word "about", "substantially" or "approximately". In this way, changes above and below the range can be used to obtain results substantially the same as the values ​​within the range. As used herein, when referring to numerical values, the terms "about", "substantially" and "approximately" have their ordinary and common meanings for those of ordinary skill in the art to which the disclosed subject matter is most closely related to the range or element in question. The amount of widening from a strict numerical boundary depends on many factors. For example, some factors that can be considered include the criticality of the element and / or the effect of a change in a given amount on the performance of the subject matter claimed for protection, as well as other considerations known to those skilled in the art. As used herein, the use of different amounts of significant figures for different numerical values ​​does not mean how the use of the limiting words "about", "substantially" or "approximately" will be used to broaden a specific numerical value or range. Therefore, generally, "about", "substantially" or "approximately" broadens the numerical value. In addition, the disclosure of ranges is intended as a continuous range that includes every value between the minimum and maximum values ​​plus the broadening of the range provided by the use of the terms "about," "substantially," or "approximately." Therefore, unless otherwise indicated herein, the recitation of a range of values ​​herein is intended merely to be used as a shorthand method of individually referring to each individual value falling within the range, and each individual value is incorporated into the specification as if it were individually recited herein. In determining the extent of a given amount of variation in some factors, such as the criticality of the slit pattern, the difference in paper width before and after unfolding, the weight and type of paper, and other considerations known to those skilled in the art that the disclosed subject matter is most closely related to the range or element in question or that the relevant art will have on the performance of the claimed subject matter are not considered to be within the capabilities of a person of ordinary skill in the art, or if not explicitly stated in the claims, the terms "about," "substantially," or "approximately" should be understood to mean the numerical value plus or minus 15%.

[0326] It should be understood that any ranges, ratios, and ratio ranges that can be formed or derived from any data disclosed herein represent further embodiments of the present disclosure and are included as part of the present disclosure as if they were explicitly set forth. This includes ranges that may be formed that include or do not include limited upper and / or lower boundaries. Therefore, those of ordinary skill in the art who are most closely associated with a particular range, ratio, or ratio range will recognize that these values ​​can be clearly derived from the data presented herein.

Claims

1. A protective product comprising: at least one expandable slit paper flap, the at least one expandable slit paper flap expanding between opposite ends of the slit paper flap; a first embossed paper sheet facing the unfolded slit paper sheet, and a second paper sheet facing an opposite side of the at least one unfolded slit paper sheet, At least one of the first embossed paper sheet and the second paper sheet is fixed to the unfolded slit paper sheet at opposite ends of the unfolded slit paper sheet to maintain the unfolded slit paper sheet in its unfolded state, the first embossed paper sheet having a plurality of embossments which increase the rigidity of the first embossed paper sheet to suppress deformation of the first embossed paper sheet fixed to the unfolded slit paper sheet.

2. The protective product of claim 1, wherein: The plurality of embossments in the first embossed sheet comprises an array of embossment shapes distributed across a face of the first embossed sheet.

3. The protective product of claim 2, wherein: The embossed shape array comprises a polygon array, and adjacent polygons share a common edge.

4. The protective product of claim 2, wherein: The embossed shape array includes a hexagonal array, and adjacent hexagons share a side.

5. The protective product of claim 1, wherein: The plurality of embossments comprises a plurality of ribs extending across a majority of the face of the first embossed sheet.

6. The protective product of claim 1 wherein the embossing comprises serrations extending inwardly toward the unfolded slit paper sheet.

7. The protective product of claim 1 wherein the embossments extend inwardly from the plane of the first embossed sheet a distance that increases the rigidity of the first embossed sheet and is less than 0.1 inches, thereby inhibiting deformation of the first embossed sheet secured to the unfolded slit sheet.

8. The protective product of claim 1, wherein the first embossed paper sheet, the unfolded slit paper sheet, and the second paper sheet are folded and secured together along a fold line to form a pocket area.

9. The protective product of claim 7, wherein the first embossed paper sheet, the unfolded slit paper sheet, and the second paper sheet are folded and secured together along a fold line to form a pocket area.

10. The protective product of claim 9, wherein the protective product is a sleeve having a flap area that is foldable to close the pocket area.

11. The protective product of claim 10, wherein the first embossed paper sheet, the unfolded slit paper sheet, and the second paper sheet are secured together with adhesive in the flap area, and the flap is crushed at least in the flap area containing the adhesive.

12. A protective product according to claim 11, wherein the area of ​​the fold line is free of adhesive.

13. The protective product of claim 1 wherein the second paper sheet is embossed.

14. The protective product of claim 13, wherein the second paper sheet has embossing alternating between depressions and projections.

15. The protective product of claim 5 wherein the embossments of the first embossed sheet extend inwardly from the plane of the first embossed sheet a distance less than 0.1 inches from the plane of the embossments sufficient to increase the rigidity of the first embossed sheet and inhibit deformation of the first embossed sheet secured to the unfolded slit sheet.

16. The protective product of claim 15, wherein: The distance is less than 0.05 inches.

17. The protective product of claim 15, wherein: The distance is less than 0.03 inches.

18. The protective product of claim 1 wherein the slit paper sheet is an expandable paper having an expansion range of 1% to 20% in the machine direction as measured in a pre-slit configuration.

19. The protective product of claim 1 wherein the slit paper sheet is an expandable paper having an expansion range of 3% to 20% in the machine direction as measured in a pre-slit configuration.

20. The protective product of claim 1 wherein the slit paper sheet is an expandable paper having an expansion range of 3% to 9% in the machine direction as measured in a pre-slit configuration.

21. The protective product of claim 1 wherein the slit paper sheet weighs 30 to 50 pounds per 3000 square feet prior to unfolding.

22. The protective product of claim 1, wherein: The first embossed paper sheet and the second paper sheet are not secured to the unfolded slit paper sheet over a majority of the area of ​​the unfolded slit paper sheet.

23. The protective product of claim 1, wherein: The first embossed paper sheet contacts the unfolded slit paper sheet at a side of the first embossed paper sheet but is not connected to the unfolded slit paper sheet.

24. The protective product of claim 1, wherein: The protective product is a recyclable paper product.

25. The protective product of claim 1, wherein: The protective product is an envelope having a bag, the bag comprising the first embossed paper sheet and the unfolded slit paper sheet, the first embossed paper sheet and the unfolded slit paper sheet being folded together to form the front wall and the back wall of the bag and being secured together at the sides of the bag, wherein the first embossed paper sheet contacts the unfolded slit paper sheet at the sides of the bag but is not connected to the unfolded slit paper sheet, and The first embossed paper sheet is fixed to the unfolded slit paper sheet at an outer peripheral end of the unfolded slit paper sheet, thereby maintaining the unfolded slit paper sheet in its unfolded state.

26. The protective product of claim 25, wherein: The first embossed paper sheet and the unfolded slit paper sheet are folded together to form the front and rear walls of the bag and are secured together with adhesive at the sides of the bag.

27. The protective product of claim 1, wherein: The at least one unfolded slit paper sheet in the unfolded state includes a plurality of unfolded slit paper sheets stacked side by side with each other in the unfolded state.

28. The protective product of claim 27, wherein: The plurality of unfolded slit sheets include two unfolded slit sheets, and further include a second embossed sheet facing opposite sides of the two unfolded slit sheets.

29. The protective product of claim 1, wherein: The embossing of the first embossed sheet is recessed toward the at least one unfolded slit sheet.

30. The protective product of claim 25, further comprising: An address label is secured to the envelope.

31. The protective product of claim 1, wherein: The protective product is an envelope; and The embossing of the first embossed paper sheet projects outwardly from the at least one unfolded slit paper sheet and faces toward the interior of a pocket of the envelope, whereby the embossing helps to limit the friction applied to an article inserted into the pocket.

32. The protective product of claim 31 wherein the embossing is hexagonal.

33. The protective product of claim 32, wherein adjacent hexagons share a common edge whereby the hexagons are connected.

34. The protective product of claim 1 wherein the plurality of embossments are sufficient to counteract the inherent tendency of the unfolded slit paper sheet to collapse and thereby inhibit wrinkling of the first embossed paper sheet.

35. A method comprising: Providing a protective product according to claim 1; and An article is placed within a bag of the protective product, wherein the unfolded slit paper sheet provides cushioning to protect the article within the bag, and wherein the first embossed paper sheet inhibits deformation of the first embossed paper sheet secured to the unfolded slit paper sheet.

36. A method comprising: Providing a protective product according to claim 31; and An article is placed in the envelope, wherein the unfolded slit paper sheet provides cushioning to protect the article in the envelope, and the first embossed paper sheet inhibits deformation of the first embossed paper sheet secured to the unfolded slit paper sheet.

37. An envelope, comprising: at least one unfolded slit paper sheet in an unfolded state; a first paper sheet facing a first side of the at least one unfolded slit paper sheet and fixed relative to the at least one unfolded slit paper sheet along at least two opposing peripheral ends of the at least one unfolded slit paper sheet; a second paper sheet, the second paper sheet facing the at least one unfolded slit paper sheet on a surface of the at least one unfolded slit paper sheet opposite to the first paper sheet, and the second paper sheet being fixed relative to the at least one unfolded slit paper sheet at least along at least two opposite peripheral ends of the at least one unfolded slit paper sheet; Wherein a) the first paper sheet and the second paper sheet are embossed sheets having a plurality of embossments, and the embossments suppress deformation of the first paper sheet and the second paper sheet due to the contraction force of the at least one unfolded slit paper sheet, or b) the first paper sheet and the second paper sheet are non-embossed sheets, and the non-embossed sheets have a heavier weight than the weight of the at least one unfolded slit paper sheet, and the non-embossed sheets suppress deformation of the first paper sheet and the second paper sheet due to the contraction force of the at least one unfolded slit paper sheet.

38. The envelope of claim 37, wherein: One of the first paper sheet and the second paper sheet is an unembossed kraft paper sheet having a weight of 40# paper or greater under TAPPI standard paper weight specifications of 3000 square feet, and the second paper sheet is embossed.

39. The envelope of claim 37, wherein: The at least one unfolded slit sheet is at least one substantially rectangular sheet that is fixed to at least one of the first sheet and the second sheet only at two opposite end regions of the at least one unfolded slit sheet.

40. The envelope of claim 37, wherein: The two opposite end regions of the at least one unfolded slit sheet are opposite ends of the at least one unfolded slit sheet in an unfolding direction of the at least one unfolded slit sheet.

41. The envelope of claim 37, wherein: The at least one unfolded slit paper sheet includes two unfolded slit paper sheets that are side by side and directly contact each other.

42. The envelope of claim 37, wherein: One of the first paper sheet and the second paper sheet is a non-embossed kraft paper sheet having a weight of 60# paper or greater under TAPPI standard paper weight specifications of 3000 square feet.

43. The envelope of claim 37, wherein: The first sheet and the second sheet contact the at least one unfolded slit sheet over a majority of the area of ​​the at least one unfolded slit sheet but are not connected to the at least one unfolded slit sheet over a majority of the area of ​​the at least one unfolded slit sheet.

44. The envelope of claim 37, wherein: The envelope has a bag with a buffer wall, wherein the second paper sheet is an inner layer forming an inner wall of the bag, the first paper sheet is an outer layer forming an outer wall of the bag, and the at least one unfolded slit paper sheet is located between the inner layer and the outer layer.

45. The envelope of claim 44, wherein the buffer wall of the bag is folded along a fold line so that the buffer wall forms the front and rear walls of the bag and the first paper sheet is the outer layer on the front and rear surfaces of the front and rear walls of the bag, wherein adhesive is applied to at least one of the first and second paper sheets along the fold line.

46. ​​An envelope according to claim 45, wherein the rear wall of the bag is longer than the front wall of the bag, and wherein the portion of the first paper sheet extending beyond one end of the front wall has an adhesive strip fixed thereto, the adhesive strip having a removable release liner for adhesively closing the envelope by removing the release liner and adhering the adhesive strip to the front wall.

47. The envelope of claim 45, wherein the rear wall of the bag is longer than the front wall of the bag and forms a flap region, wherein a portion of the first and second paper sheets contact the at least one unfolded slit paper sheet and are secured together with an adhesive, at least said portion being crushed to flatten the at least one unfolded slit paper sheet and reinforce at least a portion of the flap region.

48. The envelope of claim 41, wherein: The envelope has a bag including a buffer wall, wherein the buffer wall has four layers, wherein the first paper sheet forms the first layer of the four layers and is the outer layer forming the outer wall of the bag, the two unfolded slit paper sheets form the second and third layers of the four layers, the second and third layers are between the first and fourth layers and are in direct contact with each other, and the second paper sheet forms the fourth layer of the four layers and is the inner layer forming the inner wall of the bag.

49. A method comprising: Providing the envelope of claim 37; and An article is placed within a pocket of the envelope, wherein the at least one expanded slit paper sheet provides cushioning to protect the article within the pocket.

50. A method of manufacturing an envelope, comprising: providing at least one expandable slit paper sheet; providing a first paper sheet, the first paper sheet being configured to face a first side of the at least one expandable slit paper sheet; providing a second paper sheet, the second paper sheet being used to face the at least one unfolded slit paper sheet on a side of the at least one unfolded slit paper sheet opposite to the first paper sheet; Expanding the at least one expanded slit paper sheet to an expanded state, and fixing the at least one expanded slit paper sheet to at least the opposite portion of the outer periphery of the at least one expanded slit paper sheet that is opposite to the first paper sheet and the second paper sheet; Deformation of the first and second paper sheets in response to the contraction force of the at least one unfolded slit paper sheet is suppressed by either: a) providing the first and second paper sheets with a plurality of embossments or b) providing the first and second paper sheets as non-embossed sheets having a weight heavier than that of the at least one unfolded slit paper sheet, the weight being sufficient to suppress deformation of the first and second paper sheets.

51. A method of manufacturing a sleeve according to claim 50, wherein: The step of suppressing deformation of the first and second sheets in response to the contraction force of the at least one unfolded slit sheet includes: setting each of the first and second sheets as a non-embossed sheet and having a weight of 40# or greater under the TAPPI standard sheet weight specification for 3000 square feet.

52. The method of manufacturing a sleeve according to claim 50, further comprising providing the at least one unfolded slit paper sheet as at least one substantially rectangular sheet, and securing the at least one unfolded slit paper sheet to at least one of the first paper sheet and the second paper sheet only at two opposite end regions of the at least one unfolded slit paper sheet.

53. The method of manufacturing a sleeve according to claim 52, wherein fixing two opposite end regions of the at least one unfolded slit paper sheet comprises fixing opposite ends of the at least one unfolded slit paper sheet along an unfolding direction of the at least one unfolded slit paper sheet.

54. The method of manufacturing a sleeve according to claim 50, further comprising providing the at least one unfolded slit paper sheet as two unfolded slit paper sheets, the two unfolded slit paper sheets being placed side by side and in direct contact with each other.

55. The envelope according to claim 37, wherein the at least one expanded slit paper sheet in the expanded state is made of an expandable paper, wherein the expandable paper is made expandable in the machine direction and the cross direction without a slit pattern, and wherein the expandable paper has an expandability in the machine direction in the range of 3% to 20%.

56. The sleeve of claim 55, wherein the expansibility is in the range of 3-15% in the machine direction.

57. The envelope of claim 37, wherein the slit paper sheet prior to unfolding weighs 30 to 50 pounds per 3000 square feet.

58. A method of making the envelope according to claim 37, comprising the steps of: a series of envelope units are passed continuously in a straight-line flow between the rotary die-cutting and crushing tool and the rotating mandrel, thereby applying back pressure, wherein the envelope unit is a combination of the first paper sheet, the at least one unfolded slit paper sheet and the second paper sheet that have been fixed together, The rotary die cutting and crushing tool has a crushing part and a cutting part, the crushing part crushes a portion of the combined flap forming area, and the cutting part cuts the envelope unit from the series of envelope units to form a single envelope unit, The rotary die cutting and crushing tool has an outer circumference equal to the overall length of the envelope being produced.

59. A protective product comprising: at least one buffer paper sheet, the at least one buffer paper sheet being an expandable slit paper, a fan-folded paper or a double-sided embossed paper sheet, a first embossed paper sheet, said first embossed paper sheet facing said at least one buffer paper sheet, and a second sheet of paper, the second sheet of paper facing an opposite side of the at least one buffer sheet of paper, At least one of the first embossed paper sheet and the second paper sheet is fixed to the buffer paper sheet, the first embossed paper sheet having a plurality of embossments which increase rigidity of the first embossed paper sheet to suppress deformation of the first embossed paper sheet fixed to the buffer paper sheet.

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