Improved extended slit sheet cushioning product with novel slit patterns and paper properties

Abstract

In preferred embodiments, the present invention provides a substantially improved slit sheet cushioning product by advantageously combining novel paper properties with novel slit patterns of improved features and characteristics. In some exemplary and non-limiting example embodiments, the cushioning product of the present invention may include, for example, novel slit sheet materials and stretchable paper used, for example, as a cushioning pad or as a cushioning within an enclosure product, wherein the cushioning product may be substantially more elastic and, for example, thinner to facilitate space utilization.

Description

[0001] Cross-reference to priority application

[0002] This application claims priority to U.S. Application Serial No. 62 / 874,163, filed on July 15, 2019, the entire disclosure of which is incorporated herein by reference as if fully set forth herein.

[0003] Cross-References to Patents and Patent Applications Incorporated by Reference

[0004] The entire disclosure of each of the following patents is incorporated herein by reference in its entirety as if fully set forth herein: a) U.S. Patent No. 10,669,086, issued on June 2, 2020, b) U.S. Patent No. 10,226,907, issued on March 12, 2019, d) U.S. Serial No. 16 / 274,028, filed on February 12, 2019, as a divisional of U.S. Patent No. 10,226,907, and e) U.S. Serial No. 16 / 870,195, filed on May 8, 2020, entitled “Extensible Paper and its Use in the Production of Expanded Slit Packaging Wrap and Void Fill Products”. Technical Field

[0005] The present invention relates to the use of slit sheet materials that expand to provide cushioning products. In preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns of improved features and characteristics. In some illustrative and non-limiting example embodiments, the cushioning products of the present invention may include, for example, novel slit sheet materials and stretchable paper used, for example, as a cushioning pad or as a cushion within an enclosure product, wherein the cushioning product may be substantially more flexible, but, for example, thinner, for better utilization of space.

[0006] Related Art of Expanded Slit Sheets Incorporated by Reference

[0007] Other relevant information about paper (which can be used in the present invention), slit patterns and expansion processes can be found in U.S. Patents a) 5,538,778, b) 5,667,871, c) 5,688,578, d) 5,782,735, e) 3,908,071, f) 3,104,197, g) 3,220,116, h) 3,266,972, i) 3,269,393, j) 3,908,071, k) 6,024,832, i) 6,458,447 and m) 6,712,930, and U.S. Application Serial No. 14 / 901,977, and PCT Application No. WO1984002936A1, and U.S. Published Patent Application Nos. US 2002 / 0060034, US 2007 / 0240841, the disclosures of which are incorporated herein by reference in their entirety, as if fully set forth herein.

[0008] In a preferred embodiment, the term "expandable" as applied to a sheet of paper means paper having a slit pattern that allows the paper to expand, such as, for example, disclosed in the following U.S. Patents: (a) No. 5,538,778, (b) No. 5,667,871, (c) No. 5,688,578, (d) No. 5,782,735 and (e) No. 10,226,907, 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 allow the paper to expand lengthwise, and a corresponding reduction in width. In some embodiments, the paper produced by the slit pattern will increase in length due to the slit pattern when processed by an expander such as, for example, the type of expander described by any of the following U.S. and PCT applications: (a) 2017 / 0203866, (b) 2018 / 022266, (c) 2018 / 0127197, and (d) PCT / US2014 / 054615, the entireties of which are incorporated herein by reference.

[0009] U.S. Patent Nos. 5,667,871 and 5,688,578 (Slit Sheet Packing Material) teach the use of multiple individual slits that form parallel spaced rows to form hexagonal expanded sheets with and without separator sheets. It requires machinery to stretch the paper into a three-dimensional shape at the customer's location, such as disclosed in U.S. Patent No. 5,538,778, which teaches a method and apparatus for producing an expansion of a slit sheet material that is performed at the packaging site location. U.S. Patent No. 5,782,735 discloses an expander for expanding the slit sheet material of U.S. Patent Nos. 5,667,871 and 5,688,578.

[0010] For reference, FIG. 3(A) and FIG. 3(B) correspond to the '871 patent of U.S. Pat. Figure 1 and Figure 3. These figures depict a prior art "slit sheet" expandable paper structure. As explained in the '871 patent:

[0011] "Slit sheets (generally indicated as 10) are shown in FIG. 3(A) as they leave a slitting machine. The sheets may be formed on a flat bed slitter and produced directly as rectangular sheets, as well as formed on a rotary slitter and cut into individual sheets, or stored directly as continuous sheets in roll form. The flexible sheet 10 is preferably made from fully recycled paper, wherein the grain of the paper runs in the direction of arrow A. A flexible sheet 10 is provided wherein the slits 14 and 16 are parallel to the edges 22 and 24 of the flexible sheet 12 and perpendicular to the grain of the paper. The slits 14 and 16 are placed in rows and are separated from each other by joints 20 and legs 21 (shown in FIG. 3(B)) . The joint 20 is of constant size and provides the support required to prevent the paper from tearing when opened. The cushioning effect is produced by the flexing of the joint and the legs under load. Therefore, it is necessary that the joint 20 is of sufficient size to provide cushioning. The spacing between the multiple rows of slits 14 and slits 16 must also be of sufficient size to prevent the paper from tearing. The offset positioning between the multiple rows of slits 14 and slits 16 gives the paper resilience when opened, and is discussed in further detail below. The presence of partial slits 14 and 16 at the ends 25 and 18 of the flexible sheet 10 does not hinder the efficiency of the slit paper 10. The flexible sheet 10 lies in a first plane when laid flat. "

[0012] "When expanded, the expanded sheet (generally indicated as 12) is formed by hexagonal units 26, legs 21 and joint 20 regions, as shown in Figure 3(B). Preferably, at least a majority of the joint 20 regions lie in multiple parallel planes. The planes of the joint 20 regions form an angle of at least about 45 degrees with the plane of the flat sheet."

[0013] "The slitting operation of cutting slits in the sheet material can take several forms. In one embodiment, a rectangular sheet is cut with its total number of slits in one action. The term rectangular should be understood to include rectangles in which all four sides are equal, i.e., squares. In the case of the sheet material being subjected to rotary cutting or slitting, the pressure required for the cutting action is significantly lower than that required for flat bed cutting because essentially only a single row or a few rows of slits are cut simultaneously. Unlike prior art structures and systems, expansion simultaneously with slitting is undesirable. Therefore, a critical balance must be struck between preventing opening of the unit during the rewinding step and facilitating opening of the unit during the expansion step. By achieving this critical balance and producing a flat, unexpanded sheet, the sheet material has an effective thickness that is one twentieth of the thickness of a sheet of expanded material. This compact configuration provides optimization for transportation and storage."

[0014] In a preferred embodiment, the term "slit sheet" means an expandable paper sheet having a slit pattern. The following is a direct reference to US Pat. No. 5,667,871 (the '871 patent).

[0015] First, column 10, lines 13-48 of the '871 patent explain:

[0016] "The length of the slits and the ratio of the seam spacing between the slits affect the size of the polygon formed during the expansion step. The higher the ratio of slit length / space length, the greater the maximum angle that can be formed between the plane of the sheet and the plane of the seam area. The greater the uniformity of the shape and size of the open areas of the formed polygons and the angle at which the seam areas are inclined relative to the flat sheet, the greater the degree of interlocking of the seam areas that can be achieved. The interlocking of the seam areas (i.e., the nesting of the sheet layers) reduces the effective thickness of the sheet. However, the net effect is still a substantial increase in the effective sheet thickness. For example, a 0.008 inch thick paper with a slit pattern of 1 / 2" slits, 3 / 16" slit spacing, and 1 / 8" row spacing produces a 1 / 4" x 3 / 16" seam that can expand to less than about a quarter inch thickness and when nested will have a net effective thickness of about 0.375 inches for the two layers. It should be noted that the seam width is twice the width of the legs. The net effect is that the available expanded thickness of the paper is approximately 20 times the unexpanded thickness."

[0017] "The longer the slits relative to the stiffness of the sheet material, the weaker the interlocking and cushioning effects due to the weakness of the expansion structure. If the slits are too small, then expansion will be severely restricted and cushioning will be overly restricted. This does not mean that size is critical, but rather that size must be selected relative to the characteristics of the paper, such as the degree of stiffness, and the desired cushioning or energy absorption effect. The resistance to expansion increases with the increase in the size of the joint area. It should be understood that some resistance to opening is also desirable. An object abuts or contacts the edge of the sheet formed by the slope of the joint area, which transforms the perimeter of the opening into an upper edge and a lower edge."

[0018] Second, the '871 patent further explains at column 10, lines 58-67 and column 11, lines 1-6:

[0019] "As previously mentioned, the slit size can be varied to facilitate the opening process. The 5 / 8" slit, 3 / 16" seam, and 3 / 16 row is very easy to open because the number of hexagons is reduced. As the size of the hexagons increases and the number decreases; the tensile thickness is increased, resulting in a very workable wrapping material. This size increases the yield of the sheet and provides almost the same protection as the 1 / 2" slit. Utilizing a larger content of post-consumer waste, this size provides a cheaper product while maintaining the integrity of the wrapped product. The 1 / 2" slit, 3 / 16" seam, and 1 / 8" row pattern produces a more protective wrap due to the greater number of wraps that can be made in the same volume. Thus, a 21 / 2 pound vase dropped from a height of thirty inches (with only 1 / 2" of accumulated sheet thickness wrapped around the vase) can be protected with the 1 / 2" slit, 1 / 4 x 3 / 16 inch seam pattern."

[0020] The inventor's prior U.S. Patent No. 10,226,907 (the '907 patent) shows the technical background: "Expandable Slit Sheet Packaging Material That Interlocks When Layered and Expanded". In the '907 patent, the product includes multiple layers, each of which has a different slit pattern for the purpose of "interlocking" between the multiple layers. As explained in column 2 of the '907 patent, "the different slit patterns when expanded produce angled joint areas having the same number of rows per inch but with different angles of inclination of the joint areas so that adjacent layers can interlock". While the '907 patent describes an example where one of the layers includes a slit length of 0.4 inches, it should be noted that: 1) this 0.4 inch slit length is only used in conjunction with an adjacent layer having a larger slit length of 0.5 inches, and 2) this reduced slit length is not used in conjunction with a reduced distance between rows (i.e., the distance between rows needs to be the same as the distance between adjacent layers having a slit length of 0.5 inches). Thus, the '907 patent does not teach the improved slit sheet cushioning product of the present invention, nor does it teach the advantages thereof.

[0021] The preferred embodiments of the present invention improve and overcome various problems and limitations of the related art. Summary of the invention

[0022] Preferred embodiments overcome and improve upon the foregoing and / or other related technologies. According to some embodiments of the present invention, the use of slit patterns (forming more cells per square foot) provides greater compression resistance and cushioning resilience to an article when packaged in a wrapper or when used as a cushion in an enclosure (including, in some exemplary preferred enclosure embodiments, where the enclosure includes at least an inner or outer layer of indented paper).

[0023] In a most preferred embodiment, an expanded paper cushioning product is provided that employs an improved slit arrangement and wherein the expanded paper is a stretchable paper.

[0024] In some preferred embodiments, the slit paper pattern consisting of slits advantageously has slits ranging from 0.30 inches to 0.45 inches (i.e., in the longitudinal dimension of the slits) and spaces between rows ranging from 0.1125 inches to 0.1688 inches (i.e., the distance between adjacent rows of slits). Most preferably, the subsequent embodiments are made of stretchable paper.

[0025] In some preferred embodiments, the slit paper has slits, wherein the slit width is 0.45 inches (with a tolerance of +5%, -33%) (ie, the slit width herein refers to the longitudinal dimension of the slit). Likewise, most preferably, the subsequent embodiments are made of stretchable paper.

[0026] In some preferred embodiments, the slit pattern advantageously produces an expandable slit paper having a number of legs per square foot that is at least 20% greater than a slit paper having a slit (kerf) width of 0.50 inches.

[0027] In some preferred embodiments, the expanded slit paper cushioning product of the present invention has a number of legs per square foot that is at least 15% more than a slit paper having a slit (cut) width of 0.50 inches. In some preferred embodiments, the expanded slit paper cushioning product of the present invention has a number of legs per square foot that is at least in the range of 20% to 50% more than a slit paper having a slit (cut) width of 0.50 inches.

[0028] Furthermore, while the inventors have discovered novel means for improving the cushioning properties of an expandable slit sheet device, which novel means involve "reducing" the slit pattern size, it should be noted that such a reduction in the slit pattern size is "not only" not feasible with existing expandable slit sheet paper (i.e., it is not possible to achieve such small sizes), but is also "counter-intuitive" to the existing understanding of the cushioning properties provided by such expandable slit sheet paper. Notably, the cushioning of an expandable slit sheet paper is directly associated with the "width" of the expandable slit sheet paper in the expanded state. Therefore, to enhance cushioning, those in the art have attempted to actually "increase" such width of the expanded slit sheet paper. However, the inventors have discovered means by which smaller slit patterns can be achieved (e.g., via the use of stretchable paper), and such smaller slit patterns with such stretchable paper can ultimately provide enhanced cushioning despite the loss of cushioning due to the reduced "width" of the expandable slit sheet paper. Furthermore, the inventors have also discovered other desired applications and uses of such novel expandable slit sheet paper.

[0029] According to some preferred embodiments, a slit sheet paper cushioning product is provided, comprising: a slit sheet paper having a slit pattern, the slit pattern comprising a plurality of slits extending in a transverse direction, the slits forming a plurality of open units when expanded in a longitudinal direction, wherein the slit width ranges from 0.45 inches + 5% to 0.45 inches - 33%, and the slit sheet paper is formed of stretchable paper, which is made stretchable in the longitudinal and transverse directions in the absence of the slit pattern, and the stretchable range of the stretchable paper in the longitudinal direction is 3% to 20%.

[0030] According to some embodiments of the present invention, a slit sheet paper cushioning product is provided, comprising: a sheet paper having a slit pattern, the slit pattern comprising a plurality of slits extending in a transverse direction, the slits forming a plurality of open units when expanded in a longitudinal direction, wherein the slit width is at least 10% narrower than 0.5 inches, and the slit sheet paper is formed by a stretchable paper which is made stretchable in the longitudinal and transverse directions in the absence of the slit pattern, the stretchable range of the stretchable paper in the longitudinal direction being 3% to 20%.

[0031] According to some preferred embodiments, a slit sheet paper cushioning product is provided, comprising: at least one slit sheet paper, the at least one slit sheet paper having a slit pattern, the slit pattern comprising a plurality of slits extending in the transverse direction, the slits forming a plurality of open cells when expanded in the longitudinal direction, wherein the slit width is at least 10% narrower than 0.5 inches, and the slit sheet paper is formed by a stretchable paper, the stretchable paper is expanded into an alternating row expansion pattern, the alternating row expansion pattern comprising alternating rows, wherein the bottom side cell openings in the bottom side row are located on the bottom side of the expanded slit sheet paper, and wherein the top side cell openings in the top side row are located on the top side of the expanded slit sheet paper. According to some embodiments, the slit sheet paper is made of stretchable paper. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 5%. According to some embodiments, the stretchable range of the stretchable paper in the transverse direction is at least 5%. According to some embodiments, the stretchable paper is stretchable in the longitudinal and transverse directions without the slit pattern, and the stretchable range of the stretchable paper in the longitudinal direction is 3% to 20%.

[0032] In some embodiments, the slit sheet includes spaces between rows of slits in the range of 0.1125 inches to 0.1688 inches. In some embodiments, the slit sheet includes spaces between rows of slits less than 0.125 inches. In some embodiments, the slit sheet includes spaces between rows of slits less than 0.1125 inches. In some embodiments, the slit sheet includes spaces between rows of slits less than 0.0875 inches. In some embodiments, the slit width is less than 0.40 inches. In some embodiments, the slit width is less than 0.35 inches. In some embodiments, the slit width is less than 0.30 inches.

[0033] In some embodiments, the slit sheet paper is a rolled slit sheet paper. In some embodiments, the rolled slit sheet paper is supported on an expander device, which is adapted to rotatably support the rolled slit sheet paper for manually removing and expanding the rolled slit sheet paper. According to some embodiments, a method of using a slit sheet paper cushioning product includes manually wrapping the expanded slit sheet paper around an article to form multiple layers of expanded slit sheet paper around the article for cushioning.

[0034] In some embodiments, a slit sheet of paper is used within the wall of the enclosure for cushioning of the enclosure. In some embodiments, the enclosure comprises a single layer of the slit sheet of paper within the wall of the enclosure for cushioning so as to reduce the thickness of the wall. In some embodiments, the wall of the enclosure comprises an outer paper layer on a first side of the slit sheet of paper and an inner paper layer at a second side of the slit sheet of paper. In some embodiments, the outer paper layer and / or the inner paper layer comprises embossing.

[0035] In some embodiments, the slit sheet forms an alternating row expansion pattern that, when expanded, forms the plurality of open cells. In some embodiments, the slit sheet is in an expanded state, wherein the plurality of open cells form an alternating row expansion pattern. In some embodiments, the alternating row expansion pattern comprises alternating rows, wherein bottom cell openings in the bottom rows are located on the bottom side of the expanded slit sheet, and wherein top cell openings in the top rows are located on the top side of the expanded slit sheet.

[0036] In some embodiments, the number of support legs is at least 20% greater than the number of support legs of a slit sheet paper having 0.5 inch slits, thereby generating more cells per square foot when expanded and providing greater compression resistance and cushioning resilience than provided by a slit sheet paper having 0.5 inch slits.

[0037] According to some embodiments, the slit sheet paper cushioning product is a package, which includes: at least one slit sheet paper in an expanded state; a first paper sheet, which faces a first surface of the at least one slit sheet paper in an expanded state and is fixed relative to the at least one slit sheet paper along at least a portion of the periphery of the at least one expanded slit paper sheet; a second paper sheet, which faces an opposite surface of the at least one slit sheet paper in an expanded state and is fixed relative to the at least one slit sheet paper along at least a portion of the periphery of the at least one slit sheet paper. In some embodiments: either a) at least one of the first paper sheet and the second paper sheet is an embossed sheet having a plurality of embossments which inhibit deformation of the first and second paper sheets due to the contraction force of the at least one slit sheet in the expanded state; or b) the first paper sheet and the second paper sheet are non-embossed sheets having a heavier weight than the weight of the at least one slit sheet in the expanded state, thereby inhibiting deformation of the first and second paper sheets due to the contraction force of the slit sheet in the expanded state.

[0038] According to some other embodiments of the present invention, there is provided a slit sheet paper cushioning product, comprising: at least one slit sheet paper, the at least one slit sheet paper having a slit pattern, the slit pattern comprising a plurality of slits extending in the transverse direction, the slits forming a plurality of open cells when extended in the longitudinal direction, the slit sheet paper being formed by a stretchable paper, the stretchable paper being extended into an alternating row extension pattern, the alternating row extension pattern comprising alternating rows, wherein the bottom side cell openings in the bottom side row are located on the bottom side of the extended slit sheet paper, and wherein the top side cell openings in the top side row are located on the top side of the extended slit sheet paper. According to some embodiments, the slit sheet paper is made of stretchable paper. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 5%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 5%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 5% and the stretchable range in the transverse direction is at least 5%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 6% and the stretchable range in the transverse direction is at least 6%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 7% and the stretchable range in the transverse direction is at least 7%. According to some most preferred embodiments, the stretchable range of the stretchable paper in the longitudinal direction is at least 8% and the stretchable range in the transverse direction is at least 8%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is between 5% and 15% and the stretchable range in the transverse direction is between 5% and 15%. According to some embodiments, the stretchable range of the stretchable paper in the longitudinal direction is between 7% and 15% and the stretchable range in the transverse direction is between 7% and 15%. According to some embodiments, the plurality of slits each have a width between 0.35 inches and 0.65 inches; according to some embodiments, the plurality of slits each have a width between 0.45 inches and 0.55 inches. According to some embodiments, the plurality of slits each have a width of about 0.5 inches. According to some embodiments, the plurality of slits each have a width of less than 0.5 inches. According to some embodiments, the plurality of slits each have a width of less than 0.45 inches. According to some embodiments, the plurality of slits each have a width less than 0.4 inches.

[0039] The above and / or other aspects, features and / or advantages of various embodiments will be further understood according to the following description in conjunction with the accompanying drawings. Various embodiments may include and / or exclude different aspects, features and / or advantages where appropriate. In addition, various embodiments may combine one or more aspects or features of other embodiments where appropriate. 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

[0040] Preferred embodiments of the invention are illustrated by way of example and not limitation in the accompanying drawings, in which:

[0041] Figure 1 for an explanatory plan view showing two slit patterns and the resulting number of units per square foot;

[0042] Figure 2 is an explanatory side view of a unit structure of an extended slit sheet material showing some embodiments of the present invention compared to the background art;

[0043] FIG. 3(A) is a plan view of an exemplary slit sheet of paper in an unexpanded state according to the background art, specifically corresponding to U.S. Pat. No. 5,667,871. Figure 1 , and 3(B) is a plan view of an exemplary slit sheet paper in an expanded state according to the background art, specifically corresponding to FIG. 3 of U.S. Patent No. 5,667,871;

[0044] FIG. 4(A) shows a top plan view of a sample expanded slit sheet paper using kraft paper, the sample expanded slit sheet paper opened in a manner generally similar to that shown in FIG. 3(B);

[0045] FIG. 4(B) shows a top view of the same expanded slit sheet paper shown in FIG. 4(A), taken at an angle relative to the plane of the expanded paper, such as looking directly at the expanded unit of the paper;

[0046] FIG. 4(C) shows a top view of the same expanded slit sheet paper shown in FIG. 4(A) and FIG. 4(B), but taken at an angle relative to the plane of the expanded paper, which is opposite to the plane of the angle shown in FIG. 4(B);

[0047] FIG4(D) shows Figure 4(A) to Figure 4(C) a top view of the same expanded slit sheet paper shown, but taken at an angle relative to the plane of the expanded paper, which is located below the plane of the paper near the lower end of Figure 4(D);

[0048] FIG. 5(A) is a top plan view showing a novel alternating row expansion pattern of an expanded slit sheet paper according to some preferred embodiments of the present invention;

[0049] 5(B) shows a top view of the extended slit sheet paper shown in FIG. 5(A), the top view being taken at an angle relative to the plane of the paper, such as viewing the extended slit sheet paper from the top right side of the view of FIG. 5(A);

[0050] FIG5(C) illustrates a top view of the expanded slit sheet paper shown in FIG5(A) taken at an angle relative to the plane of the paper, such as viewing the expanded slit sheet paper from the top left side of the view of FIG5(A) and at a smaller angle than that shown in FIG5(B);

[0051] FIG5(D) shows a top view of the extended slit sheet paper shown in FIG5(A), the top view being taken at an angle relative to the plane of the paper, such as viewing the extended slit sheet paper from an angle below the view of FIG5(A);

[0052] 5(E) shows a rear plan view of the expanded slit sheet of paper shown in FIG. 5(A) from the opposite side of the expanded slit sheet of paper (ie, looking upward from the rear of the expanded slit sheet of paper in the view of FIG. 5(A));

[0053] FIG5(F) shows a rear view of the expanded slit sheet paper shown in FIG5(A) from the opposite side of the expanded slit sheet paper (i.e., looking upward from behind the expanded slit sheet paper in the view of FIG5(A)), and the rear view is taken at a certain angle relative to the plane of the paper, such as viewing the expanded slit sheet paper from the left bottom side of the view of FIG5(E);

[0054] FIG5(G) shows a rear view of the extended slit sheet paper shown in FIG5(A) from a direction similar to that shown in FIG5(F), except that it is at an angle closer to the plane of the extended slit sheet device, such as to more clearly show the alternating row pattern of the extended slit sheet paper;

[0055] FIG. 5(H) illustrates a rear view of the expanded slit sheet paper shown in FIG. 5(A) taken at an angle relative to the plane of the paper, such as viewing the expanded slit sheet paper at an angle from the top side of the view of FIG. 5(E);

[0056] Figure 6(A) to Figure 6(C) The formation of an alternating row expansion pattern is shown in accordance with a preferred embodiment of the present invention, wherein FIG. 6(A) shows an exemplary slit pattern formed in a sheet of paper, FIG. 6(B) shows the slit pattern of FIG. 6(A) with the area of ​​the paper prior to expansion highlighted for reference, and FIG. 6(C) is a photograph of an exemplary expanded slit sheet of paper having a slit pattern similar to that shown in FIG. 6(B) in an expanded state;

[0057] 7(A) and 7(B) are explanatory diagrams showing increasing cell density and decreasing slit length according to some preferred embodiments of the present invention;

[0058] 8(A) and 8(B) correspond to the respective patent applications of U.S. Patent Application Serial No. 16 / 531,017. Figure 1 and Figure 7, wherein Figure 8(A) shows a side sectional view of an exemplary pad according to some preferred embodiments, which exemplary pad is used to form an enclosure, and Figure 8(B) is a perspective view of an enclosure formed together with the enclosure pad of Figure 8(A) according to some exemplary embodiments.

[0059] In the accompanying drawings, FIG. 4(A) to FIG. 4(D), Figure 5(A) to Figure 5(G) 6(C) are photographs of actual products. Thus, these photographs show illustrative examples to scale, such that these figures show illustrative examples to scale, and the angles and relative dimensions shown in these figures are in such illustrative examples. Thus, for example, in some embodiments, the angles of the joints, legs, and other portions of the expanded slit sheet paper may be shown in such figures. Furthermore, in some alternative embodiments, such shown angles and relative dimensions may vary slightly, such as, for example, by ±15% in some examples, or ±10% in some other examples. DETAILED DESCRIPTION

[0060] While the invention may be embodied in many different forms, exemplary embodiments are described herein with the understanding that the disclosure is to be considered as providing 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 shown herein.

[0061] Introduction of the Preferred Embodiments

[0062] In preferred embodiments, the present invention provides a generally improved slit sheet cushioning product by advantageously combining novel paper properties with novel slit patterns of improved features and characteristics. In some exemplary and non-limiting example embodiments, the cushioning product of the present invention may include, for example, a novel slit sheet material and a stretchable paper used, for example, as a cushioning pad or as a cushion within an enclosure product, wherein the cushioning product may be generally more resilient, but, for example, thinner, for better utilization of space.

[0063] In a preferred embodiment, an extended paper cushioning product and a use of a novel stretchable paper are provided, wherein the extended paper cushioning product adopts an improved slit arrangement that is not feasible with existing extended slit paper products, including a compact slit pattern having, for example, reduced slit length and reduced line spacing.

[0064] According to some embodiments of the present invention, novel slit patterns can be formed that provide more cells per square foot and achieve greater compression resistance and cushioning resilience. For example, preferred embodiments have significant advantages for wrapping items that are packaged in containers (e.g., for use as cushioning wraps) or as pads for enclosures (including, in some exemplary preferred enclosure embodiments, where the enclosure includes at least an inner layer and an outer layer of indented paper).

[0065] In some preferred embodiments, the slit paper pattern consisting of slits advantageously has slits in the range of 0.30 inches to 0.45 inches (i.e., in the longitudinal dimension of the slits) and spaces between rows in the range of 0.1125 inches to 0.1688 inches (i.e., the distance between adjacent rows of slits). Most preferably, these embodiments are made of stretchable paper.

[0066] In some preferred embodiments, the slit paper has slits, wherein the slit width is 0.45 inches (+5%, -33%) (ie, the slit width herein refers to the longitudinal dimension of the slit). Also, most preferably, these embodiments are also made of stretchable paper.

[0067] In some preferred embodiments, the slit pattern advantageously produces an expandable slit paper having a number of legs per square foot that is at least 20% greater than a slit paper having a slit (kerf) width of 0.50 inches.

[0068] In some preferred embodiments, the expanded slit paper cushioning product of the present invention has a number of legs per square foot that is at least 15% more than a slit paper having a slit (cut) width of 0.50 inches. In some preferred embodiments, the expanded slit paper cushioning product of the present invention has a number of legs per square foot that is at least in the range of 20% to 50% more than a slit paper having a slit (cut) width of 0.50 inches.

[0069] Utilizing the present invention, expanded slit sheets can be formed to have greatly improved cushioning properties. In some embodiments of the present invention, the improved cushioning properties can be achieved due to one or more or all of the following:

[0070] a) In a preferred embodiment, the use of stretchable paper allows for an "easier to open" structure which allows for the formation of smaller cells whereby these smaller cells advantageously result in the formation of increased cell density and hence improved cushioning properties.

[0071] b) In some preferred embodiments, the use of stretchable paper allows for the implementation of a novel "alternating row expansion pattern" that has substantially improved cushioning properties compared to existing expansion patterns (see discussion of novel alternating row expansion patterns below in this document).

[0072] Furthermore, utilizing the present invention, novel and previously unfeasible cushioning products may be formed, such as, for example:

[0073] a) In some preferred embodiments, novel enclosure structures can be realized that have great advantages over existing enclosure structures. For example, the present invention allows for substantially thinner cushioning extended slit sheets (e.g., with substantially smaller row spacing) and also provides for significant cushioning with a single layer or with only a few layers. Thus, enclosures with much narrower widths and even with only a single cushioning layer can be realized. In addition, the enclosure can be made of lighter weight paper, resulting in an easier to use product (e.g., lower rigidity) and a lighter product (e.g., reduced shipping costs). Notably, both the lighter product weight and the narrower product width advantageously result in reduced shipping costs.

[0074] b) In some preferred embodiments, novel cushioning wraps can be realized having significant advantages over existing cushioning wraps, such as, for example, increased cushioning properties, thereby allowing, for example, a reduction in the cushioning layers required in some applications, a reduction in the amount of cushioning required, and other advantages and benefits as described herein.

[0075] The stretchable paper used in the preferred embodiment

[0076] In some most preferred embodiments, a stretchable paper such as that described in the above-referenced U.S. Patent No. 10,669,086 is employed. To this end, the following paragraphs (in quotation marks) under this section are referenced from the '086 patent, which describes the details of the stretchable paper according to some preferred embodiments that can be used in preferred embodiments of the present invention.

[0077] "For purposes of the present invention, the term "stretchable" as applied to a paper sheet means a paper sheet that is capable of stretching in the longitudinal direction of the paper sheet when a force is applied in the longitudinal direction of the paper sheet. Exemplary stretchable sheets are disclosed in U.S. Patent No. 3,908,071, U.S. Patent Application No. 14 / 901,977 (U.S. Patent No. 9,945,077), International Application No. WO 1984002936, U.S. Publication Nos. 2002 / 0060034, 2007 / 0240841 (U.S. Patent No. 2003 / 0240842) and 2008 / 0340034 (U.S. Patent No. 2003 / 0240034). 7,918,966), and U.S. Patents Nos. 3,104,197, 3,220,116, 3,266,972, 3,269,393, 3,908,071, 6,024,832, 6,458,447, and 6,712,930, the entire disclosures of which are incorporated herein by reference as if fully set forth. It should be understood that the stretch of the stretchable paper must be measured on uncut paper sheets. As disclosed in U.S. Pat. No. 3,266,972, the test and characterization procedures for measuring the elongation (stretchability) property can be performed according to the standard TAPPI test elongation T457. In addition, as disclosed in U.S. Pat. No. 3,266,972, the expression "stretchable paper" means a paper having an increased elongation in the machine direction compared to a standard non-stretchable kraft paper.

[0078] "In some preferred embodiments, by substantially slowing down the paper feeding process during the drying process to capture additional fibers, a stretchable paper can be created by changing the accumulation of paper fibers so that the paper appears to have microscopically sized paper rows; if it is desired to pleat the paper, then the microscopically sized paper rows would be seen. The difference is that the microscopic rows of stretchable paper are adhered to each other by utilizing adhesives and other types of bonding agents and a drying process. Refer to U.S. Application No. 2007 / 0240841 (US 7,918,966), where the goal is to form a non-creased stretchable paper that does not easily disconnect itself. In addition, the surface of the stretchable paper remains relatively flat."

[0079] "In a preferred embodiment of the present invention, the stretchable paper employed has low stretch properties compared to other types of stretchable papers. In this regard, the optimal stretchable paper allows a smooth transition from an unexpanded to an expanded slit sheet by providing a small amount of stretch at the beginning of the initial expansion of the stretchable slit sheet paper material."

[0080] "In some exemplary constructions, during expansion of the slit sheet, the force required to initiate the expansion is substantially higher than the force required to continue the expansion. For example, once the paper initially begins to bend at the slit, the expansion is more easily continued during continued bending at the slit. The force required to continue the expansion of the slit sheet during such continued bending is significantly reduced beyond the initial expansion described above. In some preferred embodiments, the stretchable slit sheet paper substantially reduces the force required to initiate the expansion. On the other hand, in some preferred embodiments, the stretchable paper is substantially not stretched simultaneously with the process of expanding the slit sheet paper during the continued expansion described above; otherwise, the expanded sheet may not be optimally formed into a cushioning wrap."

[0081] “It should be noted that in this application, all theories related to the function of the present invention are provided to facilitate the understanding of the inventive concept and are not provided by way of limitation. As designed, the stretchable paper stretches as part of increasing the strength of the paper. In some embodiments, the function of the present invention involves that the stretchable slit sheet paper generally utilizes the stretchable property to facilitate the rotation of the unit into the stretched formation and to prevent the slit sheet from tearing during the expansion step. This means that at the initial point of the unit rotation (i.e., the initialization of the rotation between the legs 38a and 38b on each side of the slit and joint 20), the stretchable slit sheet paper is generally strengthened by the stretching ability of the stretchable paper. Therefore, in some embodiments, the function of the present invention involves that generally at this initial point of rotation, the stretchable slit sheet paper is generally strengthened by the stretching ability of the stretchable paper. The properties of the stretchable paper are utilized at this point and are substantially complete when the unit begins to rotate into its three-dimensional shape (i.e., after this initial point, the reliance on the stretchability of the paper may be small or even non-existent). After this initial point, the slit pattern properties are more easily opened up to the extent that they form a hexagon, regardless of the paper type. Therefore, in some embodiments, the stretchable properties generally only come into play at the initial moment of expansion. In some other embodiments, although the stretchable characteristics of the paper are most greatly exerted at this initial rotation point, the stretchable characteristics of the paper may have some effect during further expansion of the paper, whereby the initial expansion point may be greatly facilitated by the stretchability and further expansion may also be facilitated at least to some extent by the stretchability."

[0082] "In some preferred embodiments, preferred extensible papers that may be employed include extensible papers where the purpose of the extensibility is to provide the type of stretch found for use with multi-wall bags for heavyweight items such as cement, seeds, etc. U.S. Patent Publication No. 2016 / 0355985 (U.S. Application No. 14 / 901,997) and U.S. Patents Nos. 3,104,197 and 3,266,972 teach the manufacture and properties of this form of extensible paper. Additional teachings may be found in RSSeth, "Understanding Sheet Extensibility," Pulp & Paper Canada T31, 106:2 (2005) No. III, pp. 33-40 (T31-T38). The disclosures of the foregoing patents, patent publications, and printed publications are incorporated herein by reference as if fully set forth."

[0083] "Prior art expanded slit sheets (see, e.g., U.S. Pat. Nos. 5,538,778, 5,667,871, 5,688,578, and 5,782,735) focus on paper strength to inhibit tearing during the expansion process, and kraft paper is satisfactory because the required strength is consistent with the thickness required to make a satisfactory wrapped product. The increased strength of the expandable sheet does not promote or increase the value / performance of the expansion of the slit sheet material. The inventors have now discovered that expandable slit sheet paper can be made by The use of an expandable sheet material provides a substantial improvement. In a preferred embodiment, such use of an expandable slit sheet paper advantageously provides a reduction in the force required to open the slit sheet and thus provides a faster and easier expansion process to the user of the expanding slit sheet. The unexpected benefit, due to the reduced force at the initial start of expansion of the slit sheet, provides an unexpected improvement to the slit sheet packaging product and makes the use of expandable paper quite unique. It is noteworthy that existing expanded slit sheet papers have remained in the market and widely used for decades without regard to the present invention or its potential advantages".

[0084] “As described herein, the inventors have discovered that the force required to expand an expandable slit sheet paper is much greater than the force required to expand an expandable slit sheet paper. By way of example, a 50 lb. Kraft paper expandable slit sheet (which is 15" wide prior to expansion) requires greater than 4 to 6 pounds or 0.4 pounds per inch, whereas the force required to expand an expandable slit sheet of the sample paper weight is 0.15 to 0.22 pounds per inch. This is a significant difference between the papers. Kraft paper has the strength to provide an acceptable expandable slit sheet. However, unexpectedly, the expandable slit sheet imparts an ease of expansion that greatly reduces the force required to expand the slit sheet, not based on the primary purpose of increasing the tensile strength of the expandable paper, but rather based on its ability to stretch. Because stretchable paper is more costly, and kraft paper is sufficiently strong, it was previously unknown that stretchable paper could benefit from making slit paper sheets of the type seen in U.S. Patent Nos. 5,538,778, 5,667,871, 5,688,578, and 5,782,735, and U.S. Non-Provisional Application No. 15 / 428,144. For example, it was not understood that stretchable slit sheets could provide equivalent strength to lightweight thin papers, which were previously unsuitable for use as wrapping products. Lightweight kraft paper tears more easily than heavier kraft paper. It has now been discovered that stretchable paper allows the use of lighter expanded slit sheet paper; the lighter expanded slit sheet paper also advantageously provides the gentler cushioning needed for fragile items when the slit sheet is expanded, compared to the more rigid cushioning provided by the heavier expanded slit sheet paper."

[0085] "Specific reference is made to the graph of Table 1 on page 5 of U.S. Patent Publication No. 2016 / 0355985 (now U.S. Patent No. 9,945,077) (as if fully recited), which describes the strength of paper based on certain manufacturing techniques. Within the graph is a column describing the elongation at the point of paper break (or fiber tear), which column is divided into two sub-columns in the machine direction (MD) and cross direction (CD) (also referred to as the cross direction). The elongation percentages of Table 1 range from 5.3% to 7.1% in the cross direction (CD) and range from 3.3% to 10.6% in the machine direction (MD)."

[0086] "Referring also to Table III of column 5 of US Patent 3,266,972, Table III indicates that the elongation percentages range from 3.7% to 4.6% in the CD (or cross direction) and from 9.7% to 11.1% in the machine direction."

[0087] "In both the '985 and '972, the changes are based on the manufacturing process, which emphasizes tensile strength and stretch in the cross or machine direction, respectively."

[0088] "The inventors have discovered that for the purposes of expanding stretchable slit sheet paper for use as a packaging wrap and / or void filler, a longitudinal stretch range of 1% to 9% provides sufficient stretchability, with 1% to 6% being preferred and 1% to 5% being most preferred. The lower the stretchability, the lower the cost per square foot of the paper. As indicated above, it should be understood that the stretchability is measured on unslit paper."

[0089] In some alternative embodiments, the longitudinal stretchability range of the stretchable slit sheet paper may have the following range:

[0090] a) 1.5% to 9%, or more preferably 1.5% to 6%, or even more preferably 1.5% to 4%; or

[0091] b) 2% to 9%, or more preferably 2% to 6%, or even more preferably 2% to 4%; or

[0092] c) 3% to 9%, or more preferably 3% to 6%, or even more preferably 3% to 4%.

[0093] "For the purpose of expanding slit sheet paper for use as a packaging wrap and / or void filler, it has been found that a cross-direction stretchability range of 1% to 5% provides sufficient stretchability, preferably 1% to 4% and most preferably 1% to 3%."

[0094] "In some alternative embodiments, the cross-directional extensibility range of the extensible slit sheet paper may have the following range: a) 1.5% to 5%, or more preferably 1.5% to 4%, or even more preferably 1.5% to 3%; or b) 2% to 5%, or more preferably 2% to 4%, or even more preferably 2% to 3%."

[0095] "In conjunction with the stretchable paper, a smaller, lighter and recyclable version of the expander can be used (such as, for example, in some exemplary embodiments, made entirely or substantially entirely of recyclable paperboard). This expands the market to customers who use very little of the wrapping material (compared to the industrial market). It also provides a less expensive expansion device for expanding the slit paper. In addition, it enhances the ease of use for the packager by providing less tearing during the wrapping process (such tearing occurs when the tension is properly set). This is the case because the roll of paper will become smaller and lighter as it continues to be used. As rolls of slit sheeting become lighter, the required tension increases. Thus, there is a need for a different tensioning method. With stretchable paper, the required tension is significantly reduced, and the strength of the paper is increased. Both benefit human wrappers by making the required tensioning far less precise to the extent that a single tension setting can be used with little or no adjustments. The increased strength of the stretchable paper keeps the product from tearing if the tension setting is higher than required, and makes it easier for the packager to use. Thus, as rolls of slit sheeting become smaller, the packager can make fewer adjustments."

[0096] "The reduction in force required to expand the slit paper allows new products to be created utilizing lighter papers. Previously, expanded slit sheet paper was primarily used as a wrapping product, however its use as a void filler would be in limited circumstances as void fillers are generally the cheapest, i.e., lowest cost of all packaging products. The increased strength of the stretchable sheet allows thinner and lighter sheet papers to be used as void filler products. If the expanded slit sheet is not used as a wrapper, then the thicker 0.005" 50 lb per 3000 square feet and above papers are not needed and the lightweight 0.003 to 0.0045" thick 30 to 40 lb per 3000 square feet papers can be used as void fillers. It can also be used to provide cushioning that other paper void filler products do not yet provide. It has been found that even though the stretchable paper has a 10% higher price, the use of the thinner paper provides far more square feet per ton and more than offsets the increased cost of the stretchable paper compared to kraft paper."

[0097] "The detailed description of the technology used in the present invention is incorporated herein by reference"

[0098] "The following is a citation from the Clupak Paper Patent (U.S. Patent No. 9,945,077):"

[0099] “Example 1:

[0100] With 84.9g / m 2The basis weight heavy Clupak paper was made using a gap forming paper machine equipped with a Clupak system at a papermaking speed of 480 m / min and using as material 100% unbleached softwood kraft pulp that had been beaten at a high consistency of 28%. The negative stretch on the Clupak was set to -4.5%.

[0101] “Example 2:

[0102] Heavy Clupak paper was made in the same manner as in Example 1, except that the paper had a 76.1 g / m 2 of basis weight, and the negative stretch on the Clupak was set to -6.0%".

[0103] “Example 3:

[0104] Heavy Clupak paper was made in the same manner as in Example 1, except that the paper had a 73.4 g / m 2 of basis weight, and the negative stretch on the Clupak was set to -4.0%".

[0105] “Example 4:

[0106] Heavy Clupak paper was prepared in the same manner as in Example 1, except that the paper had a 85.0 g / m 2 and the negative stretch on the Clupak is set to -4.0%, and the pulp blend includes 90% unbleached softwood kraft pulp and 10% unbleached hardwood kraft pulp."

[0107] "Comparative Example 1:

[0108] Heavy Clupak paper was made in the same manner as in Example 1, except that the paper had a 71.9 g / m 2 of basis weight, and the negative stretch on the Clupak was set to -10.0%".

[0109] "Comparative Example 2:

[0110] Heavy Clupak paper was made in the same manner as in Example 1, except that the paper had a 85.4 g / m 2 of basis weight, and the negative stretch on the Clupak was set to -1.0%".

[0111] "Comparative Example 3:

[0112] Heavy kraft paper was prepared in the same manner as in Example 1, except that the paper had a 76.0 g / m 2of basis weight, and the Clupak process was not performed".

[0113] Table 1

[0114]

[0115] “Evaluation Methodology:

[0116] (Measurement of tensile energy absorption index)

[0117] Measured by the method specified in JIS P8113:2006.

[0118] (Measurement of elongation at break)

[0119] Measured by the method specified in JIS P8113:2006.

[0120] (Measurement of tear index)

[0121] Measured by the method specified in JIS P8116:2000.

[0122] (Measurement of rupture index)

[0123] Measured by the method specified in JIS P8112:2008.

[0124] (Measurement of tensile stiffness index)

[0125] Measured by the method specified in ISO / DIS 1924-3.

[0126] (Measurement of degrees of freedom after disintegration)

[0127] Measured by the method specified in JIS P8220:1998 and JIS P8121:1995".

[0128] “Looking at the properties of the Clupak paper in Examples 1 to 4 and Comparative Examples 1 and 2, as well as the properties of the kraft paper in Comparative Example 3 (as shown in Table 1), the Clupak paper described in Examples 1 to 4 exhibits a good balance of various strengths and elongations and has overall excellent strength; on the other hand, the Clupak paper described in Comparative Examples 1 and 2, as well as the kraft paper described in Comparative Example 3, exhibits a poor balance of various strengths and elongations and cannot be described as having overall excellent strength.”

[0129] “The following is from “Understanding sheet extensibility” by RSSeth (Pulp and Paper Research Institute of Canada 3800 Wesbrook Mall Vancouver, BC, Canada V6S 2L9) Pulp & Paper Canada T31, 106:2 (2005) No. III, pp. 33-40 (T31-T38):

[0130] Tensile strength and extensibility or stretchability are two important failure properties of paper. They are defined by the end points of the load-elongation curve of the sheet ( Figure 1 ). Both independently and collectively, they are important for many product performance properties. For example, the tensile energy absorption (TEA) of a sheet before failure is proportional to the area under the load elongation curve. It is therefore dependent on both the tensile strength and the stretchability of the sheet. High TEA is desirable in sack papers [1]. The bursting strength of paper has been shown to be proportional to the product of the square root of tensile strength and stretchability [2]. The fracture toughness of paper has been found to depend largely on the tensile strength and stretchability of the sheet [3,4]. Sheet stretchability is also considered important for paper runnability both at the dry end of a paper machine and in the press room [5-8]. Papers with high stretchability appear to have somewhat higher tear resistance [9] and folding resistance; they are more dimensionally unstable

[10] . The factors controlling sheet tensile strength are fairly well understood [4]. Tensile strength is high when the fibers are strong, long, thin, and thin-walled. The fibers should be conformable and should have high fiber-to-fiber bond strength. If the fibers are straight and undeformed and the sheet is well formed, the sheet tensile strength is also high. Otherwise, when the sheet is strained, the stresses are distributed unevenly, leading to premature failure."

[0131] "This report deals with the factors that control the stretchability of sheets".

[0132] “Factors controlling sheet stretchability:

[0133] The greater the extension of a specimen under tensile loading, the longer it is. Therefore, as a material property, the extensibility or stretch or strain at failure is expressed as a percentage of the original specimen length ( Figure 1 )”.

[0134] “The role of bonding:

[0135] Regardless of how the bonding between the fibers is increased (by wet pressing, pulping or refining or additives), the stretchability of the finished sheet generally increases with increasing fiber piece bonding. This is observed for almost all papermaking fibers, chemical fibers, mechanical fibers, wood fibers, non-wood fibers or recycled fibers. The reason is as follows. Fibers have a certain "stretching potential". However, this potential is realized in paper only when the fibers form a bonding network. If the bonding is weak, the network fails before the stretching potential is realized; the sheet stretchability is low. As the bonding of the network increases, the stretching potential of the fibers is increasingly realized and the sheet stretchability increases. Because increasing fiber piece bonding also increases sheet tensile strength, increases in stretchability and tensile strength are usually observed for hand sheets ( Figure 2 ). The stronger the sheet, the more the stretch potential of the fibers is utilized. Because of this relationship between tensile strength and stretchability, factors such as sheet weight or composition that tend to affect tensile strength also affect sheet stretchability

[11] . Comparison of hand sheets with stretch values ​​of similar tensile strength provides a meaningful comparison of the stretch potential of various finished products."

[0136] "The following is a reference to the patent for "Extensible Paper" by Trani et al. (U.S. Patent No. 7,918,966):"

[0137] "Stretchable paper is a known paper which, due to a special treatment during its production, exhibits considerable stretchability both in the longitudinal direction, i.e. in the direction of its advancement along the production line, and in the transverse direction, i.e. in a direction perpendicular to the aforementioned directions. This treatment essentially consists in passing a paper web, not yet formed and exhibiting a moisture content of 35% / 45%, between two rollers rotating at different speeds. One of these rollers, generally the lower roller, is made of rubber and rotates at a lower speed; while the upper roller is made of steel and comprises continuous spiral-shaped grooves on its cylindrical surface. The different material properties and the different speeds of the two rollers lead to a longitudinal accumulation of the paper forming material and prepare its longitudinal stretchability, the amount of which can reach 15% to 20%. At the same time, the spiral grooves perform two functions: on the one hand, they cause a transverse accumulation of the paper forming material to prepare its transverse stretchability. The amount of this transverse stretchability can reach 10% to 15%. On the other hand, the spiral grooves help maintain the advancement of the processed paper web in the longitudinal direction of the machine."

[0138] “The following is a reference to the “Extensible Paper Web” patent by Cabell et al. (U.S. Patent No. 6,458,447):”

[0139] “Tensile and Percent Stretch Tests:

[0140] Tensile tests are used to measure force versus percent elongation properties. These tests are performed on a Thwing Albert Intellect ll-STD Model No. 1451-24PGB, available from Thwing-Albert Co. of Philadelphia, Pa.

[0141] "The specimens used for this test are 1" wide by 6" long, with the long axis of the specimen cut parallel to the direction of maximum stretchability of the specimen. The specimens should be cut with a sharp Exacto knife or some suitably sharp cutting device designed to cut exactly 1" wide specimens. (If there is more than one direction of stretchability for the material, then the specimens should be taken parallel to the respective directions of elongation). The specimens should be cut so that the areas representing the symmetry of the overall pattern of the deformed regions are represented. There will be circumstances where it is necessary to cut a larger or smaller specimen than suggested herein (due to variations in the size of the deformed portions or the relative geometries of Regions 1 and 2). In such cases, it is very important to note (along with any data reported) the size of the specimen from which the area of ​​the deformed region was taken and preferably include a schematic diagram of the corresponding areas for that instance. Three specimens of a given material were tested."

[0142] "The following is a reference to Cramer et al.'s "Extensible Paper" patent (U.S. Patent No. 3,266,972):"

[0143] “Testing and Characterization Process:

[0144] The tests and characterization procedures used to measure the various properties reported herein are listed in Table I below. Unless otherwise indicated, the code alphanumerics indicate a standard TAPPI test."

[0145] "Elongation T457:

[0146] The expression "extensible paper" means a paper having an increased elongation in the machine direction (generally a minimum of about 6%).

[0147] In Runs IA and IB of this Example, rosin size (0.3 wt. % based on pulp weight) was added at the beater and the pH was adjusted to 4.5 with alum. The slurry having a consistency of 3.6% was dripped into the beater chest and then pumped to the second chest, passed through the Jordan, and continuously diluted with "white water" to a consistency of 0.3% at the Fourdrinier headbox. The properties measured on the various sheets are reported in Table III. Each sheet had a basis weight of 49.4 to 50.3 pounds per ream."

[0148] Table III

[0149]

[0150]

[0151] "The following is a reference to the patent for "Multilayer Paper Material" by Trani et al. (U.S. Patent No. 8,518,522):"

[0152] "These and other objects which will be apparent from the subsequent description are achieved according to the present invention by a multilayer paper material comprising at least one first three-dimensional structural sheet and at least one second sheet; the at least one first three-dimensional structural sheet exhibiting a relief of a maximum dimension which is less than the width of the original sheet, the relief being obtained by local stretching of the first sheet, the first sheet having an original extensibility of not less than 5% in all directions; the at least one second sheet being made of a paper material which is connected to the first structural sheet and which defines, together with its relief, a blank space."

[0153] “As can be seen from the figure, Figure 1 In the embodiment shown, the multilayer material of the invention consists of two layers of paper 2, 4 which exhibit stretchability properties of not less than 5% and preferably not less than 15% both in the longitudinal and transverse directions.

[0154] “The following is a reference to Trani et al.’s “Extensible Paper Material” application (U.S. Application No. 2007 / 0240841):”

[0155] "Stretchable paper is a known paper which, due to a special treatment during its production, exhibits a considerable stretchability both in the longitudinal direction, i.e. in the direction of its advancement along the production line, and in the transverse direction, i.e. in a direction perpendicular to the aforementioned directions. This treatment essentially consists in passing a paper web, not yet formed and exhibiting a moisture content of 35% / 45%, between two rollers rotating at different speeds. One of these rollers, generally the lower roller, is made of rubber and rotates at a lower speed; while the upper roller is made of steel and comprises continuous spiral-shaped grooves on its cylindrical surface. The different material properties and the different speeds of the two rollers lead to a longitudinal accumulation of the paper forming material and to the preparation of its longitudinal stretchability, the amount of which can reach 15% to 20%. At the same time, the spiral grooves perform two functions: on the one hand, they cause a transverse accumulation of the paper forming material to prepare its transverse stretchability, the amount of which can reach 10% to 15%. On the other hand, the spiral grooves contribute to maintaining the advancement of the processed paper web in the longitudinal direction of the machine".

[0156] Additional details regarding the stretchable paper that may be used in some preferred embodiments are also referenced below in the '086 patent.

[0157] “The following is a direct quote from column 1, lines 4 to 19 of U.S. Patent No. 3,908,071, previously incorporated by reference into this paragraph: “Stretchable (compacted) paper produced, for example, according to the apparatus and process disclosed in U.S. Patent No. 2,624,245 has certain recognized advantages and commercial uses. Such paper is subjected to compressive compaction in the direction of web travel (machine direction or MD) between pressure roll nips while partially wet, thereby compacting and forcing the fibers together to form an inherent stretchability without wrinkling. The compacted paper has improved tensile energy absorption (TEA) rupture and tear properties, which are highly desirable for such end uses as the manufacture of paper bags.” In addition, the following is a direct quote from the abstract of U.S. Patent No. 6,024,832, previously incorporated by reference into this paragraph: “A method for producing stretchable paper, the method comprising the following stages: feeding a mixture of plant fibers to a kneading machine member, mixing the mixture with water in the kneading machine, breaking the fibers to obtain a pulp, and mixing the broken pulp into a pulp. transferring to a flow chest, feeding the broken stock from the flow chest onto a paper web forming cloth, wherein the water percentage is subsequently reduced by gravity and vacuum, pressing the web, wherein its water content is subsequently further reduced, initially drying the paper web to a substantially constant moisture content between 15% and 65%, compacting, finally drying to a moisture content between 15% and 4%, preferably 10% to 8%, glazing; wherein: the breaking stage is performed by rubbing the fibers in a multi-stage device to obtain a breaking degree of at least 30 degrees. SR, the compaction stage is performed between at least one pair of rollers, one of which is a hard material including circumferential surface ribs and driven at a relatively high speed, and the other roller is a soft material having a smooth surface and driven at a relatively low speed". In addition, the following is a direct quote from the second paragraph of the Background Art section of U.S. Patent No. 9,945,077, previously incorporated herein by reference: "On the other hand, Clupak refers to an apparatus for inserting a paper web between a roll and an endless rubber felt to compress the paper web with a nip bar and the rubber felt, while the pre-stretched felt contracts to cause the paper web to contract. The web also contracts and thereby increases its elongation at break, and such apparatus is useful for providing increased elongation at break to kraft paper used in heavy packaging applications such as those described above." Additionally, the following is a direct quotation from the paragraph at column 2, lines 41 to 56 of U.S. Patent No. 3,104,197, previously incorporated herein by reference: "The use of rubber or rubber materials in conjunction with a hard surface in the manner described is known in the treatment of paper and fabrics, but only in a general manner, and the present invention includes the use of a considerably softer and more elastic rubber than has been used heretofore. Also of vital importance in the production of extensible paper by crimping it in this manner is the difference in speed of the driving rolls.If a suitable combination of hard and soft surfaces is provided, the semi-dry paper web passing through the nip of the rolls will be carried by the shrink rubber against the web travel direction towards the nip and beyond the surface of the hard roll. This forms uniform compression folds in the paper web, imparting toughness, flexibility and stretchability".

[0158] “The following are direct citations to paragraphs

[0003] and

[0028] of U.S. Patent Publication No. 2016 / 0355985, which was previously incorporated herein by reference: (1) “

[0003] On the other hand, Clupak refers to an apparatus for inserting a paper web between a roll and an endless rubber felt to compress the paper web with a nip rod and the rubber felt, while the pre-stretched felt contracts to cause the paper web to also contract and thereby increase its elongation at break, and such apparatus is used to provide increased elongation at break to kraft paper used in heavy-duty packaging applications such as those described above”; and “

[0028] A manufacturing method utilizing the Clupak system causes a paper web to be inserted between a roll and an endless rubber felt to compress the paper web with a nip rod and the rubber felt, while the pre-stretched felt contracts to cause the paper web to also contract and thereby increase its elongation at break.” The Clupak system allows the elongation at break of the kraft paper to be adjusted in the longitudinal direction, depending on the ratio of the production speed on the inlet side of the Clupak system and the production speed on the outlet side of the Clupak system and also on the pressure applied by the nip bar."

[0159] In some embodiments, the stretchable paper employed may involve one or more of the following features, as described in the '086 patent.

[0160] Example 1: A stretchable slit sheet paper cushioning product, comprising: a slit sheet paper roll, the slit sheet paper roll having a slit pattern, the slit pattern comprising a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of open cells when expanded in a longitudinal direction, the roll preventing the length of the slit sheet paper from being pulled along the longitudinal direction to allow the length of the slit sheet paper to be expanded in the longitudinal direction, the slit sheet paper being formed of paper, the paper being stretchable in the longitudinal direction and the transverse direction before providing the slit pattern, the stretchable range of the stretchable paper in the longitudinal direction before providing the slit pattern being 3% to 20%.

[0161] Example 2: The stretchable slit sheet paper cushioning product according to Example 1, wherein the stretchable range is not less than 5% in both the longitudinal direction and the transverse direction.

[0162] Example 3: The stretchable slit sheet paper cushioning product according to Example 1, wherein the stretchable range is 3% to 15% in the longitudinal direction.

[0163] Example 4: The expandable slit-sheet paper cushioning product of Example 1, wherein the slit-sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form the open cells.

[0164] Example 5: The expandable slit-sheet paper cushioning product of Example 2, wherein the slit-sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form the open cells.

[0165] Example 6: The expandable slit sheet paper cushioning product of Example 5, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0166] Example 7: The expandable slit sheet paper cushioning product of Example 1, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0167] Example 8: A transport package, comprising: a wrapped object, the wrapped object being included in at least two layers of an expanded slit sheet paper wrapper having interlocking hexagonal units, the slit sheet paper having a slit pattern and being expanded and wrapped by applying an expansion force to form the at least two layers of the expanded slit sheet paper wrapper having interlocking hexagonal units, the slit pattern comprising a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of hexagonal units when expanded in a longitudinal direction, the slit sheet paper being formed by paper, the paper being stretchable in the longitudinal direction and the transverse direction before providing the slit pattern, the stretchable range of the stretchable paper in the longitudinal direction before providing the slit pattern being 3% to 20%.

[0168] Example 9: The transport package of Example 8, wherein the stretchable range is not less than 5% in both the longitudinal direction and the transverse direction.

[0169] Example 10: The transport package of Example 8, wherein the stretchable range is 3% to 15% in the longitudinal direction.

[0170] Example 11: The shipping package of Example 8, wherein the slit sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form the hexagonal cells.

[0171] Example 12: The shipping package of Example 11, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0172] Example 13: The shipping package of Example 8, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0173] Example 14: A method for expanding and wrapping a slit sheet of paper, the slit sheet of paper forming two or more layers of interlocking hexagonal units when expanded and wrapped, the method comprising the following steps: providing the slit sheet of paper, the slit sheet of paper having a slit pattern, the slit pattern comprising a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of hexagonal units when expanded in a longitudinal direction, wherein the slit sheet of paper is formed by paper that is stretchable in the longitudinal and transverse directions before providing the slit pattern, the stretchable paper having a stretchability range of 3% to 20% in the longitudinal direction before providing the slit pattern, thereby expanding the slit sheet of paper and wrapping the expanded slit sheet of paper to form adjacent layers, the adjacent layers being in interlocking contact, whereby the expanded layers resist shrinkage and tearing.

[0174] Example 15: The method according to Example 14, wherein the stretchable range is not less than 5% in both the longitudinal direction and the transverse direction.

[0175] Example 16: The method according to Example 14, wherein the stretchable range is 3% to 15% in the longitudinal direction.

[0176] Example 17: The method of Example 14, wherein the expanding step includes applying an expansion force of 0.15 to 0.22 pounds per inch to form the hexagonal cells.

[0177] Example 18: The method of Example 17, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0178] Example 19: The method of Example 14, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0179] Example 20: A method according to Example 14, wherein the step of wrapping the slit sheet paper to form the adjacent layers includes: wrapping the expanded slit sheet paper around the object and forming the two or more layers of overlapping interlocking hexagonal units around the object, and the overlapping interlocking hexagonal units are in direct contact substantially across the width of the layers.

[0180] Example 21: The method according to Example 20, wherein the stretchable range is 3% to 15% in the longitudinal direction and not less than 5% in the transverse direction.

[0181] Example 22: The method according to Example 20, wherein the stretchable range is 3% to 9% in the longitudinal direction and not less than 5% in the transverse direction.

[0182] Example 23: The method of Example 20, wherein the expanding step includes applying an expansion force of 0.15 to 0.22 pounds per inch to form the hexagonal cells.

[0183] Example 24: The method of Example 21, wherein the expanding step includes applying an expansion force of 0.15 to 0.22 pounds per inch to form the hexagonal cells.

[0184] Example 25: A method for protecting a transported object by wrapping and cushioning the object in an expanded slit sheet material, the method comprising the following steps: a) providing a roll having a sheet of expandable sheet material wound around it, the expandable sheet material being a flexible nonwoven fiber material and having a plurality of parallel and spaced rows of independent slits extending in the transverse direction, the flexible nonwoven fiber material being paper, the paper being stretchable in the longitudinal and transverse directions before the slits are provided, the stretchable range of the stretchable paper in the longitudinal direction before the slits are provided being 3% to 20%; b) expanding the length of the expandable sheet material unrolled from the roll by applying an expansion force to form at least one expanded slit sheet material having an array of openings; c) wrapping the at least one expanded slit sheet material around an object; and d) placing the wrapped object in a package.

[0185] Example 26: The method according to Example 25, wherein the stretchable range is 3% to 15% in the longitudinal direction and not less than 5% in the transverse direction.

[0186] Example 27: The method according to Example 25, wherein the stretchable range is 3% to 9% in the longitudinal direction and not less than 5% in the transverse direction.

[0187] Example 28: The method of Example 25, wherein the step of expanding the length of the expandable sheet material comprises applying an expansion force of 0.15 to 0.22 pounds per inch.

[0188] Example 29: The method of Example 26, wherein the step of expanding the length of the expandable sheet material comprises applying an expansion force of 0.15 to 0.22 pounds per inch.

[0189] Example 30: The method of Example 25, wherein the slit expandable paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0190] Example 31: The method of Example 28, wherein the slit expandable paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0191] Example 32: The stretchable slit-sheet paper cushioning product of Example 1, wherein the stretchable range is 3% to 11.1% in the longitudinal direction.

[0192] Example 33: The transport package of Example 8, wherein the stretchable range in the longitudinal direction is 3% to 11.1%.

[0193] Example 34: The method according to Example 14, wherein the stretchable range is 3% to 11.1% in the longitudinal direction.

[0194] Example 35: The method according to Example 25, wherein the stretchable range is 3% to 11.1% in the longitudinal direction.

[0195] Example 36: The stretchable slit-sheet paper cushioning product of Example 1, wherein the stretchable range is 3.3% to 10.6% in the longitudinal direction.

[0196] Example 37: The shipping package of Example 8, wherein the stretchable range is 3.3% to 10.6% in the longitudinal direction.

[0197] Example 38: The method according to Example 14, wherein the stretchable range is 3.3% to 10.6% in the longitudinal direction.

[0198] Example 39: The method according to Example 25, wherein the stretchable range is 3.3% to 10.6% in the longitudinal direction.

[0199] Example 40: The stretchable slit-sheet paper cushioning product of Example 1, wherein the stretchable range is 9.7% to 11.1% in the longitudinal direction.

[0200] Example 41: The shipping package of Example 8, wherein the stretchable range in the longitudinal direction is 9.7% to 11.1%.

[0201] Example 42: The method of Example 14, wherein the stretchable range is 9.7% to 11.1% in the longitudinal direction.

[0202] Example 43: A method according to Example 25, wherein the stretchable range is 9.7% to 11.1% in the longitudinal direction.

[0203] Example 44: A stretchable slit sheet paper cushioning product according to Example 1, wherein the stretchable paper is formed by imparting a treatment before providing the slit pattern, including: inserting the paper between a roller and an endless pre-stretched felt to compress the paper with a roller gap rod and the felt (or otherwise compressing the paper between two different (e.g., different moving) surfaces, such as between two different rollers).

[0204] Example 45: A transport package according to Example 8, wherein the stretchable paper is formed by imparting a treatment prior to providing the slit pattern, comprising: inserting the paper between a roller and an endless pre-stretched felt to compress the paper with a roller gap rod and the felt (or otherwise compressing the paper between two different (e.g., different moving) surfaces, such as between two different rollers).

[0205] Example 46: A method according to Example 14, wherein the stretchable paper is formed by imparting a treatment prior to providing the slit pattern, comprising: inserting the paper between a roller and an endless pre-stretched felt to compress the paper with a roller gap rod and the felt (or otherwise compressing the paper between two different (e.g., different moving) surfaces, such as between two different rollers).

[0206] Example 47: A method according to Example 25, wherein the stretchable paper is formed by imparting a treatment prior to providing the slit, comprising: inserting the paper between a roller and an endless pre-stretched felt to compress the paper with a roller gap rod and the felt (or otherwise compressing the paper between two different (e.g., different moving) surfaces, such as between two different rollers).

[0207] Example 48: The method of Example 14, wherein the expanding step includes a user manually expanding the slit sheet material.

[0208] Example 49: The method of Example 48, wherein the user manually expanding the slit sheet material comprises the user manually grasping the slit sheet material and withdrawing and unrolling the slit sheet material from the roll against resistance of the roll.

[0209] Example 50: The method of Example 25, wherein the user manually extending the length of the expandable sheet material unrolled from the roll comprises: the user manually grasping the expandable sheet material and pulling and unrolling the expandable sheet material from the roll against the resistance of the roll.

[0210] Example 51: An expandable slit sheet paper cushioning product according to Example 1, wherein the expandable paper is a nonwoven fibrous material having fiber-to-fiber bonds that prevent tearing when there is 3% to 15% expansion in the longitudinal direction, as measured before providing the slit pattern.

[0211] Example 52: A shipping package according to Example 8, wherein the extensible paper is a nonwoven fibrous material having fiber-to-fiber bonds that resist tearing when there is 3% to 15% expansion in the machine direction, as measured before providing the slit pattern.

[0212] Example 53: A method according to Example 14, wherein the extensible paper is a nonwoven fibrous material having fiber-to-fiber bonds that resist tearing when there is 3% to 15% expansion in the machine direction, as measured before providing the slit pattern.

[0213] Example 54: The method of Example 25, wherein the nonwoven fibrous material includes inter-fiber bonds that resist tearing when there is 3% to 15% expansion in the machine direction, as measured prior to providing the slits.

[0214] Example 55: The expandable slit sheet paper cushioning product of claim 1, wherein the slit sheet paper roll is wound around a cylindrical core and the length of the slit sheet paper extends from the slit sheet paper roll.

[0215] Example 56: The stretchable slit-sheet paper cushioning product of Example 1, wherein the stretchable range is 5% to 15% in the cross direction.

[0216] Example 57: The stretchable slit-sheet paper cushioning product of Example 1, wherein the stretchable range is 7.1% to 15% in the cross direction.

[0217] Example 58: A stretchable slit sheet paper cushioning product, comprising: a certain length of slit sheet paper, the slit sheet paper having a slit pattern, the slit pattern comprising a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of open units when expanded in a longitudinal direction, the slit sheet paper being formed by paper, the paper being stretchable in the longitudinal and transverse directions before providing the slit pattern, the stretchable range of the stretchable paper in the longitudinal direction before providing the slit pattern being 3% to 20%.

[0218] Example 59: The expandable slit sheet paper cushioning product according to Example 58 further includes a stopper that prevents the length of the slit sheet paper from being pulled along the longitudinal direction to allow the length of the slit sheet paper to expand in the longitudinal direction.

[0219] Example 60: The expandable slit sheet paper cushioning product of claim 59, wherein the stopper is a slit sheet paper roll and the length of the slit sheet paper extends from the slit sheet paper roll.

[0220] Example 61: The stretchable slit-sheet paper cushioning product according to Example 58, wherein the stretchable range is not less than 5% in both the longitudinal direction and the transverse direction.

[0221] Example 62: The stretchable slit-sheet paper cushioning product of Example 58, wherein the stretchable range is 3% to 15% in the longitudinal direction.

[0222] Example 63: The expandable slit-sheet paper cushioning product of Example 58, wherein the slit-sheet paper is configured such that expansion is performed by applying an expansion force of 0.15 to 0.22 pounds per inch to form the open cells.

[0223] Example 64: The expandable slit sheet paper cushioning product of Example 58, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3,000 square feet prior to expansion.

[0224] Example 65: The expandable slit sheet paper cushioning product of Example 58, wherein the expandable sheet paper cushioning product is a shipping package.

[0225] Example 66: The expandable slit-sheet paper cushioning product of Example 65, wherein the slit-sheet paper is arranged to protect an object placed inside the shipping package.

[0226] Example 67: The expandable slit-sheet paper cushioning product of Example 66, wherein the slit-sheet paper is arranged to extend around the object placed inside the shipping package.

[0227] Example 68: A method of cushioning a product using the expandable slit sheet apparatus of Example 66, the method comprising transporting the shipping package and an object protected by the expandable paper inside the shipping package.

[0228] Example 69: The expandable slit-sheet paper cushioning product of Example 1, wherein the slit pattern is configured to form a plurality of hexagonal cells when expanded in the machine direction.

[0229] Example 70: A stretchable slit sheet paper cushioning product according to Example 69, wherein the hexagonal unit is a three-dimensional hexagonal unit having a generally rectangular joining portion and a leg portion, wherein the generally rectangular joining portion is positioned at a certain inclined angle to be transverse to the original plane of the slit sheet paper, and the leg portion connects the joining portion.

[0230] Example 71: The expandable slit-sheet paper cushioning product of Example 58, wherein the slit pattern is configured to form a plurality of hexagonal cells when expanded in the machine direction.

[0231] Example 72: A stretchable slit sheet paper cushioning product according to Example 71, wherein the hexagonal unit is a three-dimensional hexagonal unit having a generally rectangular joining portion and a leg portion, wherein the generally rectangular joining portion is positioned at a certain inclined angle to be transverse to the original plane of the slit sheet paper, and the leg connects the joining portion.

[0232] Encapsulated products in some preferred embodiments

[0233] According to some preferred embodiments of the present invention, the novel stretchable sheet paper cushioning products according to the preferred embodiments of the present invention can be used in the manufacture of envelopes. In some preferred embodiments, the envelopes can be of the type disclosed in applicant's co-pending U.S. application serial No. 16 / 531,017 ('017 application), which was filed on May 6, 2020 and also filed as PCT / US2019 / 045027 (published as WO2020 / 033275 on February 13, 2020), the entire disclosure of which is incorporated by reference as if fully set forth herein.

[0234] By way of illustration, FIG. 8(A) and FIG. 8(B) correspond to the '017 application, respectively. Figure 1 and Figure 7. As shown in this exemplary embodiment, the example uses an expanded slit sheet material and an outer layer of embossed paper to produce a padded envelope with cushioning properties. Although an embossed outer paper is shown, in some embodiments, the embossing can be eliminated.

[0235] As shown in Fig. 8(A), the present exemplary embodiment has a four-layer composite pad 100, including a first layer of embossed paper 104, two layers of expanded slit paper sheets 102, 103, and a fourth top layer of embossed paper 101. In the formation of the envelope, this composite material is folded and sealed along the edges to form an envelope pouch. In a preferred embodiment, this produces a paper pad that is fully recyclable and is made primarily of recycled paper. In order to form an envelope 600 from the pad shown in Fig. 8(A), first, the pad is folded to form a pouch area 704 as shown in Fig. 8(B), and the side 703 is flattened and glued. Then, as shown in Fig. 8(B), the double-sided tape 502 is attached to the lip portion together with the release liner 701, the release liner 701 is removed to expose the adhesive and the lip portion 702 is folded, and the lip portion 702 extends through the pouch 704 to adhere the lip portion 702 to the front of the pouch to close and seal the envelope.

[0236] Although the present example includes two inner extended slit paper sheets 102, 103, in some preferred embodiments employing the novel slit sheet paper of the present invention, a single layer of extended slit sheet paper may be employed. For example, in some embodiments of the present invention, layer 104 and layer 101 may be located on opposite sides of a single layer of extended slit sheet paper. Furthermore, as indicated above, although FIG. 8(A) shows layer 101 with embossing, in some embodiments, layer 101 may be free of embossing. Similarly, as indicated above, although FIG. 8(A) shows layer 104 with embossing, in some embodiments, layer 104 may be free of embossing. Furthermore, in some embodiments, both layer 101 and layer 104 may be free of embossing.

[0237] Embossed paper used in some preferred embodiments

[0238] According to some preferred embodiments of the present invention, novel stretchable sheet paper cushioning products according to preferred embodiments of the present invention can be used in the manufacture of products including embossed paper, such as, for example, envelopes or various other products. In some preferred embodiments, products using such embossed paper can be of the type disclosed in applicant's co-pending U.S. application Ser. No. 16 / 870,195 (filed May 8, 2020 and also filed as PCT / US2020 / 32146) and the above-mentioned and '017 applications, the entire disclosures of which are incorporated by reference as if fully set forth herein.

[0239] In preferred embodiments, the term "embossing" means raising and / or lowering a certain area of ​​a sheet of paper. Most preferably, embodiments relate to raised and / or lowered areas of a sheet of paper, which are raised and / or lowered by applying a force to compress the paper to assume an embossed shape, wherein the pressure causes a deformation of the sheet of paper to have a shape including such raised and / or lowered areas. In some preferred embodiments, the sheet of paper is initially generally planar and in the initial state there are no embossed raised and / or lowered areas, then the sheet of paper is pressed to cause a deformation of the sheet of paper including the raised and / or lowered areas. In the most preferred embodiments, these raised and / or lowered areas from the original plane of the originally planar sheet of paper become "embossed" areas or "embossings". By way of example, in a most preferred embodiment, the embossing is formed by pressing an initial sheet (e.g., a planar or substantially planar sheet) between opposing pressing surfaces, such as, for example, (1) between die plates that reciprocate relative to each other to press the surface of the planar sheet, wherein the die plates have a pattern of raised and lowered areas (e.g., convex and concave areas) that form a cross pressure on the surface of the planar sheet to cause the sheet to deform and form the embossing, and / or (2) between two rollers, wherein the rollers have a pattern of raised and lowered areas (e.g., convex and concave areas) that form a cross pressure on the surface of the planar sheet to cause the sheet to deform and form the embossing. In some embodiments, the embossing may involve pressure applied by a single reciprocating die plate having a raised / lowered embossing pattern that presses a first surface of the paper, while the opposite side of the paper is pressed or supported by a resilient (e.g., rubber) member that flexibly receives the raised and / or lowered portions to cooperatively cause the embossing of the paper sheet. Similarly, in some embodiments, embossing may involve pressure applied by a single roll die having a raised / lowered embossing pattern that presses against a first surface of the paper, while an opposing side of the paper is pressed or supported by an elastic (e.g., rubber) roll member or other surface member (such as a conveyor or other member) that flexibly receives the raised and / or lowered portions to cooperatively cause embossing of the paper sheet.

[0240] In some preferred embodiments, the embossing is formed in a repeating pattern along the conveyed paper sheet, which is conveyed from an initial roll. 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 in separate areas along the surface 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, as viewed downward toward the surface of the paper sheet. It should be noted that such embossing has different shapes as seen in the side view.

[0241] Novel extended pattern

[0242] For reference, FIG4(A) shows a top plan view of a sample expanded slit sheet paper in the form of kraft paper, which is opened in a manner generally similar to that shown in FIG3(B) discussed above. In particular, the paper includes (in an unexpanded state) an array of rows similar to that shown in FIG3(A), and when expanded, the paper exhibits an expansion pattern as shown in FIG4(A). As shown in FIG4(A), the expansion pattern includes a generally flat joint portion 20 and a formation of leg portions 21, the joint portions 20 being inclined at a certain angle and extending across the width of the expanded sheet, wherein each joint portion has four corresponding leg portions 21 extending therefrom.

[0243] Also for reference, FIG. 4(B) shows a top view of the same expanded slit sheet paper shown in FIG. 4(A), taken at an angle relative to the plane of the expanded paper, such as looking directly at the expanded unit of the paper (i.e., taken at an angle generally parallel to the angle of inclination of the engagement portion 20). As shown, at this angle, the expanded pattern forms a generally hexagonal unit. Also for reference, FIG. 4(C) shows a top view of the same expanded slit sheet paper shown in FIG. 4(A) and FIG. 4(B), but taken at an angle relative to the plane of the expanded paper, the plane being opposite to the plane of the angle shown in FIG. 4(B), such that the view of the unit opening is blocked by the wide sides of the engagement portion 20 and the leg portion 21.

[0244] For further reference, FIG. 4(D) shows Figure 4(A) to Figure 4(C)4(D) . This view helps to show how the joining portions 20 extend at a constant angle, with the left edge of each joining portion at the lowest position and the right edge of each joining portion at the highest position, so as to extend upward at an inclination from the left side to the right side of the joining portion, as shown in FIG4(D). As shown in FIG4(D), this expansion pattern forms an array of open cell openings 26, each open cell opening 26 having a high side HS at the left side of the open cell and a low side LS at the right side of the open cell, as shown in FIG4(D).

[0245] In some embodiments of the present invention employing novel slit patterns as described herein, a pattern similar to Figure 4(A) to Figure 4(D) For example, in some embodiments having a smaller slit length (such as, for example, some embodiments having examples A to I in Table A below), the slit sheet paper may be configured to present a similar Figure 4(A) to Figure 4(D) The expansion pattern shown is referred to herein as the "normal expansion pattern".

[0246] However, in some embodiments of the present invention, an expansion pattern similar to that shown in FIG. 5(A) may be employed. FIG. 5(A) shows a novel expansion pattern, referred to herein as an "alternating row expansion pattern," according to some preferred embodiments of the present invention. Although some preferred embodiments of the present invention will include such novel "alternating row expansion pattern," this type of expansion pattern need not be used in all embodiments of the present invention.

[0247] Furthermore, while an alternating row expansion pattern may be used in some preferred embodiments of the present invention (which include the novel reduced size slit patterns described herein), such alternating row expansion patterns provide new and advantageous inventive features that may be implemented in the context of any desired slit size pattern, such as, for example, slit size patterns having 0.5 inch slit lengths or even greater in some preferred embodiments.

[0248] It is noteworthy that this type of alternating row expansion pattern can be achieved by using a stretchable slit sheet paper of a stretchable paper having sufficient stretchability characteristics. To this end, the stretchability is preferably adjusted to have sufficient stretchability in both the longitudinal and transverse directions to achieve such alternating row expansion pattern. For example, using a slit sheet paper with a 0.5 inch slit length, a 0.1875 joint length (between slits in the same row) and a row spacing of 0.125 inches, this type of alternating row expansion pattern has been achieved by using a stretchable paper having a stretchability of both i) 8.8 in the longitudinal direction and ii) 8.8 in the transverse direction. In some instances, this expansion pattern can be achieved by using 30#, 40# and 50# stretchable paper sheets having such slit arrangements.

[0249] In some other embodiments, such alternating row expansion patterns may be advantageously achieved with such slit sheet papers having these 0.5 inch slit lengths, an extensibility of at least about 6% in both the machine and cross directions.

[0250] In some preferred embodiments, such alternating row expansion patterns may be achieved using a slit pattern of a stretchable paper having a stretch range of at least 5% in the longitudinal direction and at least 5% in the transverse direction, or in some more preferred embodiments, a stretch range of at least 6% in the longitudinal direction and at least 6% in the transverse direction, or in some more preferred embodiments, a stretch range of at least 7% in the longitudinal direction and at least 7% in the transverse direction, or in some more preferred embodiments, a stretch range of at least 8% in the longitudinal direction and at least 8% in the transverse direction.

[0251] Significantly, the inventors have discovered that this novel alternating row expansion pattern can be formed by implementing an expandable paper even with the same original slit pattern of an unexpanded sheet. In particular, even when the same slit pattern arrangement is provided on the unexpanded paper (including slit lengths, spacing between slits in the same slit row, and spacing between adjacent slit rows), the inventors have discovered that the expansion pattern can be adjusted to achieve an alternating row expansion pattern by, for example, modifying the paper to include an expandable paper.

[0252] As shown in Fig. 5(A), the alternating row extension pattern includes alternating rows (row Ra and row Rb) having bottom-side unit openings a26 and top-side unit openings b26. In particular, as shown, the unit openings a26 in row Ra are located on the bottom side of the extended paper sheet (i.e., from the perspective of Fig. 5(A), located at the opposite side or away from the side, or down to the page perspective), and the unit openings b26 in row Rb are located on the top side of the extended paper sheet (i.e., for the perspective of Fig. 5(A), located on the near side or close to the side).

[0253] As also shown in Fig. 5(A), the joining portion formed at the area between the ends of the slits in the same slit row is different from the joining portion 20 formed in the embodiment described in, for example, Fig. 4(A). It is worth noting that, unlike presenting an angle that extends constantly upward or downward (as in the joining portion of Fig. 4(A)), the joining portion of Fig. 5(A) includes an upward and downward facing portion. That is, each joining portion includes a portion extending upward, and a portion extending downward. In addition, each joining portion in Fig. 5(A) includes a fold or an oblique portion aligned between adjacent slits in the same slit row, and the inclination angle between the two portions of the joining portion changes around the fold or the oblique portion. For example, as shown in Fig. 5(A), the joining portion in row Ra includes a first portion 20a1 and a second portion 20a2, the first portion 20a1 extending upward from the edge of the open cell a26 at the left side of the joining portion to the fold or the oblique portion at the center of the joining portion, and the second portion 20a2 extending downward from the fold or the oblique portion at the center of the joining portion to the edge of the open cell a26 at the right side of the joining portion. As shown in Figure 5(A), all of the joints within row Ra include a similar up-and-down configuration as shown, wherein a fold or angled portion at the center of the joint forms an apex or ridge of the joint, which is at the highest point of the joint in a direction toward the top side of the extended paper sheet (i.e., closest to the side for the viewing angle of Figure 5(A)).

[0254] Similarly, as also shown in FIG. 5(A), all joining portions within row Rb include a relatively "bottom-up" configuration as shown, wherein a crease or oblique portion at the center of the joining portion forms a bottom ridge of the joining portion, which is at the lowest point of the joining portion in a direction toward the bottom side of the extended paper sheet (i.e., furthest from the side for the viewing angle of FIG. 5(A)). In particular, as shown in FIG. 5(A), the joining portion in row Rb includes a first portion 20b1 extending downward from the edge of the open cell b26 at the left side of the joining portion to the crease or oblique portion at the center of the joining portion, and a second portion 20b2 extending upward from the crease or oblique portion at the center of the joining portion to the edge of the open cell b26 at the right side of the joining portion. As shown in FIG. 5(A), all joining portions within row Rb include a similar bottom-up configuration as shown.

[0255] In addition, in the expansion pattern of Figure 4 (A), the leg portion extending from the first side of the joint portion extends in different directions. In particular, the leg portion includes a first leg and a second leg; the first leg extends from the top edge of the joint portion, and the joint portion extends upward toward the side close to the extended paper (for example, in the direction toward the left top of Figure 4 (A)); the second leg extends from the top edge of the joint portion, and the joint portion extends downward toward the side far away from the extended paper (for example, in the direction toward the right top of Figure 4 (A)). In addition, the leg portion also includes a third leg and a fourth leg; the third leg extends from the bottom edge of the joint portion, and the joint portion extends upward toward the side close to the extended paper (for example, in the direction toward the left bottom of Figure 4 (A)); the fourth leg extends from the bottom edge of the joint portion, and the joint portion extends downward toward the side far away from the extended paper (for example, in the direction toward the lower right of Figure 4 (A)).

[0256] However, compared to the embodiment shown in Fig. 4(A), in the alternating row expansion pattern shown in Fig. 5(A), the leg portion extending from the first side of the joint portion extends in a similar direction. In particular, the leg portion extends in a manner to form alternating rows Ra and rows Rb, wherein these alternating rows Ra and rows Rb are located at opposite sides of the expanded slit sheet in the width direction of the sheet, that is, wherein the row Ra is at the far side of the expanded slit sheet in the width direction as viewed in Fig. 5(A), and wherein the row Rb is at the near side of the expanded slit sheet in the width direction of the sheet.

[0257] In particular, as shown in Figure 5(A), the legs include: a) a first leg 21a, which extends downward from the top edge of the joining portion 20b2 to the joining portion 20a1; b) a second leg 20b, which extends downward from the top edge of the joining portion 20b1 to the joining portion 20a2; c) a third leg 21c, which extends downward from the bottom edge of the joining portion 20b2 to another joining portion 20a1; and d) a fourth leg 20d, which extends downward from the bottom edge of the joining portion 20b1 to another joining portion 20a2.

[0258] The inventors have also discovered that this alternating row expansion pattern has a number of substantial advantages and benefits over the expansion pattern shown in FIG. 4(A). First, the alternating row expansion pattern has significant aesthetic benefits and is more aesthetically appealing and interesting. Second, the alternating row expansion pattern forms an expansion pattern that is more visually obstructed at a variety of angles. Third, the alternating row expansion pattern forms an expansion pattern with improved cushioning and handling characteristics.

[0259] Although the open cells 26 of the example shown in FIG. 4 (A) form these cells with a high side HS near the side of the extended paper and a low side LS far from the side of the extended paper (as shown in FIG. 4 (A)); However, the open cells a26 and b26 shown in FIG. 5 (A) form these cells with two sides of similar height (that is, a high side, such as, for example, cell b26, or a low side, such as, for example, cell a26). In addition, therefore, the force applied to the periphery of the open cells a26 and b26 is generally more evenly applied to the opposite sides of the open cells, rather than being applied to a single side of the open cell 26 shown in FIG. 4 (A).

[0260] Also as a reference, Figure 6(A) to Figure 6(C) An explanatory diagram showing the formation of an alternating row extended pattern is provided in accordance with a preferred embodiment of the present invention. First, FIG. 6(A) shows an exemplary slit pattern formed in a sheet of paper. In some embodiments, the slit pattern is generally similar to that shown in FIG. 3(A) discussed above. However, as discussed below, in a most preferred embodiment of the present invention, the slit pattern has novel and advantageous slits and slit pattern dimensions and relationships, as further discussed below.

[0261] As shown in FIG. 6(A), the slits include multiple rows of slits extending generally horizontally across the paper of the accompanying drawing view. Although only seven slits S are shown (for illustrative purposes), it should be understood that the product will include multiple rows of slits extending completely across the paper sheet. As shown, the slits preferably have a common slit length SL (i.e., all slits preferably have equal slit lengths), a common slit spacing SS between the ends of the slits in the same slit row (i.e., all slit spacings are preferably of equal length), and a common row spacing RS between adjacent slit rows (i.e., all spacings between rows are preferably of equal distance). In addition, as also shown, the degree of overlap between the slits in adjacent rows preferably includes spacings OL1 and OL2 of equal size (i.e., the slits in adjacent rows are preferably symmetrically aligned so as to form a symmetrical unit when expanded).

[0262] FIG6(B) shows the slit pattern of FIG6(A) with the paper area prior to expansion highlighted for reference. To this end, areas A1, A2, B1, B2, C1, C2, D1 and D2 are shaded in the figure for ease of reference. However, it should be understood that in the expanded state shown in FIG6(B), these areas are flat or planar areas along the plane of the original unexpanded paper sheet.

[0263] As shown in Fig. 6(C), when expanded, the regional slit S is caused to open and form open units a26 and b26. In addition, as shown in Fig. 6(C), the region A1 presents the orientation of the leg 21a discussed above, the region A2 presents the orientation of the leg 21b discussed above, the region B1 presents the orientation of the leg 21c discussed above, the region B2 presents the orientation of the leg 21d discussed above, the region C1 presents the orientation of the joint portion 20a1 discussed above, the region C2 presents the orientation of the joint portion 20a2 discussed above, the region D1 presents the orientation of the joint portion 20b2 discussed above, and the region D2 presents the orientation of the joint portion 20b1 discussed above.

[0264] In an embodiment employing an alternating row expansion pattern, such as that shown in FIG. 5(A), the open cells a26 and b26 form a hexagonal perimeter that "bends" at a central region, thereby not forming a regular hexagon (i.e., conforming to both equilateral and equiangular characteristics), but instead forming a hexagonal shape in which the relative joining portions 20b2 and 20b1 are closer to each other. In contrast, as best shown in, for example, FIG. 4(B), the prior expansion pattern results in a generally regular hexagon. Notably, the hexagonal open cells a26 and b26 include a first half and a second half, the first half extending generally along a first plane having edges along one of the joining portions and both the leg portions, and the second half extending generally along a second plane having edges along the other of the joining portions and both the leg portions. For example, the open unit b26 includes a first half along a first plane and a second half along a second plane, the first plane being defined by the edge of the leg 21c, the edge of the engaging portion 20b2 and the edge of the leg 21a, and the second plane being defined by the edge of the leg 21d, the edge of the engaging portion 20b1 and the edge of the leg 21b. In the present application, such a hexagon that is bent between two planes is referred to as a "bent hexagon". Referring to Figures 5(A) and 6(C), the bent hexagon of unit b26 is formed to open upward (i.e., so that the angle between the two planes opens upward), while the bent hexagon of unit a26 is formed to open downward (i.e., so that the angle between the two planes opens downward and opens relative to the angle of the bent hexagon of unit b26).

[0265] Further Discussion of Preferred Embodiments

[0266] Figure 1 For an explanatory plan view showing two slit patterns and the resulting number of units per square foot. Figure 1An explanatory plan view of a layout between an embodiment of the present application having a standard 0.5" wide cut 100 (i.e., a standard expandable slit sheet having 0.5" long slits) and an embodiment of the present application having a 0.45" wide cut 101 (i.e., an expandable slit sheet according to some embodiments of the present invention having 0.45" long slits). In this exemplary view, square lines 102 and 103 are outlines of an exemplary 12"×12" box, showing 1 square foot of expanded slit sheet material. As shown by this exemplary explanatory view, the reduction in slit length from 0.5" to 0.045" increases the number of legs in the 0.45" slit length example 101 by 23.7%.

[0267] Figure 2 As an explanatory side view, a cell structure of an extended slit sheet material of the background art 204 and two different cell structures 205 and 206 according to some embodiments of the present invention are shown, with different cell sizes 205 and 206 resulting in different heights of the extended slit sheet material. Reference lines 200, 201 and 203 show the different heights of the cell structures, with line 207 being the baseline. In this exemplary explanatory figure, the extended slit sheet 204 has a standard 0.5" slit, and the novel extended slit sheet 205 according to the first embodiment is 10% smaller than 204, and the extended slit sheet 206 is also 10% smaller than 204.

[0268] In order to expand the expandable slit sheet paper, an expansion force is required to pull the paper to cause the paper to expand and open the unit. Existing expandable slit sheet paper can be difficult to expand to a certain extent and requires significantly greater force for expansion. In addition, existing expandable slit sheet paper requires a larger slit length to allow the opening of the unit. Different slit patterns with expandable slit sheet materials require different forces for stretching. For a 15-inch wide slit material using 50# kraft paper, the current slit patterns used in the market require a pulling force of about 6 pounds. However, the inventors have found that the expandable paper reduces the force required for the same slit pattern and paper weight to, for example, 2 pounds.

[0269] The inventors have also found that this reduction allows for other slit pattern opportunities; these opportunities provide greater elasticity and reduced thickness where previously they were difficult to stretch manually and burdened automated expansion equipment. In general, the inventors have found that reducing the gap, joint and row size by 10% increases the number of supporting legs by 23.7% and more than doubles the strength of the material. This provides a cushioning solution where greater elasticity can be achieved with the same or smaller leg height.

[0270] Additionally and as is well known in the paper die cutting art, leg height affects stiffness. As leg height decreases, the legs become more rigid. This is due to fiber length, which becomes more difficult to bend or flex as the height becomes shorter. According to a preferred embodiment of the present invention, leg height, number of legs per square foot, and paper weight are balanced to provide optimal cushioning while requiring only the least amount of pulling strength to open.

[0271] Automated equipment is also affected by heavy pull strengths because it requires more maintenance replacement of hook rollers (since they wear in proportion to the pull force required). With the inventors' discovery of the unique and unexpected advantages of expandable paper used in expandable slit sheet products, these limitations based on pull force have been greatly reduced and there is a greater market opportunity for applications where greater strength is required.

[0272] Currently, there is a move towards environmentally friendly packaging products which include the use of unpowered devices, thereby eliminating the need for electricity.

[0273] A manual system is used to dispense rolls of expanded slit material that may have different cushioning properties and provide greater flexibility for wrapping more fragile items of varying weights and densities. As an example, with prior art slit sheet materials, the number of wraps on a wine bottle is too much for the cost advantage over foam. However, with the inventor's embodiments of expandable wraps having a greater number of legs per square foot (e.g., according to embodiments of the present invention), fewer wraps will be required to achieve the same level of cushioning. Thus, a very significant benefit and improvement is achieved.

[0274] In some exemplary applications, the preferred embodiments of the present invention can be used to form significantly improved novel and advantageous packaging. To this end, in some embodiments, utilizing aspects of the present invention, padded packaging (e.g., pouches or bags) are formed with reduced thickness, increased elasticity, and improved compression resistance, as well as increased storage and shipping efficiency while increasing elasticity, while utilizing the reduced stretching force required due to the novel use of stretchable paper and maintaining the same production speed and less downtime.

[0275] Currently, the compressive strength of current commercial patterns utilizing a 0.5" slit is 2.2 pounds per square inch of strength.

[0276] According to some preferred embodiments of the present invention, a preferred reduced slit pattern using 50# Kraft paper is provided, which has a slit pattern of 0.45" slits (i.e., slit length), 0.1688" joints (i.e., the distance between adjacent slits in the longitudinal direction of the slits), and 0.1125" row width (i.e., the distance between adjacent slit rows). In some embodiments, such a configuration produces a compressive strength of 2.72 to 2.92 pounds per inch, which produces a 27% increase in strength and a 10% reduction in thickness from 0.1875" to 0.16875". In the most preferred embodiment of this slit pattern, the paper used is a stretchable paper.

[0277] According to some other embodiments of the present invention, another preferred slit pattern is 0.40" slit, 0.15" joint, 0.1125" row width. In some embodiments, this latter configuration produces a compressive strength of 3.1 to 3.3 pounds per inch, which produces a 40% increase in compressive strength and a 10% reduction in thickness from 0.1875" to 0.16875". In the most preferred embodiment of this slit pattern, the paper used is a stretchable paper.

[0278] According to a preferred embodiment, this increase in strength can be advantageously used to allow for a reduced thickness of the expansion slit sheet paper, which can thus provide, for example, equivalent compressive strength while providing a reduction in overall height. For example, in the above exemplary embodiment using 50# paper, the use of 40# paper will reduce leg stiffness, but will reduce the cost of the paper.

[0279] According to some other preferred embodiments, the expandable slit paper sheet comprises a slit pattern having a slit length in the range of 0.30 inches to 0.45 inches and a space between multiple rows of slits in the range of 0.1125 to 0.1688. In the most preferred embodiment of this slit pattern, the paper used is an expandable paper.

[0280] According to some other preferred embodiments, the expandable slit paper sheet includes a slit pattern having a slit length in the range of 0.45 inches + 5% (e.g., 0.4725 inches) to 0.45 inches - 33% (e.g., 0.30 inches). In the most preferred embodiment of this slit pattern, the paper used is an expandable paper.

[0281] According to some other preferred embodiments, the expandable slit paper sheet includes a slit pattern that, when expanded, produces an expandable slit paper having a number of legs per square foot that is at least 20% greater than a slit paper sheet having a slit length of 0.5 feet, the slit paper sheet being configured to form hexagonal cells (e.g., having equilateral hexagons).

[0282] According to some other preferred embodiments, the expandable slit paper sheet includes a slit pattern that, when expanded, produces an expandable slit paper having a number of legs per square foot; the number is at least 15% more than a slit paper sheet having a slit length of 0.5 feet, the slit paper sheet being configured to form hexagonal cells (e.g., having equilateral hexagons), and more preferably, 20% to 50% more than such slit paper having a slit length of 0.5 feet, the slit paper configuration forming hexagonal cells (e.g., having equilateral hexagons).

[0283] In the most preferred embodiment, the paper employed is an expandable paper as described above. The use of such expandable paper highly advantageously allows for a reduction in the size of the slit pattern compared to existing slit patterns. It is worth noting that non-expandable paper has limitations with respect to the feasible size and dimensions of the slits, and such non-expandable paper does not allow for a reduction in size to the dimensions of the preferred embodiments described herein, because such existing paper would be inoperable and would not expand sufficiently in the event of an attempt to employ such small dimensions.

[0284] Furthermore, while the inventors have discovered novel means for improving the cushioning properties of an expandable slit sheet device, which novel means involve "reducing" the slit pattern size, it should be noted that such a reduction in the slit pattern size is "not only" not feasible with existing expandable slit sheet paper (i.e., it is not possible to achieve such small sizes), but is also "counter-intuitive" to the existing understanding of the cushioning properties provided by such expandable slit sheet paper. Notably, the cushioning of an expandable slit sheet paper is directly associated with the "width" of the expandable slit sheet paper in the expanded state. Therefore, to enhance cushioning, those in the art have attempted to actually "increase" such width of the expanded slit sheet paper. However, the inventors have discovered means by which smaller slit patterns can be achieved (e.g., via the use of stretchable paper), and such smaller slit patterns with such stretchable paper can ultimately provide enhanced cushioning despite the loss of cushioning due to the reduced "width" of the expandable slit sheet paper. Furthermore, the inventors have also discovered other desired applications and uses of such novel expandable slit sheet paper.

[0285] Notably, non-expandable expanded slit paper sheets do not operate adequately with slit lengths less than about 0.5 inches. Therefore, for expandable slit paper sheets of smaller slit sizes according to the present invention, expandable paper according to the present invention is advantageously employed.

[0286] According to some more preferred embodiments of the present invention, a slit pattern is provided, which includes a slit length of 0.35" slits (i.e., the length of the slits), a 0.13125" joint (i.e., the distance between adjacent slits in the same slit row in the longitudinal direction of the slits), and a 0.0875" row width (i.e., the distance between adjacent slit rows). In this regard, such slit patterns are preferably implemented in a slit pattern similar to, for example, that shown in Figure 6(A), wherein all slits of an expandable slit sheet have the same length, the distance between adjacent rows is constantly the same, wherein the distance between slits in the same row is constantly the same, and wherein the slit positions in adjacent rows are arranged with equal overlap to form a symmetrical unit. For these embodiments, preferably, an expandable slit sheet paper is employed; it is noted that non-expandable paper cannot be used to operatively function with such slit patterns.

[0287] Although, preferably all extended slit sheet papers will include the same slit pattern throughout the sheet, in some embodiments, such a pattern may be used within a portion or region of the paper, and / or some regions of the paper may potentially include some differences in pattern. In addition, although the slit lengths and sizes are preferably constant as indicated above, in some embodiments, there may be some variation in the size and location of the slits, as long as the operation of the product is not impeded.

[0288] In some embodiments, a slit pattern with 0.35" slits, 0.13125" seams, and 0.0875" row width can produce a compressive strength of 3.52 to 3.82 pounds per inch, which yields a 60% increase in compressive strength and a 30% reduction in thickness from 0.1875" to 0.1125".

[0289] In some preferred implementations of all the embodiments of the present invention described above, the distance of the joint (i.e., the distance SS shown in FIG. 6(A) between the slits) is approximately 1 / 3 of the length of the slit (i.e., the distance SL shown in FIG. 6(A)). When the distance SS is approximately 1 / 3 of the length of the slit, the lengths of the peripheral sides of the formed unit openings a26 and b26 are equal. However, in some preferred embodiments, the distance of the joint (i.e., SS) is preferably slightly greater than 1 / 3 of the length of the slit. For example, in the last embodiment above using a 0.35" slit length and a 0.13125" joint length, the ratio is approximately 0.375. Therefore, in this example, the length of the joint is approximately 12.5% ​​longer than 1 / 3 of the length of the slit.

[0290] In some preferred embodiments, the length of the junction will be about 25% longer or shorter than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the junction will be about 20% longer or shorter than 1 / 3 of the length of the slit. In some preferred embodiments, the length of the junction will be about 15% longer or shorter than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the junction will be about 10% longer or shorter than 1 / 3 of the length of the slit.

[0291] In some other preferred embodiments, the length of the joint will be between about 1 / 3 of the length of the slit to 25% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint will be between about 1 / 3 of the length of the slit to 20% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint will be between about 1 / 3 of the length of the slit to 15% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint will be between about 1 / 3 of the length of the slit to 10% greater than 1 / 3 of the length of the slit.

[0292] In some other preferred embodiments, the length of the joint will be between about 5% greater than about 1 / 3 of the length of the slit and about 25% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint will be between about 10% greater than about 1 / 3 of the length of the slit and about 20% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint will be between about 10% greater than about 1 / 3 of the length of the slit and about 15% greater than 1 / 3 of the length of the slit. In some other preferred embodiments, the length of the joint is such that the slit length SL is approximately set relative to the slit spacing SS as follows: SL = 2.6667 x SS.

[0293] In some preferred embodiments, the dimensions of the expandable slit sheet paper are proportionally reduced from an expandable slit sheet paper having a 0.5" slit length, a 1 / 8" (0.125 inch) spacing between rows, and a spacing between slits within the same row (i.e., joint length) of 3 / 16" (0.1875 inch) as follows: a) the row spacing is proportionally reduced by the ratio (SL(new) / 0.5), and b) the slit spacing is set to SL(new) times 2.6667. For example, some preferred embodiments include the dimensions set forth in Table A below:

[0294] Slit length (SL) Slit spacing (SS) Line spacing (RS) Example A 0.45 inch 0.1687 inches 0.1125 inches Example B 0.425 in. 0.1594 inches 0.1063 inches Example C 0.40 inch 0.1500 inch 0.1000 inch Example D 0.375 in. 0.1406 inches 0.9375 inches Example E 0.35 inches 0.13125 inches 0.0875 inches Example F 0.325 inch 0.1219 inches 0.0813 inches Example G 0.30 inch 0.1125 inches 0.0750 in. Example H 0.275 in. 0.1031 inches 0.0688 inches Example I 0.25 inch 0.9375 inches 0.0625 inches

[0295] In some preferred embodiments, the corresponding row spacings of Example A to Example I in Table A above are substantially as shown in Table A. In some preferred embodiments, the row spacings of Example A to Example I may be substantially as shown in Table A plus or minus 20%, or more preferably, substantially as shown in Table A plus or minus 15%, or more preferably, substantially as shown in Table A plus or minus 10%, or more preferably, substantially as shown in Table A plus or minus 5%.

[0296] Furthermore, in some preferred embodiments, the corresponding row spacings of Examples A to I in Table A above are preferably within the same or lower range as the row spacings shown in Table A for the corresponding slit lengths; it is noted that the use of reduced slit lengths increases the difficulty of opening the unit, which increases as the row spacing increases. Thus, in some preferred embodiments, the row spacing is proportionally reduced to a certain extent as the slit length is reduced, and the degree of reduction is the same or greater than the proportional reduction in the slit length. It is noted that although the inventors have found that the slit length can be feasibly reduced by using stretchable paper as described herein, the inventors also note that in the case where the row spacing is proportionally too large, even in the case of using stretchable paper, the reduction in slit length will increase the difficulty of opening the unit.

[0297] Although the preceding Table A shows a row spacing that is generally reduced well below the 1 / 8" (0.125 inch) row spacing of the background art, in some alternative embodiments, the row spacing of various embodiments of the present invention (including, for example, the row spacing of Examples A through I in the preceding table) may still be larger. That is, while the present invention very advantageously allows such a reduction in row spacing due to the greatly improved cushioning properties that allow the row spacing to be reduced (e.g., because the reduction in cushioning from reducing the row spacing can be offset by the improved cushioning properties of the present invention), such a significant reduction is not necessarily required as long as the cell structure can be opened for expansion.

[0298] For example, in some alternative embodiments, any of the embodiments of the present invention (having a slit length in the range of 0.40 to 0.25) may employ a smaller row spacing than the prior art, such as, for example, less than 0.125 inches, or more preferably less than 0.12 inches, or more preferably less than 0.115 inches, or more preferably less than 0.1125 inches, or more preferably less than 0.0875 inches, or in some embodiments more preferably less than 0.08 inches.

[0299] In some other alternative embodiments, the various embodiments of the present invention shown in the above Table A can be modified so that:

[0300] a) the slit spacing (which is shown as an approximate value in Table A based on the formula SL=2.6667×SS) may be adjusted based on the formula SL=K×SS, where K is a value between 2.4 and 3.3, or more preferably, where K is a value between 2.5 and 3, or more preferably, where K is a value between 2.6 and 2.8; and / or

[0301] b) The row spacing (which is shown as an approximate value in Table A based on the row spacing proportionally reduced by the ratio SL(new) / 0.5 (such as based on the formula RS(new)=0.125 / 0.5×SL(new) or RS(new)=0.25×SL(new))) can be adjusted based on the formula RS(new)=Y×SL(new), where Y is a value between 0.2 and 0.4, or more preferably, where Y is a value between 0.22 and 0.3, or more preferably, where Y is a value between 0.23 and 0.27.

[0302] In all embodiments of the present invention, most preferably, the paper is a stretchable paper. In various embodiments, the stretchable paper is a stretchable paper according to any of the embodiments or examples of stretchable paper disclosed herein.

[0303] In various embodiments, the stretchable paper can employ stretchability according to any of the embodiments described herein, including, for example, any of Examples 1 to 72 described above. In addition, the stretchable paper can include features of any of the stretchable papers described herein, related to, for example, required opening force, paper weight or type, etc. However, as described herein, in embodiments for employing an alternating row expansion pattern, it should be noted that the stretchability is adapted to achieve an alternating row expansion pattern, as described herein.

[0304] In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 3% to 20% in the longitudinal direction is adopted. In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 3% to 20% in the transverse direction is adopted. In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 3% to 15% in the longitudinal direction is adopted. In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 3% to 15% in the transverse direction is adopted. In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 7% to 15% in the longitudinal direction is adopted. In some illustrative examples, in some embodiments, a stretchable paper having a stretchable range of 7% to 15% in the transverse direction is adopted. In some illustrative examples, the stretchable range is not less than 5% in both the longitudinal and transverse directions.

[0305] Furthermore, in some exemplary embodiments, the slit sheet is an expandable slit sheet configured such that expansion is performed by applying an expansion force of 0.15 pounds to 0.22 pounds per inch to form the open cells.

[0306] In addition, in some illustrative examples, the slit sheet paper is an expandable slit sheet, wherein the slit sheet paper has a weight of about 30 to 50 pounds per 3000 square feet before expansion. It is worth noting that all embodiments of the present invention described herein (e.g., various slit patterns, including slit lengths, slit spacing, line spacing, etc.) can be used in various embodiments of paper (wherein the weight is within the present range in some embodiments), such as, for example, for 30# paper, 40# paper, 50# paper, and any paper within the present range. In addition, in other embodiments, paper below the present range of 30# to 50# (such as, for example, 20# or lower) or greater than the present range (such as, for example, 60# or greater) can be used. However, in preferred embodiments, due to the enhanced cushioning properties achieved, paper with a lower weight can be used while obtaining the same or even greater cushioning properties compared to existing expandable slit sheet paper.

[0307] As indicated above, utilizing the present invention, an expanded slit sheet can be formed to have greatly improved cushioning properties. The improvement in cushioning properties can be achieved due to one or more or all of the following:

[0308] a) In a preferred embodiment, the use of stretchable paper allows for an "easier to open" structure which allows for the formation of smaller cells whereby these smaller cells advantageously result in the formation of increased cell density and hence improved cushioning properties.

[0309] b) In some preferred embodiments, the use of stretchable paper allows for the implementation of a novel "alternating row expansion pattern" having substantially improved cushioning properties compared to existing expansion patterns.

[0310] As indicated above, utilizing the present invention, novel and previously unfeasible cushioning products may be created, such as, for example:

[0311] a) In some preferred embodiments, novel enclosure structures can be realized that have great advantages over existing enclosure structures. For example, the present invention allows for substantially thinner cushioning extended slit sheets (e.g., with substantially smaller row spacing) and also provides for significant cushioning with a single layer or with only a few layers. Thus, enclosures with much narrower widths and even with only a single cushioning layer can be realized. In addition, the enclosure can be made of lighter weight paper, resulting in an easier to use product (e.g., lower rigidity) and a lighter product (e.g., reduced shipping costs). Notably, both lighter product weight and narrower product width advantageously result in reduced shipping costs.

[0312] b) In some preferred embodiments, novel cushioning wraps can be realized having significant advantages over existing cushioning wraps, such as, for example, increased cushioning properties, thereby allowing, for example, a reduction in the cushioning layers required in some applications, a reduction in the amount of cushioning required, and other advantages and benefits as described herein.

[0313] Broad Scope of the Invention

[0314] Although exemplary embodiments of the present invention have been described herein, the present invention is not limited to the various preferred embodiments described herein, but includes any and all embodiments with equivalent elements, modifications, omissions, combinations (e.g., combinations of aspects of the various embodiments), modifications and / or variations, as understood by those skilled in the art based on this disclosure. The limitations in the claims should be interpreted broadly according to the language used in the claims, and are not limited to the examples described in this specification or during the prosecution of the application, which examples should be understood to be non-exclusive. For example, in this disclosure, the term "preferably" is non-exclusive and means "preferably but not limited to". In this disclosure and during the prosecution of this application, an apparatus-plus-function or step-plus-function limitation will only be adopted in the following cases: for a particular claim limitation, all of the following conditions exist in the limitation: a) "apparatus" or "step" is explicitly stated; b) the corresponding function is explicitly stated; and c) no structure, material, or behavior supporting the structure is stated. In this disclosure and during the prosecution of this application, the term "present invention" or "invention" may be used as an index to one or more aspects within the present disclosure. The language of the present invention or invention should not be improperly interpreted as a critical identification, should not be improperly interpreted as applicable to all aspects or embodiments (that is, it should be understood that the present invention has multiple aspects and embodiments), and should not be improperly interpreted as limiting the scope of the present application or claims. In this disclosure and during the application of this application, the term "embodiment" can be used to describe any aspect, feature, process or step, any combination thereof, and / or any part thereof, etc. In some instances, various embodiments may include overlapping features. In this disclosure, the following abbreviated terms may be used: "such as" meaning "for example".

[0315] The use of independent numerical values ​​is expressed as approximate values, as if these values ​​are preceded by the words "about", "substantially" or "approximately". Similarly, unless otherwise explicitly indicated, the numerical values ​​of the various ranges specified in the present application are expressed as approximate values, as if the minimum and maximum values ​​within the range of the expression are preceded by the words "about", "substantially" or "approximately". In this way, changes above and below the expressed range can be used to achieve results that are substantially the same as the numerical values ​​within the range. As used herein, the terms "about", "substantially" and "approximately" should have their ordinary and general meanings for the fields most closely related to the subject matter of the present disclosure or related to the disputed scope or element when referring to numerical values. The amount of widening from strict numerical boundaries depends on many factors. For example, some factors that can be considered include the criticality of the element and / or the impact that a given variation will have on the execution of the required subject matter, 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 that the use of the words "about", "substantially" or "approximately" will be used to widen the manner in which a specific numerical value or range is widened. Therefore, as a general matter, "about", "substantially" or "approximately" widens the numerical value. In addition, the disclosure of ranges is intended as a continuous range that includes each value between the minimum and maximum values ​​plus a range widening provided by the use of the terms "about," "substantially," or "approximately." Therefore, the recitation of a range of values ​​herein is intended only to serve as a shorthand method of referring individually to each individual value falling within the range, unless otherwise indicated herein; and each individual value is incorporated into the specification as if it were individually recited herein. If determining a given amount of variation in some factor (such as the criticality of the slit pattern, the difference in paper width before and after expansion, paper weight and type, and other considerations known to a person of ordinary skill in the field most closely related to the subject matter of the present disclosure or related to the disputed scope or element that will be present for the execution of the claimed subject matter) is not considered to be within the capabilities of those skilled in the art, or is not expressly stated in the claims, then the terms "about," "substantially," and "approximately" should be understood to mean ±15% of the value.

[0316] It should be understood that any ranges, ratios, and ratio ranges that can be formed or derived from any data disclosed herein represent other embodiments of the present disclosure and are included as part of the present disclosure as if they were explicitly explained. This section includes a range that can be formed, which includes or does not include a limited upper and / or lower bound. Therefore, those of ordinary skill in the art who are most closely associated with a particular range, ratio, or ratio range will understand that such values ​​are unambiguously derivable from the data presented herein.

Claims

1. A slit sheet paper cushioning product comprising: a slit sheet of paper having a slit pattern including a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of open cells when expanded in a longitudinal direction, wherein the slit width is less than 0.35 inches in the transverse direction, and the slit sheet paper is formed of stretchable paper, the stretchable paper is made to be stretchable in the longitudinal direction and the transverse direction without the slit pattern, and the stretchable range of the stretchable paper in the longitudinal direction is at least 5%, wherein the slit sheet is in an expanded state, wherein the plurality of open cells form an alternating row expansion pattern, wherein the alternating row expansion pattern comprises alternating rows wherein bottom cell openings in a bottom row are located on a bottom side of the slit sheet in an expanded state and wherein top cell openings in a top row are located on a top side of the slit sheet in an expanded state.

2. The slit sheet paper cushioning product of claim 1, wherein the slit sheet paper includes spaces between rows of slits, the spaces being in the range of 0.1125 inches to 0.1688 inches.

3. The slit sheet paper cushioning product of claim 1 wherein the slit sheet paper comprises rows of slits with spaces between them less than 0.125 inches.

4. The slit sheet paper cushioning product of claim 1 wherein the slit sheet paper comprises rows of slits with spaces between them less than 0.1125 inches.

5. The slit sheet paper cushioning product of claim 1 wherein the slit sheet paper comprises rows of slits with spaces between them less than 0.0875 inches.

6. The slit sheet paper cushioning product of claim 1 wherein the slit width is less than 0.30 inches.

7. The slit sheet paper cushioning product according to claim 1, wherein the slit sheet paper is a roll type slit sheet paper.

8. The slit sheet paper cushioning product according to claim 7, wherein the rolled slit sheet paper is supported on an expander device, the expander device being adapted to rotatably support the rolled slit sheet paper for manual removal and expansion of the slit sheet paper from a rolled state.

9. The slit sheet paper cushioning product of claim 1, wherein the slit sheet paper is used within the wall of an enclosure for cushioning of the enclosure.

10. The slit sheet paper cushioning product of claim 9, wherein said enclosure comprises a single layer of said slit sheet paper within said wall of said enclosure for cushioning so as to reduce the thickness of said wall.

11. The slit sheet paper cushioning product of claim 9, wherein the wall of the enclosure comprises an outer paper layer on a first side of the slit sheet paper and an inner paper layer at a second side of the slit sheet paper.

12. The slit sheet paper cushioning product of claim 11 wherein the outer paper layer and the inner paper layer include embossing.

13. The slit sheet paper cushioning product of claim 1, wherein the slit sheet paper forms an alternating row expansion pattern that when expanded forms the plurality of open cells.

14. The slit sheet paper cushioning product of claim 1, wherein the product is an envelope, the envelope comprising: at least one of the slit sheets of paper in an expanded state; a first paper sheet facing a first surface of at least one of the slit sheets in the expanded state and secured relative to at least one of the slit sheets along at least a portion of a periphery of the at least one of the slit sheets in the expanded state; A second paper sheet faces an opposing surface of at least one of the slit sheet sheets in the expanded state and is secured relative to at least one of the slit sheet sheets along at least a portion of the periphery of at least one of the slit sheet sheets.

15. The slit sheet paper cushioning product of claim 14, wherein: a) at least one of the first paper sheet and the second paper sheet is an embossed sheet having a plurality of embossments, the plurality of embossments suppressing deformation of the first paper sheet and the second paper sheet due to contraction force of the at least one slit sheet in the expanded state; or b) The first paper sheet and the second paper sheet are non-embossed sheets, and the weight of the non-embossed sheets is greater than the weight of the at least one slit sheet in the expanded state, thereby suppressing deformation of the first paper sheet and the second paper sheet due to the contraction force of the slit sheet in the expanded state.

16. A method of utilizing the slit sheet paper cushioning product of claim 8, the method comprising manually wrapping the slit sheet paper in an expanded state around an article to form multiple layers of the slit sheet paper in an expanded state surrounding the article for cushioning.

17. A slit sheet paper cushioning product comprising: at least one slit sheet having a slit pattern including a plurality of slits extending in a transverse direction, the plurality of slits forming a plurality of open cells when expanded in a longitudinal direction, The slit sheet paper is formed by an expandable paper that expands into an alternating row expansion pattern, the alternating row expansion pattern comprising alternating rows, wherein the bottom unit openings in the bottom row are located on the bottom side of the slit sheet paper in the expanded state, and wherein the top unit openings in the top row are located on the top side of the slit sheet paper in the expanded state.

18. The slit sheet paper cushioning product of claim 17, wherein the slit sheet paper is made of stretchable paper.

19. The slit sheet paper cushioning product of claim 18, wherein the extensible paper has an extensibility range of at least 5% in the machine direction.

20. The slit sheet paper cushioning product of claim 18, wherein the extensible paper has an extensibility range of at least 5% in the cross-machine direction.

21. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of at least 5% in the machine direction and an expandable range of at least 5% in the cross direction.

22. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of at least 6% in the machine direction and at least 6% in the cross-machine direction.

23. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of at least 7% in the machine direction and at least 7% in the cross-machine direction.

24. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of at least 8% in the machine direction and an expandable range of at least 8% in the cross-machine direction.

25. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of 5% to 15% in the machine direction and an expandable range of 5% to 15% in the cross direction.

26. The slit sheet paper cushioning product of claim 18, wherein the expandable paper has an expandable range of 7% to 15% in the machine direction and an expandable range of 7% to 15% in the cross direction.

27. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width between 0.35 inches and 0.65 inches.

28. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width between 0.45 inches and 0.55 inches.

29. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width of 0.5 inches.

30. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width of less than 0.5 inches.

31. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width of less than 0.45 inches.

32. The slit sheet paper cushioning product of claim 17, wherein each slit of the plurality of slits has a width of less than 0.4 inches.

33. The slit sheet paper cushioning product according to claim 17, wherein a joining portion is formed as an upward and downward facing portion, the joining portion being formed in an area between ends of the slits in the same slit row.

34. A slit sheet paper cushioning product according to claim 33, wherein each joining portion comprises a crease or bevel portion aligned between adjacent slits in the same slit row, the angle of inclination between the two portions of the joining portion varying about the crease or bevel portion.

35. A slit sheet paper cushioning product according to claim 34, wherein the joining portion in the first type row includes a first portion and a second portion, wherein the first portion extends upward from the edge of the open unit at the left side of the joining portion to the fold or inclined portion at the center of the joining portion, and the second portion extends downward from the fold or inclined portion at the center of the joining portion to the edge of the open unit at the right side of the joining portion.

36. A slit sheet paper cushioning product according to claim 35, wherein the joining portion within the second type row includes a configuration opposite to the first type row and includes a first portion and a second portion, wherein the first portion extends downward from the edge of the open cell at the left side of the joining portion to the fold or inclined portion at the center of the joining portion, and the second portion extends upward from the fold or inclined portion at the center of the joining portion to the edge of the open cell at the right side of the joining portion, wherein the slit sheet paper cushioning product includes the first type rows and the second type rows alternating across the slit sheet paper in an expanded state.

37. The slit sheet paper cushioning product of claim 17, wherein the open cell has a hexagonal perimeter that is bent at a central region to form a hexagonal shape such that the first and second portions of the opposing engagement portions therein are closer to each other.

38. A slit sheet paper cushioning product according to claim 36, wherein the hexagonal open unit includes a first half and a second half, wherein the first half extends generally along a first plane, the first plane having edges along one of the joining portions and both of the leg portions, and the second half extends generally along a second plane, the second plane having edges along the other of the joining portions and both of the leg portions.

39. The slit sheet paper cushioning product of claim 17, wherein the open cells are formed in alternating rows, wherein a first of the alternating rows has a row of open cells formed to open upwardly and a second of the alternating rows has a row of open cells formed to open downwardly.

40. A method of making a slit sheet paper cushioning product according to claim 17, the method comprising providing the slit sheet paper as an expandable paper having an expandable range of at least 5% in the machine direction and at least 5% in the cross machine direction.

41. The method of making a slit sheet paper cushioning product of claim 40, further comprising providing the extensible paper having an extensibility of at least 6% in the machine direction and at least 6% in the cross machine direction.

42. The method of making a slit sheet paper cushioning product according to claim 40, further comprising providing said stretchable paper, said stretchable paper having a stretch range of at least 7% in the machine direction and at least 7% in the cross direction.

43. The method of making a slit sheet paper cushioning product according to claim 40, further comprising providing said extensible paper, said extensible paper having an extensibility range of at least 8% in the machine direction and at least 8% in the cross direction.

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