Packaging material and method of forming packaging material

Abstract

A packaging material and a cylindrical transport case. The packaging material may be a convertible packaging material including an outer wall section and an inner wall section. The outer wall section has an outer surface formed thereon, and the inner wall section is formed from a plurality of sections. The convertible packaging material is convertible between a flat state and a tubular state. The cylindrical transport case may include a peripheral wall, a top cover, and a bottom cover. The peripheral wall may be configured in a flat configuration and a tubular configuration. The packaging material and the peripheral wall may include a plurality of triangular cells.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit under 35 U.S.C. §119(e) of U.S. Provisional Patent Application No. 63 / 484,021, filed on February 9, 2023, entitled “PACKAGING MATERIAL AND METHOD OF FORMING APACKAGING MATERIAL,” the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present invention relates to packaging materials. In particular, the present invention relates to packaging materials, such as shipping containers, made from corrugated cardboard. Background Art

[0004] Products are shipped using packaging materials made from corrugated cardboard (corrugated paper). Many products require shipping boxes with greater strength (such as burst resistance) than those made from single-wall corrugated cardboard. Stronger shipping boxes can be created by laminating two or three layers of corrugated cardboard together to form double-walled or triple-walled shipping boxes, respectively. Summary of the Invention

[0005] In one aspect, the present invention relates to a packaging material comprising a plurality of triangular units. The plurality of triangular units may be formed from the same continuous sheet or a plurality of sheets, such as a first sheet and a second sheet.

[0006] In another aspect, the present invention relates to a removable flat cylindrical transport box comprising a peripheral wall, a top cover, and a bottom cover. The peripheral wall includes an outer surface and an inner surface. The peripheral wall can be configured in a flat configuration or a tubular configuration. When the peripheral wall is in the tubular configuration, the inner surface defines an inner cavity for placing items to be transported therein and forms a top opening and a bottom opening. The top cover can be attached to the peripheral wall below the tubular configuration to close the top opening, and the bottom cover can be attached to the peripheral wall below the tubular configuration to close the bottom opening.

[0007] In another aspect, the present invention relates to a convertible packaging material comprising an outer wall segment and an inner wall segment. The outer wall segment has an outer surface formed thereon, and the inner wall segment is formed from a plurality of segments. The packaging material is convertible between a flat state and a tubular state, and in the tubular state, the inner wall segment forms an inner surface defining an inner cavity.

[0008] These and other aspects of the invention will become apparent from the following disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] Figure 1 is a perspective view of a packaging material according to an embodiment of the present disclosure.

[0010] Figures 2A to 2D Shows the formation Figure 1 The process of packaging materials is shown. Figures 2A to 2D yes Figure 1 End view of the packaging material shown. Figure 2A The first step is shown, Figure 2B The second step is shown, Figure 2C The third step is shown, and Figure 2D The fourth step is shown.

[0011] Figure 3A 、 3B 3C show packaging material in a configuration for forming a cylindrical shipping box according to another embodiment. Figure 3A The packaging material is shown in a flat state, and Figure 3B The packaging material is shown in a bent state. Figure 3C Shown Figure 3A A variation of the packaging material shown in .

[0012] Figure 4 is Figure 3A and Figure 3B Exploded view of a cylindrical shipping box formed from packaging material shown.

[0013] Figures 5A to 5C It also shows the different states Figure 4 The cylindrical shipping box. Figure 5A The components of the transport box are shown in a flattened state. Figure 5B The cylindrical transport box is shown in an assembled state, with the top cover removed, ready for packaging items to be transported therein. Figure 5C The cylindrical transport box is shown in the assembled state with the top cover installed.

[0014] Figure 6A and Figure 6B Respectively by Figure 3A and Figure 3B Exploded view of another cylindrical shipping box formed from packaging material shown.

[0015] Figure 7A A comparative example of a rectangular shipping box for eight plates is shown. Figure 7B A cylindrical shipping box sized for eight trays of the embodiment discussed herein is shown.

[0016] Figure 8A and Figure 8B Shown being packed into a 40-foot shipping container Figure 7A Rectangular shipping box shown. Figure 8A is a top view of a shipping container, and Figure 8B is a side view of a shipping container.

[0017] Figure 9A and Figure 9B Shown being packed into a 40-foot shipping container Figure 7B Cylindrical shipping box shown. Figure 9A is a top view of a shipping container, and Figure 9B is a side view of a shipping container.

[0018] Figure 10A and Figure 10B Shown Figure 3A and Figure 3B Variations of packaging materials. Figure 10A The packaging material is shown in a flat state, and Figure 10B The packaging material is shown in a bent state.

[0019] Figure 11A and Figure 11B Another packaging material according to another embodiment is shown. Figure 11A is a perspective view of the packaging material, and Figure 11B is an end view of the packaging material.

[0020] Figure 12A and Figure 12B Packaging material is shown in a configuration for forming a cylindrical shipping box according to another embodiment. Figure 12A The packaging material is shown in a flat state, and Figure 12B The packaging material is shown in a bent state. DETAILED DESCRIPTION

[0021] As mentioned above, stronger shipping boxes can be created by laminating two or three layers of corrugated cardboard together to form double-walled or triple-walled shipping boxes, respectively. However, double-walled or triple-walled shipping boxes are relatively thick. Thicker material increases the cost of packaging, shipping, and storage. Therefore, a packaging material that achieves greater strength with less thickness is needed. Such a material could significantly reduce these costs. The packaging material discussed in this article can be used to create shipping boxes that are stronger than single-layer corrugated cardboard, yet thinner than double-walled or triple-walled shipping boxes.

[0022] Furthermore, shipping boxes formed from corrugated cardboard, particularly double- or triple-walled corrugated cardboard, are difficult to form into other shapes and are generally limited to rectangular shipping boxes. When round or cylindrical items are transported using such rectangular shipping boxes, the rectangular boxes create void space around the items being transported, increasing the cost of filler material. Furthermore, if these void spaces could be eliminated, more shipping boxes could be accommodated within a shipping container, significantly reducing these costs. The packaging material embodiments discussed herein can also be formed into cylindrical shipping boxes.

[0023] The embodiments of the packaging materials discussed herein can also be used to form shipping boxes. As used herein, a shipping box refers to a container used to transport (deliver) or otherwise package items. Such items may be referred to herein as items to be shipped. The term "shipping box" is not limited to square or rectangular shipping boxes; rather, as used herein, a shipping box can have other shapes, such as a cylindrical shape discussed below. The term "shipping box" is used to distinguish it from the term "shipping container" also used herein. The shipping container used herein generally refers to an intermodal freight container. Such intermodal freight containers (shipping containers) are truck-sized, reusable, typically steel (or other metal) containers used to transport goods by ship, train and truck.

[0024] Figure 1 A packaging material 100 of an embodiment is shown. The packaging material 100 may be formed from single wall corrugated cardboard 102. Corrugated cardboard is sometimes also referred to as corrugated paper. Although Figure 1 Although not explicitly depicted in the drawings, the single-wall corrugated paperboard 102 may include a top sheet, a bottom sheet, and a corrugated sheet sandwiched between the top sheet and the bottom sheet. The top sheet and the bottom sheet may be flat containerboard or paperboard materials formed from a cellulosic material (e.g., natural cellulose fibers). The corrugated sheet includes a plurality of flutes. Any suitable standard flute shape commonly used in the manufacture of cardboard shipping boxes may be used.

[0025] Figure 1The illustrated packaging material 100 includes a first surface and a second surface. For ease of reference herein, the first surface will be referred to as the top surface 104, and the second surface will be referred to as the bottom surface 106, although depending on the intended use, the surfaces may have different orientations, such as an exterior surface and an interior surface, as discussed further below. As will be discussed in greater detail below, the single-wall corrugated paperboard 102 is folded or otherwise formed to form a plurality of triangular cells, more specifically, a plurality of first triangular cells 110 and a plurality of second triangular cells 120. The first triangular cells 110 and the second triangular cells 120 are arranged in an alternating pattern, wherein each first triangular cell 110 is adjacent to, and more specifically, located between, two of the second triangular cells 120; and similarly, each second triangular cell 120 is adjacent to, and more specifically, located between, two of the first triangular cells 110, except for the end cells. However, the end cells are only adjacent to one cell. If one of the first triangular cells 110 is located on an end (end cell), the end cell of the first triangular cell 110 is adjacent to one of the second triangular cells 120, and similarly, if one of the second triangular cells 120 is located on an end (end cell), the end cell of the second triangular cell 120 is adjacent to one of the first triangular cells 110. Each of the plurality of triangular cells (i.e., first triangular cells 110 and second triangular cells 120) has a longitudinal axis that, in the depicted embodiment, extends in a direction parallel to the top surface 104, the bottom surface 106, or both.

[0026] Each of the first triangular units 110 includes a base portion, referred to herein as a first base portion 112. First base portion 112 is a portion of the single-wall corrugated paperboard 102, and a plurality of first base portions 112 collectively form a top wall. Top surface 104 is the exterior surface of the top wall. Similarly, each of the second triangular units 120 includes a base portion, referred to herein as a second base portion 122. Second base portion 122 is a portion of the single-wall corrugated paperboard 102, and a plurality of second base portions 122 collectively form a bottom wall. Bottom surface 106 is the exterior surface of the bottom wall. Thus, the first triangular units 110 and the second triangular units 120 are arranged in an interlocking pattern.

[0027] The packaging material 100 also includes a plurality of transverse walls 130. In this embodiment, the transverse walls 130 are portions of the single-wall corrugated cardboard 102 and extend transversely to the top surface 104 and the bottom surface 106. The packaging material 100, or at least a portion thereof, is formed from a continuous sheet (i.e., the single-wall corrugated cardboard 102 in this embodiment), and each transverse wall 130 connects one of the first base portions 112 with one of the second base portions 122, forming one side of one of the triangular cells. The transverse walls 130 separate a first triangular cell 110 from an adjacent second triangular cell 120. Two transverse walls 130 abut against each other at opposite sides of the base portions, forming the vertices of the triangular cells. More specifically, two transverse walls 130 may abut against each other at opposite sides of the first base portion 112 to form the first vertex 114 of one of the first triangular cells 110, and two transverse walls 130 may abut against each other at opposite sides of the second base portion 122 to form the second vertex 124 of one of the second triangular cells 120. The transverse wall 130 is attached to the ends of the first base portion 112 and the second base portion 122. In the depicted embodiment, each end of the first base portion 112 abuts the end of the adjacent first base portion 112 at the second vertex 124, and each end of the second base portion 122 abuts the end of the adjacent second base portion 122 at the first vertex 114. In some embodiments, the adhesive 144 ( Figure 2B ) may be located at each of the first apex 114 and each of the second apex 124. Any suitable adhesive 144 may be used, but in this embodiment and all embodiments discussed herein, the adhesive 144 is preferably a biodegradable adhesive.

[0028] The transverse walls 130 of the depicted embodiment have the same length, so the first triangular unit 110 and the second triangular unit 120 can be isosceles triangles or equilateral triangles. In some embodiments, the length of the first base portion 112 and / or the second base portion 122 is the same as the length of each of the transverse walls 130, but in other embodiments, the length of the first base portion 112 and / or the second base portion 122 is greater or less than the length of each of the transverse walls 130. Figure 1 In the embodiment, the first triangular unit 110 and the second triangular unit 120 are each an isosceles acute triangle, but other shapes, such as an obtuse triangle, may also be used, as discussed further below. The number, size, and density of the units can be varied depending on the desired overall compressive strength, bursting strength, and flexibility. The angles and lengths of the vertices of the first base portion 112, the second base portion 122, and the transverse wall 130 of the triangular units can be varied to adjust the properties of the packaging material 100. Thus, the packaging material 100 can have a total thickness t. In one example, the total thickness t is 5 mm.

[0029] Figures 2A to 2D A process for forming packaging material 100 is shown. Figure 2A The first step is shown. In the first step, the single-wall corrugated paperboard 102 is folded into flutes, forming a folded corrugated sheet 142, and more specifically, forming a first base portion 112, a second base portion 122, and a transverse wall 130. In this step, gaps (herein referred to as first side gaps) 116 may exist between adjacent first base portions 112, and gaps (herein referred to as second side gaps) 126 may exist between adjacent second base portions 122.

[0030] Figure 2B The second step is shown. In the second step, adhesive 144, if used, is applied to the end of the first base portion 112 and / or the end of the second base portion 122. In the depicted embodiment, adhesive 144 is applied to each end of the first base portion 112 and / or the second base portion 122.

[0031] Figure 2C A third step is shown. After or simultaneously with the application of adhesive 144, the folded corrugated fiber sheet 142 is clamped and formed into triangular units (e.g., first triangular unit 110 and second triangular unit 120). The first base portion 112 and the second base portion 122 are thereby positioned relative to each other to form the first triangular unit 110 and the second triangular unit 120 and the transverse wall 130. A clamping force is applied longitudinally to the folded corrugated fiber sheet 142 to close the first side gap 116 and the second side gap 126, thereby forming the first triangular unit 110 and the second triangular unit 120. In the depicted embodiment, the clamping force is applied to form a completely enclosed unit (e.g., first triangular unit 110 and second triangular unit 120). When the ends of adjacent first base portions 112 and adjacent second base portions 122, respectively, abut against each other, first apex 114 and second apex 124 are formed, and in the depicted embodiment, the adhesive 144 holds the first apex 114 and the second apex 124 in place. The third step forms the clamped corrugated cardboard sheet 146 , and in some embodiments, the clamped corrugated cardboard sheet 146 is the packaging material 100 after the adhesive 144 has dried.

[0032] Figure 2D A fourth step is shown, which is optional. One or more sheets may be applied to the clamped corrugated fiberboard 146. Figure 2DAs depicted, a top sheet 152 is applied to the top surface 104 and a bottom sheet 154 is applied to the bottom surface 106. The top sheet 152 and / or the bottom sheet 154 can be a cellulose sheet. In some embodiments, the cellulose sheet is a flexible cellulose sheet such as paper, but a harder cellulose sheet such as linerboard, fiberboard, or even a corrugated material such as single-wall corrugated cardboard can be used. The top sheet 152 and the bottom sheet 154 can be laminated to the top surface 104 and the bottom surface 106, respectively, using an adhesive.

[0033] Figure 3A and Figure 3B A cylindrical shipping box 200 ( Figure 4 ) of the peripheral wall 220 ( Figure 4 ) of the packaging material 212. The packaging material 212 is similar to the packaging material 100 discussed above. The same reference numerals will be used for the same and similar components and features, and a detailed description of these features will be omitted herein. The packaging material 212 can be configured in a flat configuration (e.g., Figure 3A as shown) and tubular configurations (as Figure 3B ). The packaging material 212 of this embodiment provides a "knock-down flat" ("kdf") shipping container (cylindrical shipping container 200), as will be discussed further below.

[0034] In this embodiment, the first surface is an outer surface 214 similar to the top surface 104 discussed above, and the second surface is an inner surface 216 similar to the bottom surface 106 discussed above. The plurality of first base portions 112 collectively form an outer wall (also referred to as an outer wall segment), and the plurality of second base portions 122 collectively form an inner wall (also referred to as an inner wall segment). The outer surface 214 is the outer surface of the outer wall, and the inner surface 216 is the outer surface of the inner wall. In the flat configuration, adjacent second base portions 122 are spaced apart from one another, and a second side gap 126 is maintained between adjacent second base portions 122. In the flat configuration, the second triangular units 120 are therefore spaced apart from one another, and the first triangular unit 110 is an open triangular unit opposite the first base portion 112 (i.e., at the first vertex 114). The second vertices 124 of the second triangular units 120 can be adhered to one another in the manner discussed above, such as by applying adhesive 144 at the second vertices 124, applying the top sheet 152 to the outer surface 214, or both. Although in Figure 3A and Figure 3B14. The top sheet 152 is depicted, but in this embodiment, the top sheet 152 is optional. To form this spaced-apart arrangement when flat, the first base portions 112 are longer than the corresponding second base portions 122 to which they are connected, and the first triangular unit 110 is not attached at the first vertex 114, such as without the adhesive 144 applied at the first vertex 114. Each of the first base portions 112 can be longer than each of the second base portions 122.

[0035] The packaging material 212 may be bent to form an arcuate shape, such as a tubular shape (see Figure 4 ),like Figure 3B As the packaging material 212 bends, the second base portions 122 close together, thereby reducing the distance (i.e., the size) of the second side gaps 126 between adjacent second base portions 122. More specifically, adjacent second base portions 122 can be closed to contact each other (i.e., the second base portions 122 abut each other), thereby closing the second side gaps 126 and forming a closed first vertex 114 of each of the first triangular units 110. Since the first vertex 114 is not attached as discussed above, the packaging material 212 can be closed at Figure 3B The arc (or tubular) configuration shown and Figure 3A Move back and forth between the flat configurations shown.

[0036] As described above, the number, size, and density of cells can be varied, and the angles of the vertices forming the triangular cells can be varied. Figure 3C A packaging material 213 is shown, which is Figure 3A A variation of packaging material 212 is shown. Figure 3C The packaging material 213 is shown in a flattened state. Figure 3C The packaging material 213 is depicted with Figure 3A The packaging material 212 shown is similar, but includes a first triangular unit 110 and a second triangular unit 120 having an obtuse triangle shape. More specifically, the angle between the transverse wall 130 at the first vertex 114 and the second vertex 124 is an obtuse angle, thereby forming an obtuse triangle, and more specifically an obtuse isosceles triangle in the depicted embodiment. When the transverse wall 130 is at this angle, the transverse wall 130 is at an obtuse angle. Figure 3A Compared to the packaging material 212 shown, the packaging material 213 may be less rigid and provide an enhanced cushioning effect. Figure 3C As depicted, the length of the base portion (ie, the first base portion 112 or the second base portion 122 ) may be longer than each of the transverse walls 130 .

[0037] Although shown and described as a convertible wrapper having gaps 126 that allow the wrapper 213 to be bent into a tubular shape or contoured into other suitable shapes, Figure 3C The obtuse triangle unit depicted in can be used with other embodiments discussed herein. For example, Figures 1 to 2D The packaging material 100 shown may include Figure 3C The depicted obtuse isosceles triangle unit, wherein the second base portions 122 abut each other. In another example, the first fins 412 and the second fins 422 discussed further below can be oriented to form the shapes depicted herein. As described above, the top sheet 152 can be optional.

[0038] Figure 4 2 is an exploded view of a cylindrical transport box 200. The cylindrical transport box 200 includes a peripheral wall 220 and, as described above, Figure 3A and Figure 3B The packaging material 212 shown can be used to form the peripheral wall 220. The packaging material 212 is configured from a flat Figure 3A ) bent to form a tubular shape ( Figure 3B ). The peripheral wall 220 includes an axial direction, and the longitudinal direction of the plurality of triangular cells (e.g., the first triangular cells 110 and the second triangular cells 120) of the packaging material 212 extends along the axial direction of the cylindrical shipping box 200. The packaging material 212 may include a first edge 222 and a second edge 224, and the packaging material 212 is bent so that the first edge 222 and the second edge 224 contact each other. The first edge 222 and the second edge 224 are held in place to maintain the packaging material 212 in a tubular configuration. An adhesive tape 218, such as an adhesive tape, may be used to secure the first edge 222 and the second edge 224 and maintain the packaging material 212 in a tubular shape.

[0039] The peripheral wall 220 includes an opening at each end, more specifically, a top opening 232 and a bottom opening 234. The cylindrical shipping box 200 includes a top cover 240 and a bottom cover 250 to respectively close the top opening 232 and the bottom opening 234. The inner surface 216 defines an inner cavity 226 having an inner diameter. Therefore, the top cover 240 and the bottom cover 250 are each preferably sized to be larger than the inner diameter. The top cover 240 and the bottom cover 250 can each be circular, with an overall diameter greater than the inner diameter of the inner cavity 226. The outer surface 214 can define the outer diameter of the peripheral wall 220, and the overall diameter can substantially correspond to the outer diameter of the peripheral wall 220.

[0040] The peripheral wall 220 includes a top end 236 and a bottom end 238. In the depicted embodiment, a top cover 240 is positioned adjacent the top end 236 of the peripheral wall 220, and a bottom cover 250 is positioned adjacent the bottom end 238 of the peripheral wall 220. More specifically, the top cover 240 includes an inwardly facing surface 242 adjacent the top end 236, and the bottom cover 250 includes an inwardly facing surface 252 adjacent the bottom end 238. The top cover 240 and the bottom cover 250 can be attached to the peripheral wall 220, such as by using one or more adhesive strips 218.

[0041] Each of the top cover 240 and the bottom cover 250 may be made of the same material as the peripheral wall 220, such as single-wall corrugated cardboard. Figure 4 As depicted, each of the top cover 240 and the bottom cover 250 is multi-layered. The top cover 240 includes an outer layer 244 and an inner layer 246. The overall dimensions of the top cover 240 discussed above apply to the outer layer 244, and the inner layer 246 is sized and shaped to be inserted into the inner cavity 226. Figure 4 As depicted, inner layer 246 is circular in shape, having a diameter that is less than the overall diameter of outer layer 244 and equal to or less than the inner diameter of lumen 226. Inner layer 246 can provide a bearing surface 248 against which inner surface 216 bears or presses when an inward force is applied to outer surface 214 of peripheral wall 220. Bearing surface 248 can be the outer peripheral surface of inner layer 246. Thus, inner layer 246 can provide structural support for peripheral wall 220 and help maintain the shape of peripheral wall 220. Inward-facing surface 242 is formed on outer layer 244, and inner layer 246 can be attached to inward-facing surface 242, such as by an adhesive.

[0042] The bottom cover 250 also includes an outer layer 254 and an inner layer 256 having a load-bearing surface 258. The outer layer 254 of the bottom cover 250 is similar to the outer layer 244 of the top cover 240, and the inner layer 256 of the bottom cover 250 is similar to the inner layer 246 of the top cover 240. The discussion of the features of the top cover 240 applies to the corresponding features of the bottom cover 250.

[0043] Figures 5A to 5C The process of forming a cylindrical shipping box 200 and packaging an item 10 to be shipped therein is shown. Figure 5A Components of a cylindrical shipping box 200 are shown including a peripheral wall 220 in a flat configuration. As described above, the packaging material 212 used to form the peripheral wall 220 provides a "knock-down flat" ("kdf") shipping box. As used herein, "knock-down flat" refers to a shipping box that can be assembled and disassembled into a flat state for storing or shipping only the packaging material (i.e., the packaging material 212, the top cover 240, and the bottom cover 250), without the items 10 to be shipped. The cylindrical shipping box 200 of this embodiment provides a cylindrical box that has all the advantages (e.g., strength) of the solid triangular structure of the packaging material 212. As Figure 5A As shown, when the KDF tube is in a flat state, the KDF tube can be transported and stored in a flat state, saving 80%-90% of the volume compared to conventional tubes.

[0044] To form the cylindrical shipping container 200, the packaging material 212 for the peripheral wall 220 is as described above with reference to Figure 3B The tube is bent in the manner discussed above to form a tube, more specifically a tubular peripheral wall 220. Figure 5A , the wrapping material 212 includes a tab 228, which may be a portion of the top sheet 152 that extends beyond the first edge 222 of the wrapping material 212. The peelable adhesive strip 209 is applied to the inner surface of the tab 228 and serves as the adhesive strip 218. The covering is removed from the peelable adhesive strip, and the inner surface of the tab 228 is attached to the outer surface 214, and more specifically to the top sheet 152 at the second edge 224. Figure 4 ). The bottom cover 250 is then attached to the peripheral wall 220 as discussed above.

[0045] Figure 5B The cylindrical shipping box 200 is shown in an assembled state (after completing the above steps) ready to be packed with the item 10 to be shipped. Figure 5B 2 (not shown) to provide access to the inner cavity 226. The object 10 to be transported is then placed into the inner cavity 226. As discussed further below, the tubular shape facilitates transporting round or cylindrical objects such as, for example, plates or bowls. Figure 5B A tray 12 is shown as the item 10 to be transported, and after forming the peripheral wall 220, and in some embodiments, after attaching the bottom cover 250 to the peripheral wall 220, the item 10 to be transported can be placed into the interior cavity 226. After all of the items 10 to be transported are placed in the interior cavity 226 along with any packaging material 14 (such as, for example, a corrugated sheet separating the trays 12), the top cover 240 can be attached. Figure 5C The cylindrical shipping case 200 is shown in an assembled state with the top cover 240 installed. After shipping, the process can be reversed and the cylindrical shipping case 200 can be "disassembled" to return the components, specifically the peripheral wall 220, to its flat configuration.

[0046] Figure 6A FIG is an exploded view of another cylindrical shipping case 202. The cylindrical shipping case 202 is similar to the cylindrical shipping case 200 discussed above. Figures 4 to 5C In the embodiment shown, an adhesive strip 218, such as a tape, is used to connect the first edge 222 and the second edge 224 of the packaging material 212 to form the tubular shape. However, the tubular shape can also be maintained by other means. Figure 6AAs shown, for example, a removable ring 260 may be used to maintain the tubular shape in addition to or in lieu of adhesive tape 218. Ring 260 may be annular with an opening sized to correspond to the outer diameter of peripheral wall 220. Figure 3A and Figure 3B The cylindrical shipping box 202 shown can be formed into a tubular shape, and then one or more rings 260 are slidably placed over the tubular shape to maintain the shape. Thus, the rings 260 circumscribe the peripheral wall 220 to maintain the peripheral wall 220 in a tubular shape. Figure 6A Two rings are shown, and the rings 260 are located at each end of the tubular shape (i.e., the peripheral wall 220), but they can also be located on other parts of the tube (i.e., the peripheral wall 220). These rings 260 can be a single corrugated layer formed into an annular ring 260, so that the rings 260 can be part of the kdf transport device discussed above. When the cylindrical shipping box 202 is used multiple times, the rings 260 can be particularly advantageous because the rings 260 can be easily removed without damaging the packaging, thereby converting the cylindrical shipping box 202 from its tubular configuration back to its flat configuration. In some embodiments, the rings 260 can be integrally formed with the top cover 240 and / or the bottom cover 250.

[0047] Figure 6B FIG is an exploded view of another cylindrical shipping case 204. The cylindrical shipping case 204 is similar to the cylindrical shipping cases 200, 202 discussed above. Figure 6A , the ring 260 is shown as being placed outside the peripheral wall 220. Additionally or alternatively, an inner ring 262 may also be located within the inner cavity 226 of the peripheral wall 220. Similar to the inner layer 246, the outer peripheral surface of the inner ring 262 forms a bearing surface 264, similar to the bearing surface 248 of the top cover 240 and the bottom cover 250 discussed above. In the assembled configuration, the bearing surface 264 abuts the inner surface 216 of the packaging material. Thus, the inner ring 262 can help maintain the shape of the tube (i.e., the peripheral wall 220) and provide configuration support to prevent the peripheral wall 220 from bending or collapsing. The inner ring 262 can be annular with a central opening 266 to allow the item 10 to be transported to be placed in the inner cavity 226.

[0048] As described above, the cylindrical shipping boxes 200 of the embodiments discussed herein can provide significant savings in shipping costs, such as shipping costs via shipping containers, because more cylindrical shipping boxes can fit into a shipping container than corresponding rectangular shipping boxes. Figure 7A Shown is a tray for eight plates 12 ( Figure 5B ) is a comparative example of a rectangular transport box 20. Figure 7B A cylindrical shipping box 206 sized to hold eight trays 12 (such as one of the cylindrical shipping boxes discussed above) is shown.

[0049] Figure 8A and Figure 8B The 40-foot shipping container 30 is shown. Figure 7A 2. Comparative Example (rectangular shipping box 20) in FIG. Figure 8A is a top view of the shipping container 30, and Figure 8B is a side view of the transport container 30. Figure 8A and Figure 8B The top and sides of the shipping container 30 are not shown separately to show the rectangular shipping boxes 20 stacked therein. Figure 8A and Figure 8B As shown, thirteen layers of boxes can be stacked in the shipping container, with 328 boxes per layer, for a total of 4,264 boxes, and eight pallets per box, for a total of 34,112 pallets.

[0050] Figure 9A and Figure 9B The 40-foot shipping container 30 is shown. Figure 7B A cylindrical transport box 206 is provided. Figure 9A is a top view of the shipping container 30, and Figure 9B is a side view of the transport container 30. Figure 9A and Figure 9B The top and sides of the shipping container 30 are not shown separately to show the cylindrical shipping boxes 206 stacked therein. Figure 9A and Figure 9B As shown, thirteen layers of boxes can be stacked in the shipping container, with 383 boxes per layer, for a total of 4,979 boxes, and eight plates per box, for a total of 39,832 plates. As can be seen from these examples, the cylindrical shipping boxes 206 of the embodiments discussed herein allow for the use of more shipping boxes, thereby allowing for the transport of more plates 12 in a 40-foot shipping container 30, compared to rectangular shipping boxes 20 sized to transport the same number of plates 12 per box.

[0051] Figure 10A and Figure 10B Another packaging material 300 is shown which may be used, for example, to form the cylindrical shipping box discussed above, such as Figures 4 to 5C A cylindrical shipping box 200 is shown. Figure 10A The packaging material 300 is shown in a flat configuration, and Figure 10B The packaging material 300 is shown in a tubular configuration. Figure 3A and Figure 3BThe present invention is a variation of the packaging material of the present invention and is similar to the packaging material 212 discussed above. In the embodiment discussed above, each of the second triangular units 120 has the same size. In this embodiment, the second triangular units 120 have a plurality of different sizes. For example, the transverse wall 130 may have different lengths for different second triangular units 120, and the second base portion 122 may have different lengths for different second triangular units 120. When the object 10 ( Figure 5B When the object 10 to be transported is placed in the cylindrical shipping box 200, a void space may exist between the object 10 to be transported and the inner surface 216 of the peripheral wall 220. In this case, a void-filling material may be added to secure the object 10 to be transported within the cylindrical shipping box 200. The use of void-filling may be particularly necessary when the object 10 to be transported has an irregular shape. Second triangular units 120 of various sizes may be arranged to secure the object 10 to be transported within the cylindrical shipping box 200, thereby eliminating or at least reducing the need for void-filling.

[0052] Figure 11A and Figure 11B Another packaging material 400 is shown according to another embodiment. Figure 11A is a perspective view of packaging material 400, and Figure 11B is an end view of the packaging material 400. The packaging material 400 of this embodiment is the same as that of the packaging material 400 described above. Figure 1 The packaging material 100 discussed is similar, but Figure 11A and Figure 11B The packaging material 400 is not made of a single sheet of single-wall corrugated cardboard, but is made of two sheets of single-wall corrugated cardboard to form a plurality of first triangular units 110 and a plurality of second triangular units 120. The packaging material 400 includes a first sheet 410 and a second sheet 420 positioned opposite to each other. The first sheet 410 (also referred to as the top sheet) is formed at Figure 11B The second sheet 420 (also referred to as the bottom sheet) is shown in solid lines. Figure 11B The first sheet 410 includes a first base portion 112 forming a first surface (eg, top surface 104), and the second sheet 420 includes a second base portion 122 forming a second surface (eg, bottom surface 106).

[0053] Each of the first sheet 410 and the second sheet 420 is a folded corrugated sheet and includes folded protrusions, which are wrinkles or areas where each sheet folds onto itself. These folded protrusions are referred to as fins in this article. The first sheet 410 includes a plurality of fins, which are referred to as first fins 412 in this article, and the second sheet 420 includes a plurality of fins, which are referred to as second fins 422 in this article. The first fins 412 are arranged parallel to each other, and the second fins 422 are also arranged parallel to each other. The first fins 412 are separated from each other by the first base portion 112, and the second fins 422 are separated from each other by the second base portion 122. The first fins 412 are connected to the ends of the adjacent first base portions 112 and, as described above, can be formed by folding the first sheet 410.

[0054] Thus, the first fin 412 may have a V-shape or a U-shape and include a first leg 414 extending from one of the first base portions 112 and a second leg 416 extending from the adjacent first base portion 112. The first leg 414 is connected to the second leg 416 at a peak 418. As will be discussed below, the first leg 414 and the second leg 416 collectively form the transverse wall 130 of one of the first triangular cells 110 and one of the second triangular cells 120. Thus, the peak 418 is the end of the transverse wall 130 that is distal from the base portion (more specifically, the first base portion 112). The end of each of the first leg 414 and the second leg 416 that connects to the first base portion 112 is the base end or proximal end. The first leg 414 and the second leg 416 may be continuously connected to each other at the peak 418 and may be a continuation of the same corrugated material at the peak 418 without being cut or separated.

[0055] Other portions of the first leg 414 and the second leg 416 (outside of the peak 418) may also be connected to each other. For example, an adhesive may be applied between the inner surface of the first leg 414 and the inner surface of the second leg 416. Although the adhesive may be applied to the entire length of the inner surface of the first leg 414 and / or the inner surface of the second leg 416, in this embodiment, the adhesive 144 is applied between adjacent first base portions 112 (for clarity, the adhesive is not shown in FIG. Figure 11B ). Thus, the first leg 414 and the second leg 416 are also connected to each other at the base end portion. Connecting the first leg 414 and the second leg 416 at the base end portion helps prevent the first sheet 410 from unfolding when a force is applied to the peak 418, for example, thereby providing rigidity to the first sheet 410 and providing a protective (cushioning) effect to the entire packaging material 400.

[0056] The foregoing discussion regarding the first fins 412 also applies to the second fins 422 , and each of the second fins 422 includes a first leg 424 , a second leg 426 , and a peak 428 , similar to the first leg 414 , the second leg 416 , and the peak 418 , respectively.

[0057] The first fins 412 protrude from the first base portion 112 on the same side of the first sheet 410, and similarly, the second fins 422 of the second sheet 420 protrude from the second base portion 122 on the same side of the second sheet 420. The first sheet 410 and the second sheet 420 are positioned opposite each other, with the first fins 412 protruding toward the second sheet 420 and the second fins 422 protruding toward the first sheet 410. The distal ends (i.e., peaks 418) of the first fins 412 can be positioned to contact the inner surface 429 of the second sheet 420, and similarly, the distal ends (i.e., peaks 428) of the second fins 422 can be positioned to contact the inner surface 419 of the first sheet 410. The inner surface 419 of the first sheet 410 can be the inner surface of each first base portion 112, and similarly, the inner surface 429 of the second sheet 420 can be the inner surface of each second base portion 122. At least one of the first fin 412 or the second fin 422 may be positioned at an oblique angle to the inner surface 419 or the inner surface 429, respectively, to form a plurality of triangular units (ie, the first triangular units 110 and the second triangular units 120) of the packaging material 400. Figure 11A and Figure 11B As depicted, the first fin 412 or the second fin 422 is positioned at an oblique angle to the inner surface 419 or the inner surface 429, respectively. More specifically, the peak 418 of the first fin 412 is positioned to form the first apex 114, such as at one end of the second base portion 122, and similarly, the peak 428 of the second fin 422 is positioned to form the second apex 124, such as at one end of the first base portion 112.

[0058] Adhesive 144 may be applied at the peaks 418 of the first fin 412 and the peaks 428 of the second fin 422 to attach the first sheet 410 to the second sheet 420. As described above, adhesive 144 may be applied at other locations. However, bonding using adhesive 144 may be applied selectively, and the first fin 412 and the second fin 422 may be bonded (e.g., glued) or non-bonded (e.g., non-glued) or a mixture of the two. For example, it may be desirable to leave air spaces between the folds of the vertically oriented portions of the corrugated sheet, or not glue some of the folds to the horizontal plane, to provide cushioning for a strong triangular structure. Reference above Figure 2D The top sheet 152 (paper) and bottom sheet 154 (paper) shown and discussed may also be used with Figure 11A and Figure 11BThe packaging material 400 shown is used together, but as shown in this embodiment, there are a large number of internal gluing surfaces, thereby eliminating the need for the top sheet 152 and the bottom sheet 154.

[0059] Figure 11A and Figure 11B The packaging material 400 shown or above Figure 1 The illustrated packaging material 100 can replace a conventional three-layer corrugated structure (three-walled box) with two layers of corrugated material. This allows for thinner, less bulky packaging, significantly saving shipping and storage costs, and reducing energy consumption. For example, the following table compares the packaging material of this embodiment with a double-walled or triple-walled shipping container, demonstrating these savings.

[0060]

[0061]

[0062] Figure 12A and Figure 12B A cylindrical shipping box 200 ( Figure 4 ) of the peripheral wall 220 ( Figure 4 ) packaging material 402. Figure 1 The packaging material 100 shown is similar to that described above with reference to Figure 11A and Figure 11B The two pieces of packaging material 400 discussed can also be modified to form the peripheral wall 220 of a "knock-down flat" ("kdf") shipping container (cylindrical shipping container 200), and Figure 12A and Figure 12B The illustrated packaging material 402 depicts this modification. The packaging material 402 is similar to the packaging material 400 discussed above. The same reference numerals will be used for the same and similar components and features, and a detailed description of these features will be omitted herein.

[0063] The packaging material 402 may be configured in a flat configuration (e.g. Figure 12A as shown) and tubular configurations (as Figure 12B (as shown). In the flat configuration, adjacent second base portions 122 are spaced apart from one another, and a second side gap 126 is maintained between adjacent second base portions 122. Adjacent second base portions 122 are not bonded to one another, and similarly, the first and second legs 424, 426 of the second fins 422 are not adhered to one another and are not attached at the base portion. In the flat configuration, the first and second legs 424, 426 of the second fins 422 are therefore spaced apart from one another. To achieve this spaced-apart arrangement when flattened, the first base portion 112 is longer than the second base portion 122.

[0064] The packaging material 402 may be bent to form an arcuate shape, such as a tubular shape (see Figure 4 ),like Figure 12B As the packaging material 402 bends, the second base portions 122 close closer to each other, thereby reducing the length of the second side gap 126 between the first leg 424 and the second leg 426. In some embodiments, the second base portions 122 can be brought into contact with each other (i.e., the second base portions 122 abut each other), thereby closing the second side gap 126. Since the first leg 424 and the second leg 426 are not attached as discussed above, the packaging material 402 can be brought into contact with each other (i.e., the second base portions 122 abut each other), thereby closing the second side gap 126. Figure 12B The arc (or tubular) configuration shown and Figure 12A Move back and forth between the flat configurations shown.

[0065] Although corrugated sheet materials are described, the packaging material of this embodiment may use other sheet materials, including relatively thick paper sheets (e.g., non-corrugated cardboard). Furthermore, although the packaging material discussed herein is described as being formed from cellulose sheets, and more specifically, corrugated cardboard, other materials may also be used to form the shipping boxes discussed herein. For example, plastic sheets may be used.

[0066] Although described as packaging material, the embodiments discussed herein can also be used as packaging material to provide additional cushioning or void filling. In this case, the materials discussed herein are placed in a shipping box around the item 10 to be shipped.

[0067] Although the present invention has been described with respect to certain specific exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art based on this disclosure. Therefore, it should be understood that the present invention may be implemented differently than as specifically described. Therefore, the exemplary embodiments of the present invention are to be considered in all respects to be illustrative rather than restrictive, and the scope of the present invention is to be determined by any claims supported by this application and its equivalents, rather than by the foregoing description.

Claims

1. A detachable flat cylindrical transport box, comprising: a peripheral wall, the peripheral wall comprising an outer surface and an inner surface, the peripheral wall being configurable in a flat configuration and a tubular configuration, wherein when the peripheral wall is in the tubular configuration, the inner surface defines an inner cavity for placing an item to be transported therein and forming a top end opening and a bottom end opening; a top cover attachable to the peripheral wall of the tubular configuration to close the top end opening; as well as A bottom cover is attachable to the peripheral wall below the tubular configuration to close the bottom end opening.

2. The cylindrical transport box according to claim 1, wherein the peripheral wall is formed by a packaging material including a plurality of base portions, the inner surface being formed by the plurality of base portions, wherein in the flat configuration, adjacent base portions of the plurality of base portions are spaced apart from each other and a gap is formed between the adjacent base portions, and Wherein in the tubular configuration, the adjacent base portions are brought closer together than in the flat configuration, thereby reducing the size of the gap between the adjacent base portions.

3. The cylindrical shipping box of claim 2, wherein in the tubular configuration, the adjacent base portions abut one another.

4. The cylindrical shipping box of claim 2, wherein the plurality of base portions are a plurality of second base portions, and the packaging material further comprises a plurality of first base portions, the outer surface being formed by the plurality of first base portions.

5. The cylindrical shipping box according to claim 4, wherein adhesive is applied between adjacent first base parts of the plurality of first base parts to bond the plurality of first base parts to each other, and adjacent second base parts of the plurality of second base parts have no adhesive between the adjacent second base parts.

6. The cylindrical shipping box of claim 4, wherein a first base portion of the plurality of first base portions is longer than a corresponding second base portion of the plurality of second base portions.

7. The cylindrical shipping box of claim 4, wherein the plurality of first base portions and the plurality of second base portions are formed from a same continuous sheet of material, and The packaging material further comprises a plurality of transverse walls, each transverse wall connecting a first base portion of the plurality of first base portions with a second base portion of the plurality of second base portions.

8. The cylindrical shipping box of claim 7, wherein the plurality of first base portions and the plurality of second base portions are positioned relative to each other to form a plurality of triangular cells with the plurality of transverse walls.

9. The cylindrical shipping box of claim 8, wherein the plurality of triangular units comprises a plurality of triangular units of different sizes.

10. The cylindrical shipping box of claim 8, wherein two transverse walls of the plurality of transverse walls are positioned together opposite corresponding base portions of the plurality of first base portions and the plurality of second base portions to form a vertex of each triangular unit.

11. The cylindrical shipping box of claim 10, wherein the angle between the two transverse walls of the plurality of transverse walls at the vertex is an acute angle.

12. The cylindrical shipping box of claim 10, wherein an angle between said two of said plurality of transverse walls at said vertex is an obtuse angle.

13. The cylindrical shipping box of claim 4, wherein the plurality of first base portions are formed from a first sheet of material and the plurality of second base portions are formed from a second sheet of material.

14. The cylindrical shipping box of claim 13, wherein the second sheet material includes a plurality of second fins, each second fin of the plurality of second fins connecting adjacent second base portions of the plurality of first base portions.

15. The cylindrical shipping box according to claim 14, wherein each of the plurality of second fins includes a first leg and a second leg connected to each other at a peak, each of the first leg and the second leg having a base end at an end opposite to the peak, and Wherein in the flat configuration, the gap is formed between the base end of the first leg and the base end of the second leg.

16. The cylindrical shipping box of claim 13, wherein the first sheet includes a plurality of first fins and the second sheet includes a plurality of second fins, the first sheet and the second sheet being positioned opposite each other, wherein the plurality of first fins protrude toward the second sheet, and the plurality of second fins protrude toward the first sheet.

17. The cylindrical shipping box according to claim 16, wherein the plurality of first fins and the plurality of second fins are arranged to form a plurality of triangular units, the plurality of first fins and the plurality of second fins forming transverse walls of the plurality of triangular units.

18. The cylindrical shipping box of claim 16, wherein each first fin of the plurality of first fins connects adjacent first base portions of the plurality of first base portions, and each second fin of the plurality of second fins connects adjacent second base portions of the plurality of second base portions.

19. The cylindrical shipping case of claim 1 further comprising an annular ring, wherein in the tubular configuration, the annular ring circumscribes the peripheral wall to maintain the peripheral wall in a tubular shape.

20. A convertible packaging material comprising: an outer wall segment having an outer surface formed thereon; as well as an inner wall section, said inner wall section being formed from a plurality of segments, wherein the packaging material is convertible between a flat state and a tubular state, and In the tubular state, the inner wall section forms an inner surface defining an inner cavity.

21. The convertible packaging material of claim 20, wherein the plurality of segments are a plurality of base portions, the inner surface being formed by the plurality of base portions, wherein in the flat state, adjacent base portions of the plurality of base portions are spaced apart from each other, and a gap is formed between the adjacent base portions, and Wherein in the tubular configuration, the adjacent base portions are brought closer together than in the flat configuration, thereby reducing the size of the gap between the adjacent base portions.

22. The convertible packaging material of claim 21 , wherein the outer wall section is formed from a first sheet material and the plurality of base portions are formed from a second sheet material, the second sheet material comprising a plurality of fins, each fin connecting adjacent ones of the plurality of base portions, and The first sheet and the second sheet are positioned opposite each other, wherein the plurality of fins protrude toward the first sheet.

23. The convertible packaging material of claim 21 , wherein the plurality of base portions is a plurality of second base portions and the outer wall segment comprises a plurality of first base portions, the plurality of first base portions and the plurality of second base portions being formed from a same continuous sheet of material, and The packaging material further comprises a plurality of transverse walls, each transverse wall connecting a first base portion of the plurality of first base portions with a second base portion of the plurality of second base portions.

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