Packaging material and method of manufacturing a packaging material

Abstract

The present invention relates to a cellulose packaging material, a layer for a cellulose packaging material, and a panel for a layer. The panel can be a cushioning panel, and more specifically a cellulose cushioning panel, e.g. a cushioning panel formed from a molded pulp or a corrugated fiberboard sheet. The panel can be a rigid panel, and more specifically a cellulose rigid panel. The cellulose cushioning panel can form a cushioning layer, and the rigid panel can form a rigid layer. The cushioning block and the packaging material can be formed from the cushioning layer and the rigid layer.

Description

[0001] Cross-references to related applications

[0002] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 673,406, filed July 19, 2024, entitled "PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKING MATERIAL," filed January 24, 2024, entitled "PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKING MATERIAL," filed January 24, 2024, entitled "PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKING MATERIAL," filed January 24, 2024, entitled "PACKING MATERIAL AND METHOD OF MANUFACTURING THE PACKING MATERIAL," filed September 15, 2023 ... The entire contents of the aforementioned application are incorporated herein by reference. Technical Field

[0003] This invention relates to packaging materials and methods for manufacturing packaging materials. Background Technology

[0004] Various packaging materials are used to secure and protect goods within shipping containers (including cardboard boxes) to prevent damage if these goods move within the container during transport or are subjected to other impacts (e.g., drops or collisions) during sea, air, and land transport. These packaging materials include bubble wrap, expanded polystyrene foam (EPS foam), and other plastic foam packaging that can be molded into blocks or other shapes, filler granules, and inflatable plastic bags (also known as air cushions). These plastic products are discarded as waste after they have been used during transport. Plastic waste takes significantly longer to decompose and produces carbon dioxide in the process. Furthermore, EPS foam is not easily biodegradable and takes many, many years to decompose efficiently. Summary of the Invention

[0005] In one aspect, the present invention relates to cushioning panels, and more specifically, to cellulose cushioning panels, for example, cushioning panels formed from molded pulp or corrugated fiberboard sheets.

[0006] In another aspect, the present invention relates to rigid panels, and more specifically, to cellulose rigid panels.

[0007] In another aspect, the present invention relates to packaging materials comprising multiple layers, such as a cushioning layer formed by the cushioning panel, the rigid panel, or both.

[0008] In another aspect, the present invention relates to a packaging material comprising one or more cushioning layers. Each cushioning layer includes a first cushioning panel and a second cushioning panel. The first cushioning panel has a first base layer having a plurality of first protrusions extending therefrom. Each of the first protrusions has a distal end distal to the first base layer. The first cushioning panel is a molded pulp panel. The second cushioning panel has a second base layer having a plurality of second protrusions extending therefrom. Each of the second protrusions has a distal end distal to the second base layer. The second cushioning panel is a molded pulp panel. The first cushioning panel is positioned such that the plurality of first protrusions project toward the second cushioning panel. The second cushioning panel is positioned such that the plurality of second protrusions project toward the first cushioning panel, and at least a portion of the plurality of second protrusions is a second contact protrusion. The distal end of the second contact protrusion contacts the first cushioning panel.

[0009] In another aspect, the present invention relates to a composite packaging material comprising one or more cushioning layers arranged having a product side and an outer side, and a cellulose sheet positioned on the outer side of the one or more cushioning layers. Each cushioning layer includes a first cushioning panel and a second cushioning panel. The first cushioning panel has a first base layer having a plurality of first protrusions extending therefrom. The first cushioning panel is a molded pulp panel. The second cushioning panel has a second base layer having a plurality of second protrusions extending therefrom. The second cushioning panel is a molded pulp panel. The first cushioning panel and the second cushioning panel are positioned in contact with each other, wherein the plurality of first protrusions project toward the second cushioning panel and the plurality of second protrusions project toward the first cushioning panel.

[0010] In another aspect, the present invention relates to a composite packaging material comprising a cushioning layer and a rigid panel. The cushioning layer includes a cushioning panel having a base layer having a plurality of protrusions extending therefrom. Each of the protrusions has a distal end distal to the base layer. The cushioning panel is a molded pulp panel. The rigid panel contacts the cushioning layer. The rigid panel is formed of a cellulose material. When a load is applied in the thickness direction of the rigid panel or the cushioning panel, the stiffness of the rigid panel is greater than the stiffness of the cushioning panel.

[0011] In another aspect, the present invention relates to a packaging material comprising one or more cushioning blocks, each capable of being positioned on the product side of the cushioning block around an object to be transported. Each cushioning block comprises one or more cushioning layers. Each cushioning layer comprises a first cushioning panel and a second cushioning panel. The first cushioning panel has a first base layer having a plurality of first protrusions extending therefrom. Each of the first protrusions has a distal end distal to the first base layer. The first cushioning panel is a molded pulp panel. The second cushioning panel has a second base layer having a plurality of second protrusions extending therefrom. Each of the second protrusions has a distal end distal to the second base layer. The second cushioning panel is a molded pulp panel. The first cushioning panel is positioned such that the plurality of first protrusions project toward the second cushioning panel, and the second cushioning panel is positioned such that the plurality of second protrusions project toward the first cushioning panel.

[0012] These and other aspects of the invention will become apparent from the following disclosure. Attached Figure Description

[0013] Figure 1 This illustrates packaging materials formed according to this disclosure to protect articles to be transported.

[0014] Figure 2 This is a schematic diagram of a cushioning block that can be used to form packaging materials.

[0015] Figure 3A This is a top view of a cushioning panel, which can be used as a cushioning layer for packaging material.

[0016] Figure 3B It is along Figure 3A The line 3B-3B is cut off. Figure 3A The cross-sectional view of the buffer panel shown.

[0017] Figure 3C From similar Figure 3B A cross-sectional view of the buffer panel captured from the perspective of [the viewer's perspective].

[0018] Figure 3D From similar Figure 3B A cross-sectional view of the buffer panel captured from the perspective of [the viewer's perspective].

[0019] Figure 3E From similar Figure 3B A cross-sectional view of the buffer panel captured from the perspective of [the viewer's perspective].

[0020] Figure 3F From similar Figure 3B A cross-sectional view of the buffer panel captured from the perspective of [the viewer's perspective].

[0021] Figure 3G This is a schematic diagram of another buffer panel, which may be a buffer layer to be formed into packaging material.

[0022] Figure 3H This indicates that it is in a compressed state. Figure 3G A schematic diagram of the buffer panel shown.

[0023] Figure 4A This is a top view of the buffer layer formed by positioning the first buffer panel relative to the second buffer panel.

[0024] Figure 4B It is along Figure 4A The line 4B-4B is cut off. Figure 4A The cross-sectional view of the buffer layer shown.

[0025] Figure 4C From similar Figure 4B The perspective captured Figure 4A and Figure 4B The cross-sectional view of the multiple buffer layers shown.

[0026] Figure 4D This is a schematic diagram of a buffer layer formed by positioning a first buffer panel relative to a second buffer panel.

[0027] Figure 5A This is a top view of the buffer layer formed by positioning the first buffer panel relative to the second buffer panel.

[0028] Figure 5B It is along Figure 5A The line 5B-5B is cut off. Figure 5A The cross-sectional view of the buffer layer shown.

[0029] Figure 5C From similar Figure 5B The perspective captured Figure 5A and Figure 5B The cross-sectional view of the multiple buffer layers shown.

[0030] Figure 6A This is a top view of the buffer layer formed by positioning the first buffer panel relative to the second buffer panel.

[0031] Figure 6B It is along Figure 6A The line 6B-6B in the middle is cut off Figure 6A The cross-sectional view of the buffer layer shown.

[0032] Figure 6C From similar Figure 6B The perspective captured Figure 6A and Figure 6BThe cross-sectional view of the multiple buffer layers shown.

[0033] Figure 7A This is a top view of the buffer layer formed by positioning the first buffer panel relative to the second buffer panel.

[0034] Figure 7B It is along Figure 7A The line 7B-7B is cut off. Figure 7A The cross-sectional view of the buffer layer shown.

[0035] Figure 8A From similar Figure 4B A cross-sectional view of the buffer layer taken from the perspective of [the viewer's perspective].

[0036] Figure 8B From similar Figure 4B A cross-sectional view of the buffer layer taken from the perspective of [the viewer's perspective].

[0037] Figure 8C From similar Figure 4B A cross-sectional view of the buffer layer taken from the perspective of [the viewer's perspective].

[0038] Figure 9A This is a top view of the buffer layer formed by positioning the first buffer panel relative to the second buffer panel.

[0039] Figure 9B It is along Figure 9A The line 9B-9B in the middle is cut off Figure 9A The cross-sectional view of the buffer layer shown.

[0040] Figure 9C From similar Figure 9B The perspective captured Figure 9A and Figure 9B The cross-sectional view of the multiple buffer layers shown.

[0041] Figure 9D From similar Figure 9B A cross-sectional view of different types of buffer panels in another arrangement, taken from a different perspective.

[0042] Figure 10A and Figure 10B This illustrates a method for forming a buffer layer. Figure 10A It is the first step, and Figure 10B This is the second step.

[0043] Figures 11A to 11E This demonstrates another method for forming a buffer layer. Figure 11A It is the first step, and Figure 11B This is the second step. Figure 11C Optional additional steps are shown. Figure 11D Another optional additional step is shown. Figure 11E Alternative optional additional steps are shown.

[0044] Figure 12 This is an exploded view of a cushioning block that can be used to form packaging materials.

[0045] Figure 13 This is an exploded view of cushioning blocks that can be used to form packaging materials.

[0046] Figure 14A This is a schematic diagram of a rigid sheet panel, and more specifically, a honeycomb panel that can be used to form a buffer block.

[0047] Figure 14B This is a schematic diagram showing the core of a honeycomb panel.

[0048] Figure 15A From similar Figure 4B A cross-sectional view of a buffer block using honeycomb panels in conjunction with a rigid layer, taken from a perspective of [unclear - possibly a specific angle or perspective].

[0049] Figure 15B From similar Figure 4B A cross-sectional view of a buffer block using honeycomb panels in conjunction with a rigid layer, taken from a perspective of [unclear - possibly a specific angle or perspective].

[0050] Figure 15C From similar Figure 4B A cross-sectional view of a buffer block using honeycomb panels in conjunction with a rigid layer, taken from a perspective of [unclear - possibly a specific angle or perspective].

[0051] Figure 15D From similar Figure 4B A cross-sectional view of a buffer block using honeycomb panels in conjunction with a rigid layer, taken from a perspective of [unclear - possibly a specific angle or perspective].

[0052] Figure 16A This is a schematic diagram of corner-shaped packaging material.

[0053] Figure 16B yes Figure 16A An exploded view of the corner-shaped packaging material shown.

[0054] Figure 17 This is a schematic diagram of a U-shaped packaging material.

[0055] Figure 18 These are schematic diagrams of two corner-shaped packaging materials and a U-shaped packaging material arranged side by side.

[0056] Figure 19A This is a schematic diagram of corner-shaped packaging material.

[0057] Figure 19B yes Figure 19A An exploded view of the corner-shaped packaging material shown.

[0058] Figure 20A This is a schematic diagram of a corner-shaped packaging material within a flat configuration.

[0059] Figure 20B It is in a folded configuration Figure 20A A schematic diagram of corner-shaped packaging materials.

[0060] Figure 21A This is a schematic diagram of a corner-shaped packaging material within a flat configuration.

[0061] Figure 21B It is in a folded configuration Figure 21A A schematic diagram of corner-shaped packaging materials.

[0062] Figure 22A This is a top view of the corner-shaped packaging material.

[0063] Figure 22B yes Figure 22A A schematic diagram of the corner-shaped packaging material shown.

[0064] Figure 23 This is a schematic diagram of corner-shaped packaging material.

[0065] Figure 24A This is a schematic diagram of a U-shaped packaging material.

[0066] Figure 24B This is a schematic diagram of a U-shaped packaging material.

[0067] Figure 25A From similar Figure 4B A cross-sectional view of an irregular buffer layer taken from a certain perspective.

[0068] Figure 25B From similar Figure 4B A cross-sectional view of an irregular buffer layer taken from a certain perspective.

[0069] Figure 25C From similar Figure 4B A cross-sectional view of an irregular buffer layer taken from a certain perspective.

[0070] Figure 26A This is a schematic diagram of a transport container with buffer blocks in a flat configuration.

[0071] Figure 26B It is in a folded configuration Figure 26A A schematic diagram of a transport container.

[0072] Figure 27A This is a schematic diagram of a transport container with buffer blocks in a flat configuration.

[0073] Figure 27B It is in a folded configuration Figure 27A A schematic diagram of a transport container.

[0074] Figure 28A This is a schematic diagram of a transport container with buffer blocks in a flat configuration.

[0075] Figure 28B It is in a folded configuration Figure 28A A schematic diagram of a transport container.

[0076] Figure 29A This is a schematic diagram of a transport container with buffer blocks in a flat configuration.

[0077] Figure 29B It is in a folded configuration Figure 29A A schematic diagram of a transport container.

[0078] Figure 30A From similar Figure 3B A cross-sectional view of the first foldable molded buffer panel taken from a certain perspective.

[0079] Figure 30B From similar Figure 3B A schematic diagram of the second foldable molded buffer panel taken from a certain perspective.

[0080] Figure 30C Is using Figure 30A The first foldable molded cushioning panel and Figure 30B A schematic end view of the transport container formed by the second foldable molded buffer panel.

[0081] Figure 31 This is a schematic diagram of the buffer panel.

[0082] Figure 32 Is using Figure 31 A schematic diagram of the buffer block of the buffer panel.

[0083] Figure 33 This is a schematic diagram of a rigid sheet panel, and more specifically, a formed corrugated fiberboard rigid sheet panel.

[0084] Figure 34 Is using Figure 33 A schematic diagram of a buffer block for a formed corrugated fiberboard rigid sheet panel.

[0085] Figure 35 This is a schematic diagram of the buffer panel.

[0086] Figure 36 Is using Figure 35 A schematic diagram of the buffer block of the buffer panel.

[0087] Figure 37A This is a schematic diagram of the buffer panel.

[0088] Figure 37B yes Figure 37A A detailed view of a portion of the buffer panel, which shows Figure 37A Details in 37B.

[0089] Figure 38 Is using Figure 37A A schematic cross-sectional view of the buffer block of the buffer panel.

[0090] Figure 39A It is an exploded view of a buffer block with a rigid layer, and more specifically, a rigid sheet panel with a lattice structure.

[0091] Figure 39B yes Figure 35 A schematic diagram of the buffer block shown in Figure A. Detailed Implementation

[0092] As mentioned above, with increasing awareness of the negative environmental impacts of plastics and EPS foams, companies and consumers are increasingly seeking environmentally friendly, recyclable, and biodegradable products for packaging. The packaging materials discussed herein offer environmentally friendly, recyclable, and biodegradable products while providing adequate protection and cushioning at an affordable cost. In particular, the embodiments discussed herein can be environmentally friendly, recyclable, and biodegradable alternatives to EPS and other plastic foams, such as expanded polyethylene or EPE foam.

[0093] Figure 1 A packaging material 100 formed according to the present disclosure is shown for protecting articles to be transported, such as flat-screen TVs, during transportation. The articles to be transported are referred to herein as product 10. The packaging material 100 may be arranged around product 10 in various different arrangements to protect the product during transportation. However, as will be discussed further below, the packaging material 100 may be arranged such that some of its features are closer to product 10 than other features. The packaging material 100 may include a product side and include a product side surface. In some arrangements, the product side surface may contact product 10.

[0094] Packaging material 100 is positioned around product 10, and product 10 and packaging material 100 positioned around it can be placed in a shipping container, such as shipping box 20. Figure 1The shipping container 20 shown is a corrugated cardboard shipping container, but the packaging material 100 discussed herein can be used with other shipping containers. The shipping container 20 includes a plurality of walls 22 defining an internal cavity 24; more specifically, each wall 22 may include an inward-facing surface 26 that marks the internal cavity 24. As will be discussed further below, the packaging material 100 may be arranged such that some of its features are closer to the shipping container 20 than others. The packaging material 100 may include container sides and include container side surfaces. The container side surfaces may contact the inward-facing surface 26 of the shipping container (e.g., shipping container 20). The shipping container 20 may also include a plurality of flaps 28 that can be used to open and close the shipping container 20 to allow access to the internal cavity 24 through the openings.

[0095] exist Figure 1 In the diagram, multiple packaging materials 100 are shown surrounding the product 10. The packaging materials 100, or portions thereof, may be positioned around the product 10 before the product 10 is placed in the shipping case 20. Other packaging methods may be used, such as placing the packaging materials 100 before, after, together with, or in combination with the product 10, within the internal cavity 24 of the shipping case 20.

[0096] As will be discussed further below, packaging material 100 may be composed of multiple cushioning blocks arranged in different ways to form packaging material 100. Figure 1 As shown, packaging material 100 includes, for example, corner-shaped packaging material 102 and U-shaped packaging material 104. In some embodiments, such as in Figure 1 In the embodiments shown for protecting the television (product 10), the U-shaped packaging material 104 can be elongated, and the packaging material 100 can also be arranged to form an elongated packaging material.

[0097] Figure 2 A buffer block 200 is shown, and more specifically, a packaging material 100 that can be used to form the packaging material discussed herein is shown. Figure 1The cushioning block 201. As described above, the packaging material 100 discussed herein may be formed from one or more cushioning blocks 200. The cushioning block 200 discussed herein may have several different constructions, but the reference numeral 200 is generally used to refer to any one of the cushioning blocks 200 discussed herein. The cushioning block 200 discussed herein may include multiple layers. In some cushioning blocks 200, at least some of these layers may differ from each other in material, construction, or both, and these different layers have various different structures, resulting in different strengths, stiffness, and cushioning properties. The cushioning block 200 having these different layers and the packaging material 100 may be referred to herein as a composite cushioning block and a composite packaging material. The composite cushioning block and composite packaging material may, for example, be a cushioning layer 210 combined with at least one other different layer, as discussed further below.

[0098] The materials used in the construction also directly affect this performance. As discussed in more detail below, the cushioning block 200 can be formed from cellulose materials. Certain layers or portions thereof are formed from molded pulp (also known as molded fiber), fiberboard including corrugated fiberboard sheets (also known as corrugated cardboard), and paper sheets in different arrangements. The inventors have discovered that the specific arrangement and construction of these different layers can successfully protect the product 10 during transport, including situations where other arrangements using some layers alone do not provide the same level of protection.

[0099] Buffer block 200 may include one or more buffer layers. Figure 2 The buffer block 201 shown includes two buffer layers 210, namely, a first buffer layer 210a and a second buffer layer 210b. Each buffer layer 210 can be formed from one or more buffer panels 300. Various different buffer panels 300 that can be used to form the buffer layers 210 will be further discussed below, and the reference numeral 300 is generally used herein to refer to various different buffer panels. More specifically, in Figure 2 In this configuration, the buffer layer 210 is formed by a first buffer panel 220 (e.g., a top buffer panel) and a second buffer panel 230 (e.g., a bottom buffer panel). As will be discussed further below, the buffer layer 210 can be used in a variety of different arrangements to form the buffer block 200, but the buffer layer 210 can also be used as the buffer block 201 on its own.

[0100] Figure 3A This is a top view of buffer panel 301, which can be used as buffer panel 300 to form the buffer layer 210 discussed herein. Figure 2 ). Figure 3B It is along Figure 3A The cross-sectional view of the buffer panel 301, taken by line 3B-3B. (See figure) Figure 3A and Figure 3BAs shown, the buffer panel 301 can be used to form Figure 2 The buffer layer 210 shown, and more specifically, the buffer panel 301 can be used to form one or both of the first buffer panel 220 or the second buffer panel 230.

[0101] The cushioning panel 300 (e.g., cushioning panel 301) discussed herein is formed from a cellulose material, which is like a natural cellulose material; thus, the cellulose material is recyclable and biodegradable. Cushioning panel 301 can be formed using a molding pulping process (also known as a molding fiber process). The pulp or fiber used in this process is preferably cellulose pulp and fiber, and even more preferably pulp produced from post-consumer recycled paper, including newsprint, recycled paperboard / fiberboard, recycled paperboard, recycled corrugated board (OCC), and the like. Waste paper, including paperboard / fiberboard, recycled paperboard, and OCC, can be dissolved in water to defiberize the paper fibers, thereby forming an aqueous pulp of paper (cellulose) fibers. Other suitable sources of cellulose (paper) fibers can be used, and in some embodiments, recycled paper fibers can be blended with other cellulose (paper) fibers. Depending on the source of the cellulose fibers, other suitable defiberizing and pulping methods (e.g., the Kraft method) can be used. Therefore, the cushioning panel 300 formed using this process can also be referred to as a molded cushioning panel.

[0102] One such molding pulp process is a vacuum forming process or a wet fiber molding process. A forming tool having a surface shaped corresponding to the buffer panel 300 discussed herein (e.g., a surface with multiple cylindrical protrusions) can be placed in an aqueous pulp of paper (cellulose) fibers. The forming surface can be referred to as a mold or molding surface. For example, a vacuum is drawn through the molding surface to remove moisture and to cause the paper fibers to accumulate on the molding surface and take the shape of the molding surface. Once the desired thickness of paper fibers has been accumulated, the molding surface is removed from the aqueous pulp, allowing the now-molded paper fibers to dry. The molded paper fibers can be removed from the molding surface to complete drying, for example, in a drying oven.

[0103] Other suitable fiber molding processes can be used, including, for example, dry fiber molding. In such a dry fiber molding process, the pulp / fiber is defibered, for example by milling, and then molded in a dry form (e.g., without a water-containing pulp). The dried defibered paper fibers can be molded in a die under pressure and temperature to form the desired shape, for example, the shape discussed herein. In some processes, the dried defibered paper fibers can be loosely formed into a sheet (referred to as a fiber sheet) by vacuum, wound (or otherwise shaped) to the desired thickness, and then fed into a die. Prior to being fed into the die, the fiber sheet may optionally include a thin sheet of paper, which is applied to at least one of the top or bottom of the fiber sheet.

[0104] Figure 3A and Figure 3B The buffer panel 301 shown is formed of a base layer 310 having a plurality of protrusions 320 extending therefrom. The base layer 310 may be a generally planar layer. The base layer 310 may include a protruding side having a protruding side surface 312. Each of the protrusions 320 may extend from the protruding side surface 312. The other side of the base layer 310 is referred to herein as the back side, and thus the base layer 310 may include a back side surface 314. Figure 3A and Figure 3B In the middle, the protrusions 320 all extend from the protrusion side surface 312, and the back side surface 314 of the buffer panel 301 is a generally flat surface.

[0105] Each of the protrusions 320 has a distal end 322 on the distal side of the base layer 310. Each protrusion 320 has a geometric shape. Figure 3A and Figure 3B As shown, protrusion 320 is cylindrical, and more specifically, cylindrical. As will be discussed further below, protrusion 320 can be other geometric shapes, such as cylinders, rectangular prisms, pyramids, or cones. Figure 3A and Figure 3B As shown, all the protrusions 320 of the buffer panel 301 have the same geometry, but the buffer panel 301 may have protrusions 320 with multiple different geometries. That is, one of the protrusions 320 has a first geometry, and another protrusion 320 has a second geometry that is different from the first geometry.

[0106] Each of the protrusions 320 may be a hollow protrusion in which a cavity 324 is formed. Thus, each of the protrusions 320 may include one or more sidewalls extending from the base layer 310 and defining the cavity 324. Each of the protrusions 320 may be closed at one end. For example, in Figure 3A and Figure 3B In this cavity, the distal end 322 is closed and includes an end wall that partially defines the cavity 324. The distal end 322, and more specifically, the end wall, can have various suitable shapes. For example... Figure 3B As shown, the distal end 322 is circular. The distal end 322 may have, for example, a spherical dome shape, such as a hemispherical shape. Alternatively, for example, the distal end 322 may be flat, and the protrusion 320 may have a U-shaped cross-section.

[0107] In the illustrated embodiment, the cavity 324 of the protrusion 320 is an open cavity having an opening 326 formed in the base layer 310, and more specifically in the back surface 314 of the base layer 310. The opening 326 is an opening into the cavity 324. Depending on how the buffer panels 301 are arranged, the cavity 324 can become a closed cavity 324 relative to other features of the buffer block 200, for example, when multiple buffer panels 301 are arranged back-to-back, with the back surface 314 of one buffer panel 301 abutting against another buffer panel 301. For example, in Figure 2 The opening 326 can also be seen in the middle.

[0108] The base layer 310 has a thickness. The thickness of the base layer 310 can be less than the length of the protrusion 320. The length of each protrusion 320 can be taken as the distance from the protrusion side surface 312 to the tip 328 of the distal end 322. Figure 3B In this context, all protrusions 320 have the same length, but as will be discussed further below, protrusions 320 may have multiple different lengths.

[0109] Multiple protrusions 320 can be arranged in a two-dimensional (2D) array having multiple rows and columns. The length and width of the buffer panel 301 have corresponding length and width directions. The multiple protrusions 320 can be arranged in both the length and width directions. Figure 3A (See also Chinese) Figure 2 The protrusions 320 in each row are evenly spaced from each other, and the protrusions 320 in each column are also evenly spaced from each other. However, other arrangements may be used.

[0110] As mentioned above, the protrusion 320 can have other shapes, such as other geometries. Figures 3C to 3F A buffer panel with protrusions 320 of different geometries is shown. In addition to the shape of the protrusions 320, these buffer panels also have features similar to those described above. Figure 3A and Figure 3B The features discussed are the same as or similar to those of buffer panel 301, and this discussion applies to this. For clarity, for other buffer panels discussed herein, Figure 3A and Figure 3B The protrusion shown is referred to as cylindrical protrusion 331.

[0111] Figure 3C From similar Figure 3B A cross-sectional view of the buffer panel 303 taken from the perspective of [the viewer's perspective]. Figure 3C The protrusion 320 of the cushioning panel 303 shown has a dome shape. The dome shape can be, for example, a spherical dome shape, such as a hemispherical shape. For clarity, for other cushioning panels discussed herein, Figure 3C The protrusion shown is referred to as dome protrusion 333.

[0112] Figure 3D From similar Figure 3B A cross-sectional view of the buffer panel 305 taken from the perspective of [the viewer's perspective]. Figure 3D The protrusions 320 of the cushioning panel 305 shown have a pyramidal or conical shape. The base can have various suitable shapes, including a circular base with corresponding curved sidewalls, or a rectangular base, such as a square base, with corresponding triangular or trapezoidal sidewalls. For clarity, for other cushioning panels discussed herein, Figure 3D The protrusion shown is referred to as pyramidal protrusion 335. It is not a key feature. Figure 3D The pyramid-shaped protrusion 335 shown has a flat distal end 322.

[0113] Figure 3E From similar Figure 3B A cross-sectional view of the buffer panel 307 taken from the perspective of [the viewer's perspective]. Figure 3E The protrusion 320 of the cushioning panel 307 shown has arched sidewalls. Similar to the pyramidal protrusion 335, the base can have various suitable shapes, including circular and square bases. For clarity, for the other cushioning panels discussed herein, Figure 3E The protrusion shown is called bow protrusion 337. Figure 3E The bow-shaped protrusion 337 shown has a flat distal end 322.

[0114] Figure 3F From similar Figure 3B A cross-sectional view of the buffer panel 309 taken from the perspective of [the viewer's perspective]. Figure 3F The protrusions 320 of the buffer panel 309 shown have a rectangular prism geometry. The base can be various rectangular shapes, including squares. For clarity, for other buffer panels discussed herein, Figure 3F The protrusion shown is referred to as rectangular protrusion 339. Figure 3F The rectangular protrusion 339 shown has a flat distal end 322.

[0115] Figure 3GAnother type of cushioning panel 302 is shown, which can be used as one of the cushioning panels 300 discussed herein. Cushioning panel 302 is similar to the cushioning panel 300 discussed above, but instead of the protrusions 320 being arranged in multiple rows or columns, the protrusions 320 are ridges 332. The ridges 332 are elongated and extend parallel to each other. The ridges 332 can have various shapes, including... Figure 3G The dome-shaped or arched distal end 322 shown.

[0116] Figure 3H Showing a compressed state Figure 3G The buffer panel 302 is shown. When a force is applied in a direction perpendicular to the buffer panel 302, the ridge 332 can be deformed, for example, by spreading out on the distal end 322 and by moving portions of the base layer 310 together closer together, thereby reducing the size of the opening 326.

[0117] As described above, buffer layer 210 ( Figure 2 A buffer layer 300 can be formed by arranging two or more buffer panels 300. The following discussion will refer to some of the buffer panels 300 discussed above (e.g., buffer panel 302 with dome-shaped protrusions 333), but the discussion also applies to other buffer panels 300 where the protrusions 320 have other shapes. Generally, reference numeral 210 is used to apply to any of the buffer layers 210, regardless of the specific configuration described below. Similarly, first buffer panel 220 and second buffer panel 230 are generally used for buffer panels involving buffer layers 210, regardless of the specific shape of the protrusions.

[0118] Figure 4A and Figure 4B The buffer layer 211 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 4A This is a top view of buffer layer 211, and Figure 4B It is along Figure 4A The cross-sectional view of the buffer layer 211 taken by line 4B-4B is shown. Each of the first buffer panel 220 and the second buffer panel 230 is shown as a buffer panel 303 with a dome-shaped protrusion 333, but as mentioned above, the first buffer panel 220 and the second buffer panel 230 can be other buffer panels 300 with protrusions 320 of alternative shapes. Figures 3A to 3F Therefore, the first buffer panel 220 has a first base layer 222 and a plurality of first protrusions 224 extending therefrom. Similarly, the second buffer panel 230 has a second base layer 232 and a plurality of second protrusions 234 extending therefrom. Each of the plurality of first protrusions 224 has a first geometry, and each of the plurality of second protrusions 234 has a second geometry. Figure 4A and Figure 4B In the diagram, the second geometry is the same as the first geometry and is shown as a dome-shaped protrusion 333. However, the second geometry can be a different geometry from the first geometry.

[0119] The first buffer panel 220 is positioned such that a plurality of first protrusions 224 protrude toward the second buffer panel 230, and the second buffer panel 230 is positioned such that a plurality of second protrusions 234 protrude toward the first buffer panel 220. The first base layer 222 has an inner side 226 and an outer side 228. The inner side 226 of the first base layer 222 is positioned opposite the second buffer panel 230, and the plurality of first protrusions 224 extend from the inner side 226 of the first base layer 222. The second base layer 232 also has an inner side 236 and an outer side 238. The inner side 236 of the second base layer 232 is positioned opposite the first buffer panel 220, and the plurality of second protrusions 234 extend from the inner side 236 of the second base layer 232.

[0120] exist Figure 4A and Figure 4B In this configuration, the first protrusion 224 and the second protrusion 234 are opposite to each other, and more specifically, directly opposite each other. When the first protrusion 224 and the second protrusion 234 are directly opposite each other, the distal end 322 of the first protrusion 224 can contact the distal end 322 of the second protrusion 234. A protrusion that contacts another surface (e.g., another cushioning panel) (more specifically, a protrusion having a distal end 322 that contacts another surface) is referred to herein as a contact protrusion, and thus at least a portion of the first protrusion 224 and at least a portion of the second protrusion 234 are contact protrusions. At least a portion of the first protrusion 224 is a first contact protrusion, wherein the distal end 322 of the first contact protrusion contacts the second cushioning panel 230, and at least a portion of the second protrusion 234 is a second contact protrusion, wherein the distal end 322 of the second contact protrusion contacts the first cushioning panel 220. More specifically, in Figure 4A and Figure 4B In this configuration, the first contact protrusion and the second contact protrusion are positioned directly opposite each other, wherein the distal end 322 of each first contact protrusion contacts the distal end 322 of the corresponding second contact protrusion. In this case, both the first protrusion 224 and the second protrusion 234 are contact protrusions; however, in other cases, as will be discussed further below, only one of the first protrusion 224 or the second protrusion 234 is a contact protrusion.

[0121] Figure 4C From similar Figure 4B A cross-sectional view of multiple buffer layers 211 taken from a perspective. As described above, packaging material 100 ( Figure 1 It may include a buffer block 200 having a single buffer layer 210. Figure 2 ), such as Figure 5B The cushioning layer 211 is shown. Other packaging materials 100 may include cushioning blocks 200 having multiple cushioning layers 210. For example, Figure 5C Four buffer panels 300 are shown, which are arranged to form two buffer layers 210, and more specifically to form a first buffer layer 211a and a second buffer layer 211b. Figure 4C Each of the first buffer layer 211a and the second buffer layer 211b shown above is referenced above. Figure 4B The discussion concerns buffer layer 211, and this discussion applies here. Although the first buffer layer 211a and the second buffer layer 211b are shown to have the same arrangement, the first buffer layer 211a and the second buffer layer 211b may be arranged differently from each other.

[0122] Figure 4D This is a perspective view of the buffer layer 211c formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 4D In the first buffer panel 220 and the second buffer panel 230, each is a buffer panel 302 having a ridge 332, which is consistent with the above reference. Figure 4A and Figure 4B The buffer layers 211 discussed are arranged in a similar manner to each other, with them directly opposite each other.

[0123] like Figure 5C As shown, packaging material 100, such as buffer block 200 ( Figure 1 It may have two or more buffer layers, including a first buffer layer 211a and a second buffer layer 211b. The outer side 238 of one of the first base layer 222 or the second base layer 232 of the first buffer layer 211a abuts against the outer side 238 of one of the first base layer 222 or the second base layer 232 of the second buffer layer 211b. Figure 4C In the first buffer layer 211a, the outer side 238 of the second base layer 232 abuts against the outer side 238 of the first base layer 222 in the second buffer layer 211b.

[0124] Figure 5A and Figure 5B The buffer layer 212 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 5A This is a top view of buffer layer 212, and Figure 5B It is along Figure 6A The cross-sectional view of the buffer layer 212 taken by line 6B-6B in the figure. Figure 5A and Figure 5BThe first protrusion 224 and the second protrusion 234 are shown in direct opposition, but as mentioned above, other arrangements of the first buffer panel 220 and the second buffer panel 230 can be used to form the buffer layer 210 discussed herein, for example, an offset arrangement. Figure 5A and Figure 5B A buffer layer 212 with such an offset arrangement is shown.

[0125] The first protrusion 224 and the second protrusion 234 are offset from each other. More specifically, the first protrusion 224 and the second protrusion 234 are offset from each other in one of the length or width directions of the buffer panel 303, but aligned in the other direction. Figure 5A In the diagram, the first protrusion 224 is shown with a solid line, and the second protrusion 234 is shown with a dashed line. (As can be seen in...) Figure 5A As can be seen, the rows of protrusions of the first buffer panel 220 and the second buffer panel 230 are still aligned with each other, but the columns of the first buffer panel 220 and the second buffer panel 230 are offset from each other.

[0126] More specifically, at least some of the second protrusions 234 are each positioned between two adjacent first protrusions 224, and at least some of the first protrusions 224 are each positioned between two adjacent second protrusions 234. In the illustrated embodiment, some of the first protrusions 224 are located on the edge of the first buffer panel 220 and are referred to herein as edge protrusions. Edge protrusions are not positioned between two adjacent second protrusions 234, but rather adjacent to only one second protrusion 234. Each of the first protrusions 224 and the second protrusions 234 may include an edge protrusion. More specifically, at least a portion of the first protrusion 224 may be an edge protrusion, and / or at least a portion of the second protrusion 234 may be an edge protrusion. Other protrusions of the first protrusions 224 and the second protrusions 234 may be internal protrusions. More specifically, at least a portion of the first protrusion 224 may be an internal protrusion, and / or at least a portion of the second protrusion 234 may be an internal protrusion. Each inner protrusion of the first protrusion 224 is positioned between two adjacent second protrusions 234, and each inner protrusion of the second protrusion 234 is positioned between two first protrusions 224. Figure 5A and Figure 5B In the middle, the inner protrusion of the first protrusion 224 contacts two adjacent second protrusions 234, and the inner protrusion of the second protrusion 234 contacts two adjacent first protrusions 224.

[0127] Figure 5C From similar Figure 5B A cross-sectional view of multiple buffer layers 212 taken from the perspective of [the viewer's perspective]. Figure 5A and Figure 5BThe two or more buffer layers 212 shown can be referenced above. Figure 4C The first buffer layer 211a and the second buffer layer 211b discussed are arranged adjacent to each other in a similar manner. More specifically, Figure 5C The plurality of buffer layers 213 shown includes a first buffer layer 212a and a second buffer layer 212b. Figure 6C In the first buffer layer 212a, the outer side 238 of the second base layer 232 abuts against the outer side 238 of the first base layer 222 in the second buffer layer 212b. Although these can be arranged in different ways, the opening 326 of the second protrusion 234 in the first buffer layer 212a is aligned with the opening 326 of the first protrusion 224 in the second buffer layer 212b to form a closed cavity between the cavity 324 of the second protrusion 234 in the first buffer layer 212a and the cavity 324 of the first protrusion 224 in the second buffer layer 212b.

[0128] Figure 6A and Figure 6B The buffer layer 213 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 6A This is a top view of buffer layer 213, and Figure 6B It is along Figure 6A The cross-sectional view of the buffer layer 213 cut by line 6B-6B in the figure. Figure 6A and Figure 6B A buffer layer 213 with an alternative offset arrangement is shown.

[0129] The first protrusion 224 and the second protrusion 234 are offset from each other. More specifically, the first protrusion 224 and the second protrusion 234 are offset from each other in both the length and width directions of the buffer panel 303. Figure 6A In the diagram, the first protrusion 224 is shown in solid line, and the second protrusion 234 is shown in dashed line. (As can be seen in...) Figure 6A As seen in the image, at least a portion of the second protrusion 234 (e.g., an internal protrusion) is located in the gap between the first protrusions 224. Figure 6A In this arrangement, the gap is located between four adjacent first protrusions 224. With this arrangement, at least a portion of the first protrusions 224 (e.g., internal protrusions) is also located in the gap between the second protrusions 234. Figure 6A In this context, the gap is located between four adjacent second protrusions 234. Figure 6A and Figure 6B In the middle, the inner protrusion of the first protrusion 224 contacts four adjacent second protrusions 234, and the inner protrusion of the second protrusion 234 contacts four adjacent first protrusions 224.

[0130] Figure 6C From similar Figure 6B A cross-sectional view of multiple buffer layers 213 taken from the perspective of [the viewer's perspective]. Figure 6A and Figure 6B The two or more buffer layers 213 shown can be referenced above. Figure 5C The first buffer layer 212a and the second buffer layer 212b discussed are arranged adjacent to each other in a similar manner. Figure 5C The discussion of the features in the text applies to the first buffer layer 213a and the second buffer layer 213b shown in FIG. 7C, but with reference to the above. Figure 6A and Figure 6B The offset arrangement is discussed.

[0131] Figure 7A and Figure 7B The buffer layer 214 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 7A This is a top view of buffer layer 213, and Figure 7B It is along Figure 7A The cross-sectional view of the buffer layer 214 taken by line 7B-7B in the figure. Figure 7A and Figure 7B A buffer layer 213 with yet another offset arrangement is shown. Figure 6A and Figure 6B In this arrangement, the first protrusion 224 and the second protrusion 234 contact other protrusions, but other arrangements can be used. Figure 7A and Figure 7B In this configuration, the first protrusion 224 and the second protrusion 234 do not contact each other, but instead contact other portions of the second buffer panel 230 and the first buffer panel 220, respectively. More specifically, the distal end 322 of the first protrusion 224 contacts the protruding side surface 312 of the second base layer 232, and the distal end 322 of the second protrusion 234 contacts the protruding side surface 312 of the second protrusion 234.

[0132] The buffer layer 210 discussed herein can provide a certain level of cushioning for product 10. The buffer layer 210 has a certain degree of elastic deformability to provide a first level of cushioning, but also provides energy absorption through wrinkling or deformation. These different arrangements of the buffer layer 210 provide different levels of energy absorption, which can be adjusted as needed. Additionally, as mentioned above, the first protrusion 224 and the second protrusion 234 can have various shapes, for example, different geometries. These different geometries can have different configurations to provide different cushioning or rebound. For example, Figure 8A The buffer layer 215 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 8A From similar to the above Figure 4BThe view is a cross-sectional view of the buffer layer 214 taken from a certain perspective, but each of the first buffer panel 220 and the second buffer panel 230 in the buffer layer 215 has Figure 3D The pyramid-shaped protrusion 335 shown is a buffer panel 305. Similarly, Figure 8B The buffer layer 216 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 8B From similar to the above Figure 4B The view is a cross-sectional view of the buffer layer 216 taken from a certain perspective, but each of the first buffer panel 220 and the second buffer panel 230 in the buffer layer 216 has Figure 3E The buffer panel 307 shows the bow-shaped protrusion 337. Although Figure 8A and Figure 8B The first protrusion 224 and the second protrusion 234 are shown to be directly opposite each other, but other arrangements, including the offset arrangements discussed above, can be used.

[0133] Figure 8C Also shown is a buffer layer 217 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 8C From similar to the above Figure 4B A cross-sectional view of the buffer layer 216 taken from a specific perspective. In the buffer layer 210 discussed above, the first buffer panel 220 and the second buffer panel 230 are arranged such that the first protrusion 224 protrudes toward the second buffer panel 230 and the second protrusion 234 protrudes toward the first buffer panel 220, but as... Figure 8C As shown, the first buffer panel 220 and the second buffer panel 230 are arranged such that the first protrusion 224 protrudes away from the second buffer panel 230 and the second protrusion 234 protrudes away from the first buffer panel 220. As with the discussion of the multiple layers applicable here, the first buffer panel 220 and the second buffer panel 230 are positioned such that the back surface 314 of the first buffer panel 220 abuts against the back surface 314 of the second buffer panel 230.

[0134] Figure 9A and Figure 9B The buffer layer 218 is shown as formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 9A This is a top view of buffer layer 213, and Figure 9B It is along Figure 9A A cross-sectional view of the buffer layer 218 taken by line 9B-9B. As mentioned above, the geometry of the second protrusion 234 may differ from that of the first protrusion 224. Figure 9A and Figure 9B In China, use Figure 4DThe buffer panel 305 with pyramidal protrusions 335 shown in FIG. 4F forms the first buffer panel 220, and the buffer panel 309 with rectangular protrusions 339 shown in FIG. 4F forms the second buffer panel 230. Although other arrangements can be used, Figure 9A and Figure 9B Showing the above reference Figure 5A and Figure 5B The offset arrangement of the buffer layer 218 is discussed. In the previous buffer layer 210, both the first protrusion 224 and the second protrusion 234 include contact protrusions; however, depending on the arrangement and geometry, only one of the first protrusion 224 or the second protrusion 234 may include a contact protrusion. Figure 9A and Figure 9B As shown, for example, the second protrusion 234 includes a contact protrusion, wherein the distal end 322 of the second protrusion 234 contacts the first buffer panel 220, but the distal end 322 of the first protrusion 224 does not contact the second buffer panel 230.

[0135] Figure 9C From similar Figure 9B A cross-sectional view of multiple buffer layers 218 taken from the perspective of [the viewer's perspective]. Figure 9A and Figure 9B The two or more buffer layers 218 shown can be referenced above. Figure 5C The first buffer layer 212a and the second buffer layer 212b discussed are arranged in a similar manner to be adjacent to each other. Figure 5C The discussion of the feature part in the middle is applicable to Figure 9C The first buffer layer 218a and the second buffer layer 218b are shown in the figure.

[0136] Figure 9D This illustrates multiple cushioning panels of different types in another arrangement. Besides the arrangement of the protrusions relative to each other, the shape of the protrusions also causes each sheet to have a different level of stiffness. As will be discussed in more detail below, it can be advantageous to use a combination of a first cushioning layer 219a and a second layer 219b, the second layer 219b having a greater stiffness than the first cushioning layer 219a, especially when the first cushioning layer 219a is positioned as a more rigid layer (…). Figure 9D The second layer (219b) is closer to product 10. Figure 9D In the diagram, the first buffer layer 219a is shown using the reference above. Figure 4A and Figure 4B The buffer layer 211 shown and described herein, and the second layer 219b are shown having Figure 3F The rectangular protrusion 339 shown is a buffer panel 309. However, other buffer panels can be used to form these layers, as long as the rigidity is as described above.

[0137] Figure 10A and Figure 10B A method for forming a buffer layer 210 (e.g., the buffer layer 211 discussed above) is shown. Figure 10A It is the first step, and Figure 10B This is the second step. After forming each of the first cushioning panel 220 and the second cushioning panel 230 using the molding pulp method discussed above, adhesive 241 can be applied to the first cushioning panel 220, the second cushioning panel 230, or both. Figure 10A The figure shows adhesive 241 being applied to a second cushioning panel 230. More specifically, adhesive 241 is shown being applied to the protruding side of the second cushioning panel 230, including the distal end 322 of the second protrusion 234. The first cushioning panel 220 is then positioned relative to the second cushioning panel 230, the positioning, as shown, may include positioning the first protrusion 224 directly opposite the second protrusion 234, wherein the distal end 322 of the first protrusion 224 contacts the distal end 322 of the second protrusion 234. The adhesive 241 is then allowed to dry, bonding the distal end 322 of the first protrusion 224 to the distal end 322 of the second protrusion 234.

[0138] Figure 11A and Figure 11B Another method for forming buffer layer 210 (e.g., buffer layer 211 discussed above) is shown. Figure 11A The first step is shown, and Figure 11B The second step is shown. In this method, the first buffer panel 220 and the second buffer panel 230 are formed as a single buffer panel 240, wherein the first buffer panel 220 is a first portion 243 of the buffer panel 240 and the second buffer panel 230 is a second portion 245 of the buffer panel 240. The first portion 243 and the second portion 245 are separated by a connecting portion 247. The connecting portion 247 may be a portion of the buffer panel 240 on which the protrusion 320 is not formed. The connecting portion 247 may be a flat sheet portion of the buffer panel 240. After the adhesive 241 is applied in the manner discussed above, the first portion 243 may be rotated relative to the second portion 245, as indicated by the arrow, so as described above relative to Figure 10B The discussion method is defined, such as Figure 11B As shown in the image.

[0139] Figure 11C Optional additional steps are shown. As will be discussed further below, the cushioning layer 210 and the cushioning block 200 can be positioned relative to each other to form various packaging materials. (See reference...) Figure 16A and Figure 16BAs discussed, the third buffer block 116 and the fourth buffer block 118 can be arranged laterally relative to each other, for example, to form an L-shape, with a product cavity 122 between the third buffer block 116 and the fourth buffer block 118. One way to arrange them laterally is... Figure 11B Following the steps shown, the buffer panel 240 is further folded. For example, one end of the buffer panel 240 may be rotated relative to the other end of the buffer panel 240 to form two buffer blocks (e.g., a third buffer block 116 and a fourth buffer block 118) positioned laterally to each other. The buffer panel 240 may include a corner portion 249, and the corner portion 249 may be notched or otherwise cut to facilitate rotation before rotating one of the first base portion 222 and the second base portion 232. Additionally, one end of the buffer panel 240 may be further rotated to form multiple buffer layers (e.g., referred to above). Figure 4C The discussion focuses on the first buffer layer 211a and the second buffer layer 211b, rather than stopping the folding to form an L-shape.

[0140] Figure 11D Another optional additional step is shown. The buffer panel 240 can be referenced above. Figure 11C The method of discussion is further rotated to form a U-shape, which has, for example, a first buffer block 112, a second buffer block 114 and a third buffer block 116, which will be discussed in more detail below. Figure 11C One end of the L-shape shown can be further rotated to be arranged laterally with the other section of the buffer panel 240.

[0141] Figure 11E This illustrates yet another optional additional step in forming multiple layers. Figure 11B In this process, the buffer panel 240 is folded back once to form a buffer layer, and then one end of the buffer layer is folded to the other end. Here, in Figure 11E In this process, the buffer panel 240 itself is folded multiple times to form multiple buffer layers. Therefore, the base layer of the buffer panel 240 can have a serpentine structure after being folded.

[0142] Figure 12 The buffer block 202 is shown, which can be used as the packaging material 100 discussed herein. Figure 1The buffer block 202 is a composite buffer block having one or more buffer layers 210 combined with at least one other layer having a different construction, such as different materials or different structures. In this embodiment, the other layer is a cellulose sheet 250. The cellulose sheet 250 can be a paper sheet having various reference weights. Thicker and stiffer cellulose sheets 250 can be used, including, for example, fiberboard sheets. The cellulose sheet 250 can abut against and be attached to the buffer layer 210. More specifically, the cellulose sheet 250 can abut against and be directly attached to one of the outer sides 228 of the first buffer panel 220 or the outer side 238 of the second buffer panel 230. The cellulose sheet 250 can include a first surface 252 and a second surface 254. The first surface 252 can abut against and be directly attached to one of the outer sides 228 of the first buffer panel 220 or the outer side 238 of the second buffer panel 230. The adhesive can be applied to the first surface 252 of the cellulose sheet 250, to one of the outer side 228 of the first cushioning panel 220 or the outer side 238 of the second cushioning panel 230, or both, to directly attach the cellulose sheet 250 to the cushioning layer 210.

[0143] Multiple cellulose sheets 250 can be used in different arrangements. In some arrangements, a first cellulose sheet and a second cellulose sheet can be abutted against and directly attached to the outer side 228 of a first cushioning panel 220 and the outer side 238 of a second cushioning panel 230, respectively. In some embodiments, the cellulose sheet 250 is formed on the outer side of the cushioning block 202 and may be referred to as a cover layer.

[0144] Figure 13 The buffer block 203 is shown, which can be used as the packaging material 100 discussed herein. Figure 1 ) buffer block 200. Figure 13 The buffer block 203 shown is also a composite buffer block, but the buffer block 203 can be corrugated fiberboard sheet 260 (also known as corrugated cardboard) instead of cellulose sheet 250. Figure 13The corrugated fiberboard sheet 260 shown is a single-wall corrugated fiberboard sheet, but other corrugated fiberboard sheets 260 can be used, including, for example, double-wall and triple-wall corrugated fiberboard sheets. The corrugated fiberboard sheet 260 includes a top sheet 261, a bottom sheet 263, and corrugated sheets 265 sandwiched between the top sheet 261 and the bottom sheet 263. When the corrugated fiberboard sheet 260 is a double-wall or triple-wall corrugated fiberboard sheet, the corrugated fiberboard sheet 260 may include a plurality of corrugated sheets 265 sandwiched between the top sheet 261 and the bottom sheet 263, wherein intermediate or middle sheets separate the corrugated sheets 265.

[0145] Each of the liner (e.g., top sheet 261, bottom sheet 263, and middle or intermediate sheet) and corrugated sheet 265 can be a suitable sheet made of cellulose fibers, typically used in the construction of cardboard shipping boxes. Each corrugated sheet 265 includes multiple grooves. Any suitable standard groove shape typically used in the construction of cardboard shipping boxes can be used. These grooves are referred to herein as internal grooves to distinguish them from other grooves formed in the packaging materials discussed below.

[0146] The corrugated fiberboard sheet 260 can be positioned and arranged in a similar manner to the cellulose sheet 250 described above. More specifically, the corrugated fiberboard sheet 260 may include a first surface 267 and a second surface 269, where the first surface 267 is the outward-facing surface of the top sheet 261 and the second surface 269 is the outward-facing surface of the bottom sheet 263. The first surface 267 and the second surface 269 of the corrugated fiberboard sheet 260 can be positioned and arranged in a similar manner to the first surface 252 and the second surface 254 of the cellulose sheet 250 described above. In some embodiments, the corrugated fiberboard sheet 260 is formed on the outer side of the buffer block 202, and like the cellulose sheet 250, the corrugated fiberboard sheet 260 may be referred to as a cover layer. The corrugated fiberboard sheet 260 may also be a structural layer of the buffer block 203.

[0147] For certain applications (including the television applications discussed above), a combination of robust and rigid protection and cushioning is desired. Therefore, in some embodiments, one or more cushioning panels 300 arranged and constructed in the manner discussed above... Figures 3A to 3G It can be used in conjunction with additional layers of a more robust and rigid construction. For example, a buffer layer 210 with one or more buffer panels 300 can be used. Figure 2 Together with another panel or sheet panel having a more robust and rigid construction than cushioning panel 300 and cushioning layer 210, they form a composite cushioning block. These sheet panels are referred to herein as rigid sheet panel 400. Figure 14A To distinguish them from the buffer panel 300, and when a load is applied in the thickness direction of the rigid sheet panel 400, the buffer panel 300, or the buffer layer 210, the stiffness of the rigid sheet panel 400 is greater than the stiffness of the buffer panel 300, the buffer layer 210, or both. The composite buffer block may include one or more rigid layers 270 ( Figures 15A to 15D It is formed of one or more rigid sheet panels 400. Various different rigid sheet panels 400 that can be used to form the rigid layer 270 are further discussed below, and the reference numeral 400 is generally used herein to refer to various different rigid panels.

[0148] Figure 14A This shows materials that can be used to form the cushioning block 200 and the packaging material 100. Figure 1 ) rigid sheet panel 400. Figure 14A The rigid sheet panel 400 shown is a honeycomb panel 410. The honeycomb panel 410 includes a top sheet 412 and a bottom sheet 414. The honeycomb panel 410 may include a first surface 416 and a second surface 418, the first surface 416 being the outward-facing surface of the top sheet 412 and the second surface 418 being the outward-facing surface of the bottom sheet 414. Each of the top sheet 412 and the bottom sheet 414 is a cellulose sheet, and the discussion above regarding the cellulose sheet 250 applies to these sheets. The honeycomb panel 410 also includes a core 420 sandwiched between the top sheet 412 and the bottom sheet 414.

[0149] Figure 14B The core 420 of the honeycomb panel 410 is shown. The core 420 includes a plurality of strips 422. The strips 422 are cellulose strips of cellulose sheet, and the discussion above regarding cellulose sheet 250 applies to these cellulose strips. The core 420 is formed by attaching the strips 422 together (e.g., using an adhesive) to form a plurality of monomers 424 defined by the strips 422. Figure 14B In this assembly, monomer 424 has a hexagonal shape, but other shapes can be used. Strip 422 can be oriented in a direction transverse to the top sheet 412 and bottom sheet 414; for example, strip 422 can be oriented in a direction perpendicular to the top sheet 412 and bottom sheet 414. Monomer 424 is also oriented in a direction transverse to the top sheet 412 and bottom sheet 414; for example, monomer 424 can be oriented in a direction perpendicular to the top sheet 412 and bottom sheet 414. The thickness of the top sheet 412 and bottom sheet 414 can be greater than the thickness of strip 422.

[0150] Figures 15A to 15D A buffer block 200 is shown, and more specifically a composite buffer block is shown, which is formed by combining one or more buffer layers 210 with one or more rigid layers 270. Figure 15A The buffer block 204 is shown, which has the buffer layer 212 discussed above and a rigid layer 270 formed using a honeycomb panel 410. The rigid layer 270, and more specifically the honeycomb panel 410, are... Figure 15A The honeycomb panel 410 is shown in contact with the buffer layer 210. As described above, the honeycomb panel 410 includes a top sheet 412 having a first surface 416. The top sheet 412 can be positioned against a second buffer panel 230 of the buffer layer 210. The first surface 416 of the top sheet 412 can abut against and be directly attached to one of the outer surfaces 228 of the first buffer panel 220 or the second buffer panel 230. An adhesive can be applied to the first surface 416 of the honeycomb panel 410 or to one or both of the outer surfaces 228 of the first buffer panel 220 or the second buffer panel 230 to directly attach the honeycomb panel 410 to the buffer layer 210. Figure 15A In the middle, the top sheet 412 abuts against the second base layer 232 of the buffer layer 210.

[0151] Protrusions 320 (e.g., first protrusion 224, second protrusion 234, or both) can be integrated with the unit 424 of the cellular panel 410. Figure 14B They are oriented in the same direction. The first protrusion 224, the second protrusion 234, the monomer 424, or a combination thereof may be oriented in the thickness direction of the buffer block 204.

[0152] Figure 15B A buffer block 205 is shown, which has a rigid layer 270 formed using a honeycomb panel 410. The buffer block 205 is similar to the one described above. Figure 15A The buffer block 204 is under discussion, but as... Figure 15B As shown, the buffer layer 210 is formed of a buffer panel 300 (e.g., the buffer panel 303 discussed above). The buffer panel 303 may be positioned in different orientations, for example, in which the protrusion 320 extends toward the honeycomb panel 410, for example, in which the distal end 322 of the protrusion 320 contacts the first surface 416 of the top sheet 412.

[0153] Figure 15C Another buffer block 206 is shown, which has a rigid layer 270, which is a honeycomb panel 410. Figure 15C The buffer block 206 shown is similar to the one referenced above. Figure 15B The buffer block 205 is discussed, but here, the protrusion 320 protrudes away from the honeycomb panel 410. The base layer 310 may abut against the honeycomb panel 410, for example, against the top sheet 412. More specifically, the back surface 314 may be positioned to abut against and directly contact the first surface 416.

[0154] Figure 15DThis shows another buffer block 207. Buffer block 207 is similar to the one mentioned above. Figure 15A The buffer block 204 is discussed. The buffer block 207, in addition to including the buffer layer 210 and the rigid layer 270, also includes a corrugated fiberboard sheet 260. The corrugated fiberboard sheet 260 can be integrated into various locations within the buffer block 207. The corrugated fiberboard sheet 260 can be positioned adjacent to, for example, against, the buffer layer 210, the rigid layer 270, or both. The corrugated fiberboard sheet 260 can be positioned on the outer surface of the buffer block 207, for example, on the outside of the rigid layer 270 or the buffer layer 210, but the corrugated fiberboard sheet 260 can be positioned between the buffer layer 210 and the rigid layer 270. Figure 15D As shown, for example, corrugated fiberboard sheet 260 is positioned adjacent to rigid layer 270 and more specifically against the honeycomb panel 410 of rigid layer 270.

[0155] As mentioned above, the packaging material 100 discussed in this article ( Figure 1 The product 10 can be formed by one or more buffer blocks 200. The buffer blocks 200 can surround the product 10 in various ways and in various combinations. Figure 1 Arrangement. In the following discussion, packaging material 100 will be described as forming a uniform structure, for example, by means of corrugated fiberboard sheet 260 connected to each other by cushioning blocks 200. Cushioning blocks 200 can be arranged around product 10 in a manner discussed below without needing to be connected to each other.

[0156] Figure 16A and Figure 16B The corner-shaped packaging material 110 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials discussed is 102. Figure 16B This is an exploded view of the corner-shaped packaging material 110. The corner-shaped packaging material 110 includes one or more cushioning blocks capable of being positioned around the product 10. More specifically, the corner-shaped packaging material 110 includes a plurality of cushioning blocks, including a first cushioning block 112, a second cushioning block 114, a third cushioning block 116, and a fourth cushioning block 118. Each of these cushioning blocks 112, 114, 116, and 118 includes one or more cushioning layers 210, and more specifically, as shown... Figure 16A and Figure 16B As shown, there are two buffer layers 210. Figure 16A and Figure 16B The buffer layer shown is the one mentioned above. Figures 4A to 4C The buffer layer 211 shown and described may be used, but other buffer layers 210 may be used, and each of these buffer blocks 112, 114, 116 and 118 includes a first buffer layer 211a and a second buffer layer 211b.

[0157] The first buffer block 112 and the second buffer block 114 are positioned opposite each other with a product cavity 122 between them. The first buffer block 112 and the second buffer block 114 may be oriented parallel to each other, wherein the thickness direction of each of the first buffer block 112 and the second buffer block 114 is oriented in the same direction. The first buffer block 112 may be a front buffer block, and the second buffer block 114 may be a rear buffer block. The first buffer block 112 and the second buffer block 114 may have different shapes, and as... Figure 16A and Figure 16B As shown, the first buffer block 162 and the second buffer block 114 each have the same shape, which is L-shaped.

[0158] The third buffer block 116 is positioned along one edge of each of the first buffer block 112 and the second buffer block 114 to form a bottom buffer block. The third buffer block 116 may be positioned on the long side of the first buffer block 112 and the second buffer block 114. The third buffer block 116 is positioned laterally, and more specifically, the third buffer block 116 is orthogonal to the first buffer block 112 and the second buffer block 114.

[0159] A fourth buffer block 118 is positioned along one edge of each of the first buffer block 112 and the second buffer block 114 to form a side buffer block. The fourth buffer block 118 may be positioned on the short sides of the first buffer block 112 and the second buffer block 114. The fourth buffer block 118 is laterally positioned, and more specifically, the fourth buffer block 118 is orthogonal to the first buffer block 112 and the second buffer block 114. The third buffer block 116 and the fourth buffer block 118 are also laterally positioned relative to each other, and more specifically, the third buffer block 116 and the fourth buffer block 118 are orthogonally positioned relative to each other.

[0160] The third buffer block 116 and the fourth buffer block 118 also define the boundaries of the product cavity 122. Figure 16A The product cavity 122 shown is a slot, but it can be formed into other shapes by means of the arrangement of the product cavity 122. In the arrangement shown, each of the buffer blocks 112, 114, 116, and 118 defines a product cavity 122 in which the product 10 can be placed. The buffer blocks 112, 114, 116, and 118 include a product side and a product side surface 124, which is the surface of each of the buffer blocks 112, 114, 116, and 118 facing the product cavity 122.

[0161] Buffer blocks 112, 114, 116, and 118 also include a container side and a container side surface 126, said container side surface 126 being a surface extending outward from the corner-shaped packaging material 110 and away from the product cavity 122. Each of buffer blocks 112, 114, 116, and 118 includes a backing sheet, such as a corrugated fiberboard sheet 260, positioned on the container side of buffer blocks 112, 114, 116, and 118. More specifically, the corner-shaped packaging material 110 includes a first corrugated fiberboard sheet portion 132, a second corrugated fiberboard sheet portion 134, a third corrugated fiberboard sheet portion 136, and a fourth corrugated fiberboard sheet portion 138, which correspond to the first buffer block 112, the second buffer block 114, the third buffer block 116, and the fourth buffer block 118, respectively, and are arranged in the manner discussed above. Although corrugated fiberboard sheet portions 132, 134, 136, and 138 can be formed independently as separate sheets on buffer blocks 112, 114, 116, and 118, corrugated fiberboard sheet portions 132, 134, 136, and 138 are... Figure 16A and Figure 16B The portion shown is a corrugated fiberboard sheet 130 that is interconnected and folded in a manner that forms an open box-shaped structure.

[0162] Figure 17 The U-shaped packaging material 142 is shown, which can be used, for example, as described above. Figure 1 One of the U-shaped packaging materials 104 discussed. The U-shaped packaging material 142 is similar to the one mentioned above. Figure 16A and Figure 16B The corner-shaped packaging material 110 discussed is used to form the U-shaped packaging material 142, which includes a first cushioning block 112, a second cushioning block 114, and a third cushioning block 116, arranged in a U-shape similar to the arrangement discussed above. The shape of each of the first cushioning block 112 and the second cushioning block 114 is shown as an elongated rectangular block to form an elongated product cavity 122.

[0163] Figure 18 Two corner-shaped packaging materials 110 and a U-shaped packaging material 142 are shown arranged adjacent to each other. The product cavities 122 of the corner-shaped packaging materials 110 and the U-shaped packaging materials 142 can be aligned with each other to form a cavity for product 10 ( Figure 1 A continuous cavity. Although in Figure 18 In China (and also in) Figure 1 The packaging materials 100 (shown in the middle) are adjacent to each other, but packaging materials 100 such as corner-shaped packaging material 110 and U-shaped packaging material 142 can be spaced apart from each other with gaps between them.

[0164] Figure 19A and Figure 19BAnother corner-shaped packaging material 144 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials discussed is 102. Figure 19B This is an exploded view of corner-shaped packaging material 144. Figure 19A and Figure 19B The corner-shaped packaging material 144 shown is similar to the one referenced above. Figure 16A and Figure 16B The discussion concerns the corner-shaped packaging material 110, and this discussion applies to it. In this corner-shaped packaging material 144, a first corrugated fiberboard sheet portion 132, a second corrugated fiberboard sheet portion 134, a third corrugated fiberboard sheet portion 136, and a fourth corrugated fiberboard sheet portion 138 are formed on the product-side surface 124 of each cushioning block 112, 114, 116, and 118, rather than on the container-side surface 126. In this embodiment, the corrugated fiberboard sheet 130, and more specifically the corrugated fiberboard sheet portions 132, 134, 136, and 138, define a cavity rather than defining the surface of the cushioning layer 210. In other embodiments, the corrugated fiberboard sheet portions 132, 134, 136, and 138 may be formed on either side of the cushioning layer 210 (e.g., using...). Figure 16A and Figure 16B Features and Figure 19A and Figure 19B (Combination of characteristic parts).

[0165] Figure 20A and Figure 20B Another corner-shaped packaging material 150 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials discussed is 102. Figure 20A and Figure 20B The corner-shaped packaging material 150 shown is similar to the one referenced above. Figure 16A and Figure 16B The corner-shaped packaging material 110 under discussion. As described above, the first corrugated fiberboard sheet portion 132, the second corrugated fiberboard sheet portion 134, the third corrugated fiberboard sheet portion 136, and the fourth corrugated fiberboard sheet portion 138 can be part of the corrugated fiberboard sheet 130. An advantage of using the corrugated fiberboard sheet 130 is that the cushioning blocks 112, 114, 116, and 118 can be attached to a surface of the corrugated fiberboard sheet 130, for example, the inner surface of the corrugated fiberboard sheet 130, and subsequently the corrugated fiberboard sheet 130 can be folded from a flat configuration to a folded configuration to form the corner-shaped packaging material 150. Suitable attachment measures include, for example, adhesives to attach the cushioning blocks 112, 114, 116, and 118 (or portions thereof, such as cushioning layers) to this surface of the corrugated fiberboard sheet 130. Figure 20A and Figure 20B The corner-shaped packaging material 150 shown can be configured in both flat and folded configurations. Figure 20A The flat configuration is shown in the figure, and in Figure 20B The folded configuration is shown below. In the folded configuration, the shape of the corner-shaped packaging material 150 is set as described above. Figure 16A and Figure 16B As discussed.

[0166] exist Figure 20A In the flat configuration shown, the first buffer block 112 can be spaced apart from the third buffer block 116 with a gap between them. The corrugated fiberboard sheet 130 includes a first connecting portion 152 spanning between the first buffer block 112 and the third buffer block 116. The connecting portion of the corrugated fiberboard sheet 130 (e.g., the first connecting portion 152) is a portion of the corrugated fiberboard sheet 130 to which no buffer block is attached, and allows the first buffer block 112 to fold relative to the third buffer block 116. The first connecting portion 152 connects the first corrugated fiberboard sheet portion 132 to the third corrugated fiberboard sheet portion 136. Similarly, the second buffer block 114 is spaced apart from the third buffer block 116, wherein a second connecting portion 154 connects the second corrugated fiberboard sheet portion 134 to the third corrugated fiberboard sheet portion 136 to allow the second buffer block 114 to fold relative to the third buffer block 116. Similarly, the fourth buffer block 118 is spaced apart from the third buffer block 116, wherein the third connecting portion 156 connects the fourth corrugated fiberboard sheet portion 138 to the third corrugated fiberboard sheet portion 136 to allow the fourth buffer block 118 to fold relative to the third buffer block 116.

[0167] In order to Figure 20A The flat configuration in the middle moves to Figure 20BIn the folded configuration shown, the first buffer block 112, the second buffer block 114, and the fourth buffer block 118 are folded relative to the third buffer block 116, as indicated by the arrows. Although buffer blocks 112, 114, and 118 are shown folded relative to the third buffer block 116, they can be attached to each other in other configurations to fold in different directions. For example, the first buffer block 112, the second buffer block 114, and the third buffer block 116 can be connected to the fourth buffer block 118 via a corrugated fiberboard sheet 130 to fold relative to the fourth buffer block 118. Additionally, although described with reference to the corrugated fiberboard sheet 130, other backing or connecting materials, such as paper sheets, can be used. More generally, a buffer block (e.g., a first buffer block 112) can be connected to another buffer block (e.g., a third buffer block 116) with gaps formed between them by connecting materials, so that the first buffer block (e.g., the first buffer block 112) can be folded from a flat configuration to a folded configuration.

[0168] To hold the corner-shaped packaging material 150 in a folded configuration, the corrugated layer 130 may include tabs 158, which are attached, for example, to the corrugated fiberboard sheet 130 or a portion thereof, such as a portion of a fourth corrugated fiberboard sheet portion 138. A peelable adhesive strip 159 may be applied to the inner surface of each tab 158 and serve as an adhesive strip to hold the corner-shaped packaging material 150 in a folded configuration. Instead of the peelable adhesive strip 159 (or other than the peelable adhesive strip 159), other measures may be used to hold the corner-shaped packaging material 150 in a folded configuration. For example, instead of the peelable adhesive strip 159, adhesive may be applied to various locations of the corner-shaped packaging material 150, for example, to the inner surface of the tab 158. Alternatively or alternatively, an adhesive strip (e.g., tape) may be used. When using an adhesive strip such as tape, the tabs 158 may be omitted.

[0169] Figure 21A and Figure 21B Another corner-shaped packaging material 160 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials 102 discussed. Corner-shaped packaging material 160 is similar to... Figure 20A and Figure 20B The corner-shaped packaging material 150 shown, and the corner-shaped packaging material 160, can be configured in both flat and folded configurations. Figure 21A The flat configuration is shown in the figure, and in Figure 21B The folded configuration is shown. As described above, a single molded pulp cushioning panel can be used in the formation of the corner-shaped packaging material 160, and Figure 21A and Figure 21B The corner-shaped packaging material 160 shown is formed from a single foldable molded cushioning panel 170, for example, as referenced above. Figure 3A and Figure 3B The buffer panel 301 is discussed. Although referring to buffer panel 301 ( Figure 3A and Figure 3B The description is provided, but the buffer panel 300 discussed herein (e.g., Figures 3A to 3G Any one of them.

[0170] The foldable molded cushioning panel 170 includes a first protrusion 162, a second protrusion 164, a third protrusion 166, and a fourth protrusion 168, which are respectively referenced above. Figure 20A and Figure 20B The first buffer block 112, the second buffer block 114, the third buffer block 116, and the fourth buffer block 118 discussed are arranged in a similar manner. Each of these protruding segments 162, 164, 166, and 168 is a segment containing a protrusion 320 (e.g., a cylindrical protrusion 331).

[0171] The foldable molded cushioning panel 170 includes a first connecting portion 172 spanning between a first protruding segment 162 and a third protruding segment 166. The connecting portion of the foldable molded cushioning panel 170 (e.g., the first connecting portion 172) may be a portion of the cushioning panel 170 on which the protrusions 320 are not formed. The connecting portion may be a flat sheet portion of the foldable molded cushioning panel 170. The first connecting portion 172 connects the first protruding segment 162 to the third protruding segment 166 and allows the first protruding segment 162 to fold or otherwise rotate relative to the third protruding segment 166. Similarly, a second protruding segment 164 is spaced apart from the third protruding segment 166 and connected to the third protruding segment 166 via the second connecting portion 174, allowing the second connecting portion 174 to fold or otherwise rotate relative to the third corner-shaped packaging material 146. Similarly, the fourth protrusion 168 is spaced apart from the third protrusion 166 and connected to the third protrusion 166 via the third connecting portion 176, so as to allow the fourth protrusion 168 to fold or otherwise rotate relative to the third protrusion 166.

[0172] The foldable molded cushioning panel 170 can be referenced above. Figure 20A and Figure 20B The corner-shaped packaging material 150 discussed herein is folded from a flat configuration to a folded configuration in a similar manner and is held within the folded configuration, and this discussion applies to this. The additional layers discussed herein can be attached to each of the protruding segments 162, 164, 166, and 168 to form the various cushioning blocks discussed herein.

[0173] Figure 22A and Figure 22B Another corner-shaped packaging material 146 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials discussed is 102. Figure 22A It is a top view of corner-shaped packaging material 146, and Figure 22B This is a perspective view of corner-shaped packaging material 146. Figure 22A and Figure 22B The corner-shaped packaging material 146 shown is similar to the one referenced above. Figure 16A and Figure 16B The corner-shaped packaging material 110 is discussed, and this discussion applies here. However, in Figure 22A and Figure 22B In the corner-shaped packaging material 146 shown, each of the cushioning blocks 112, 114, 116 and 118 is a composite cushioning block that includes a rigid layer 270. Figure 22A and Figure 22B The rigid layer 270 shown includes one or more honeycomb panels 410, but any of the rigid sheet panels 400 discussed herein may be used.

[0174] More specifically, the first buffer block 112 and the second buffer block 114 include the above-mentioned references Figure 15B The discussion focuses on buffer block 205. The third buffer block 116 and the fourth buffer block 118 include the above references. Figure 15A The buffer block 204 under discussion, but with multiple buffer layers 210, for example, as referenced above. Figure 5B The first buffer layer 212a and the second buffer layer 212b are discussed. However, as mentioned above, buffer layers 210 with different arrangements and numbers can be used.

[0175] In each of buffer blocks 112, 114, 116, and 118, buffer layer 210 may be positioned on the product side. More specifically, buffer layer 210 is positioned adjacent to product cavity 122 and is positioned as described above. Figure 16A and Figure 16B The discussion defines the product cavity 122. Moreover, the rigid layer 270 and more specifically the honeycomb panel 410 are positioned between the cushioning layer 210 and the corrugated fiberboard sheet 130 on the container side of the packaging material 146 that forms a corner shape.

[0176] In some embodiments, the third buffer block 116 and the fourth buffer block 118 form packaging material 100. Figure 1 The inventors have discovered that it is advantageous to surround the outer edge with product 10 ( ). Figure 1Additional buffers, such as additional buffer layers 210, are placed opposite each other. Thus, the third buffer block 116 and the fourth buffer block 118 forming the outer edge can have more buffer layers 210 than the first buffer block 112 and the second buffer block 114.

[0177] Figure 23 Another corner-shaped packaging material 148 is shown, which can be used, for example, as described above. Figure 1 One of the corner-shaped packaging materials 102 discussed. As mentioned above, it can be attached to the outer edge of the product 10 ( Figure 1 An additional buffer layer 210 is placed on the opposite side of the first surface. Figure 23 The corner-shaped packaging material 148 shown is similar to Figure 22A and Figure 22B The corner-shaped packaging material 146 shown is omitted here from the first buffer block 112 and the second buffer block 114, with only the honeycomb panel 410 and the corrugated fiberboard sheet 130 present.

[0178] Figure 24A The U-shaped packaging material 180 is shown, which can be used, for example, as referenced above. Figure 1 One of the U-shaped packaging materials 104 is discussed. The formation of the U-shaped packaging material 180 is similar to that described above. Figure 17 The formation of the U-shaped packaging material 142 is discussed. The U-shaped packaging material 180 includes, as referred to above... Figure 17 The third buffer block 116 is positioned as discussed above. (Refer to the above text.) Figure 22A and Figure 22B Similar to the corner-shaped packaging material 146 discussed herein, the third cushioning block 116 is a composite cushioning block including a rigid layer 270. The rigid layer 270 of the third cushioning block 116 shown in Figure 24, along with other cushioning blocks, includes one or more honeycomb panels 410, but any of the rigid sheet panels 400 discussed herein can be used. More specifically, the third cushioning block 116 includes the features described above. Figure 15A The buffer block 204 under discussion, but with multiple buffer layers 210, for example, as referenced above. Figure 5B The first buffer layer 212a and the second buffer layer 212b are discussed.

[0179] The U-shaped packaging material 180 also includes a plurality of cushioning blocks positioned on the first side of the U-shaped packaging material 180, which, as described above... Figure 17The first cushioning block 112 discussed is similar. More specifically, the U-shaped packaging material 180 includes a first-side first-end cushioning block 181, a first-side second-end cushioning block 183, and a first-side middle cushioning block 185 on the first side. Each of the first-side first-end cushioning block 181, the first-side second-end cushioning block 183, and the first-side middle cushioning block 185 shown in FIG. 25 includes one or more cushioning layers 210 (e.g., referred to above). Figure 5B The composite buffer block is formed by the buffer layer 212 discussed and one or more rigid layers 270 (e.g., honeycomb panel 410). The first-side first end buffer block 181, the first-side second end buffer block 183, and the first-side intermediate buffer block 185 are connected to each other by corrugated fiberboard sheet 130, and more specifically, by a first corrugated fiberboard sheet portion 132 positioned on the first side of the U-shaped packaging material 180. Each of the first-side first end buffer block 181 and the first-side second end buffer block 183 is separated from the first-side intermediate buffer block 185 by a first-side connecting portion 187 of the corrugated fiberboard sheet 130.

[0180] Similarly, the U-shaped packaging material 180 includes a plurality of cushioning blocks positioned on the second side of the U-shaped packaging material 180, which, as described above... Figure 17 The second buffer block 114 discussed is similar. More specifically, the U-shaped packaging material 180 includes a second-side first-end buffer block 182, a second-side second-end buffer block 184, and a second-side intermediate buffer block 186 on the first side. Each of the second-side first-end buffer block 182, second-side second-end buffer block 184, and second-side intermediate buffer block 186 shown in FIG. 25 is formed by one or more buffer layers 210, for example, as referenced above. Figure 5B The buffer layer 212 under discussion. The second-side first end buffer block 182, the second-side second end buffer block 184, and the second-side intermediate buffer block 186 are connected to each other via corrugated fiberboard sheet 130, and more specifically, via second corrugated fiberboard sheet portions 134 positioned on the second side of the U-shaped packaging material 180. Each of the second-side first end buffer block 182 and the second-side second end buffer block 184 is separated from the second-side intermediate buffer block 186 by a second-side connecting portion 188 of the corrugated fiberboard sheet 130.

[0181] The first end buffer block 181 on the first side is positioned opposite the first end buffer block 182 on the second side, with a product cavity 122 between them. The second end buffer block 183 on the first side is positioned opposite the second end buffer block 184 on the second side, with a product cavity 122 between them. The middle buffer block 185 on the first side is positioned opposite the middle buffer panel 186 on the second side, with a product cavity 122 between them.

[0182] Although some configurations of the buffer blocks are shown, the first-side first-end buffer block 181, the second-side first-end buffer block 182, the first-side second-end buffer block 183, the second-side second-end buffer block 184, the first-side intermediate buffer block 185, and the second-side intermediate buffer block 186 can be formed using other buffer blocks discussed herein. In practice, the cushioning protection provided by the first buffer layer 212a and the second buffer layer 212b of the third buffer block 116 would be sufficient, and in this case, the sides of the U-shaped packaging material 180 may include a rigid layer 270, unlike the honeycomb panel 410, which has no buffer layer. Similarly, although shown as separated buffer blocks, the first-side first-end buffer block 181, the first-side second-end buffer block 183, and the first-side intermediate buffer block 185 can be a single continuous elongated buffer block, and similarly, the second-side first-end buffer block 182, the second-side second-end buffer block 184, and the second-side intermediate buffer block 186 can be a single continuous elongated buffer block.

[0183] Figure 24B The U-shaped packaging material 190 is shown, which can be used, for example, as referenced above. Figure 1 One of the U-shaped packaging materials 104 is discussed. The formation of the U-shaped packaging material 190 is similar to that described above. Figure 24A The formation of the U-shaped packaging material 180 is discussed. Instead of having multiple cushioning blocks on the first and second sides, the U-shaped packaging material 190 has one block on the first side, namely the first side block 192, and one block on the second side, namely the second side block 194. Each of the first side block 192 and the second side block 194 includes a rigid panel 400, and more specifically, includes a rigid panel without a cushioning layer. Figure 24B The rigid panel 400 shown is a honeycomb panel 410, but any of the rigid panels discussed herein can be used. In cases where packaging materials with only rigid panels (e.g., honeycomb panels) are known to fail, it has been found that adding a cushioning layer (third cushioning block 116) on the underside can provide sufficient cushioning for the product 10 (such as a television). Although only the rigid panel 400 is shown, the first side block 192 and the second side block 194 can include any cushioning block, such as the composite cushioning blocks discussed herein.

[0184] Figures 25A to 25C The diagram shows another buffer layer formed by the first buffer panel 512 and the second buffer panel 514, which is referred to herein as the irregular buffer layer 500. The irregular buffer layer 500 discussed herein can be used as any of the buffer layers discussed above, especially when the buffer layer abuts against or otherwise contacts the product 10. Figure 25AAn irregular buffer layer 510 is shown that can be used to form a buffer block. The first buffer panel 512 and the second buffer panel 514 are similar to the first buffer panel 220 (see, for example, [link to relevant documentation]). Figure 2 ) and second buffer panel 230 (for example, see Figure 2 When the buffer panel (e.g., the first buffer panel 512) is a molded buffer panel, the first buffer panel 512 can be molded into various shapes. For example, the first buffer panel 512, and more specifically the product side and product side surface 124 of the buffer block formed using the irregular buffer layer 510, can be shaped to conform to the shape of the product 10, for example, the irregularly shaped product 12. Therefore, the irregular buffer layer 510, and more specifically the first buffer panel 512 formed therefrom, can include a product side recess 516, a product side protrusion 518, or both, which are formed on the product side of the buffer block formed using the irregular buffer layer 510. Thus, the product side recess 516 and the product side protrusion 518 can be formed on the back surface 314 of the first buffer panel 512.

[0185] Figure 25B Another irregular buffer layer 520 is shown, which is similar to the one mentioned above. Figure 25A The irregular buffer layer 510 is discussed. The irregular buffer layer 520 is formed by a first buffer panel 522 and a second buffer panel 524, which are similar to the first buffer panel 512 and the second buffer panel 514, respectively. In the aforementioned first buffer panel 512 and second buffer panel 514, the protrusions 320 (e.g., first protrusion 224 and second protrusion 234) on the protruding sides of the first buffer panel 512 and the second buffer panel 514 may have a repeating or regular pattern arrangement. However, as... Figure 25B As shown, the first protrusion 224 may be a non-repeating pattern, for example, it may be omitted on the non-protrusion portion 526 of the first buffer panel 522, which is, for example, the portion of the first buffer panel 522 that includes the product-side recess 516.

[0186] Figure 25C This shows yet another irregular buffer layer 530, similar to the one described above. Figure 25B The irregular buffer layer 520 is discussed. The irregular buffer layer 530 is formed by a first buffer panel 532 and a second buffer panel 534, the first buffer panel 532 and the second buffer panel 534 being similar to the first buffer panel 522 and the second buffer panel 524, respectively. Figure 25CIn the first buffer panel 532, the first protrusion 224 is omitted, and the second protrusion 234 of the second buffer panel 534 has a non-repeating pattern, for example, an enlarged protrusion 536 abutting against the non-protruding portion 526.

[0187] Figures 26A to 30C Various configurations of the buffer blocks discussed herein that form shipping containers are shown. Although the packaging material discussed herein is 100 ( Figure 1 ) can be used with transport container 20 ( Figure 1 The containers are separated and placed inside the shipping container 20, but other configurations, such as those discussed below, can be used to form a shipping container.

[0188] Figure 26A and Figure 26B This illustrates the use of buffer block 200 discussed herein (for example, see...). Figure 2 The transport container 600 is formed from this. The transport container 600 can be configured in both flat and folding configurations. Figure 26A The flat configuration is shown in the figure, and in Figure 26B The diagram illustrates a folded configuration. The transport container 600 includes a corrugated fiberboard sheet 610, similar to the corrugated fiberboard 130 discussed above. The corrugated fiberboard sheet 610 is divided to form multiple segments, which can be folded from a flat state to a folded state and form a box in the folded state. Various patterns can be used for dividing the fiberboard sheet 610. Although the transport container 600 can have other shapes, Figure 26B The transport container 600 shown is a rectangular transport container, and the fiberboard sheet 610 comprises multiple segments including a front segment 611, a left side segment 612, a right side segment 613, a rear segment 614, a first top flap 615, a second top flap 616, a first bottom flap 617, and a second bottom flap 618. The buffer block 200 can be referenced above. Figure 20A and Figure 20B The same manner of discussion applies to each of the multiple segments of the fiberboard sheet 610. More specifically, the transport container 600 may include a front buffer block 621, a left side buffer block 622, a right side buffer block 623, a rear buffer block 624, a first top buffer block 625, a second top buffer block 626, a first bottom buffer block 627, and a second bottom buffer block 628, which are respectively attached to the inner surfaces of the front segment 611, the left side segment 612, the right side segment 613, the rear segment 614, the first top flap 615, the second top flap 616, the first bottom flap 617, and the second bottom flap 618.

[0189] Each of the buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 can be separated from each other, with gaps between them. Therefore, the corrugated fiberboard sheet 610 may include a connecting portion 619 between adjacent buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628. The connecting portion 619 is similar to the connecting locations discussed above, for example, the first connecting portion 152. The connecting portion 619 allows adjacent buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 to be separated from each other. Figure 26A The flat configuration shown folds to Figure 26B The folding configuration shown is used to form a transport container 600, in which a product cavity 122 for the products to be transported is formed. The transport container 600 can be held in the folding configuration using methods used for transport boxes (e.g., strips of adhesive (e.g., tape) or adhesive applied to the overlapping portions of the transport container 600).

[0190] Figure 27A and Figure 27B This illustrates the use of buffer block 200 discussed herein (for example, see...). Figure 2 The transport container 601 is formed by [the above reference]. Transport container 601 is similar to [the above reference]. Figure 26A and Figure 26B The transport container 600 is discussed. The transport container 601 can be configured in both flat and folding configurations. Figure 27A The flat configuration is shown in the figure, and in Figure 27B The folded configuration is shown in the diagram. An advantage of using the buffer block 200 discussed herein is that the buffer block 200 can be configured to more directly conform to the product 10 and, in particular, not have a rectangular shape. Buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 can have locations where additional layers are added to better conform to the shape of the product 10 and form a product cavity 122 with a non-rectangular cross-section. As... Figure 27A and Figure 27B As shown, for example, each of the front buffer block 621 and the rear buffer block 624 includes a portion thereon on which an additional layer 632 (e.g., an additional buffer layer) is formed. In order to accommodate the additional layer 632, other buffer blocks 621, 622, 623, 624, 625, 626, 627 and 628 (e.g., the first top buffer block 625, the second top buffer block 626, the first bottom buffer block 627 and the second bottom buffer block 628) may include cutouts 634 to accommodate the additional layer 632.

[0191] Figure 28A and Figure 28B This illustrates the use of buffer block 200 discussed herein (for example, see...). Figure 2 The transport container 602 is formed by [the above reference]. Figure 27A and Figure 27B The transport container 601 is discussed. The transport container 602 can be configured in both flat and folding configurations. Figure 28A The flat configuration is shown in the figure, and in Figure 28B The folded configuration is shown in the diagram. As described above, the irregular buffer layer 500 can be advantageously used to form the irregular buffer block 636. Figure 28A and Figure 28B As shown, one or more buffer blocks can be irregular buffer blocks 636, such as back buffer block 624. Other buffer blocks, such as second top buffer block 626 and second bottom buffer block 628, can be shaped to accommodate irregular buffer blocks 636 when in a folded configuration.

[0192] Figure 29A and Figure 29B Another shipping container 603 is shown. Shipping container 603 is similar to... Figure 28A and Figure 28B The transport container 602 shown can be configured in both flat and folding configurations. Figure 29A The flat configuration is shown in the figure, and in Figure 29B The folding configuration is shown. Instead of using corrugated fiberboard sheet 610, the transport container 603 consists of a single foldable molded cushioning panel 640 (similar to the one described above). Figure 3A and Figure 3B The discussion of buffer panel 301 and the above references Figure 21A and Figure 21B The corner-shaped packaging material 160 is formed as discussed. Although referencing cushioning panel 301 ( Figure 3A and Figure 3B The description is provided, but the buffer panel 300 discussed herein (e.g., Figures 3A to 3G Any one of them.

[0193] The foldable molded cushioning panel 640 includes a front protrusion 641, a left protrusion 642, a right protrusion 643, a rear protrusion 644, a first top wing protrusion 645, a second top wing protrusion 646, a first bottom wing protrusion 647, and a second bottom wing protrusion 648, arranged similarly to the arrangement of the front section 611, left section 612, right section 613, rear section 614, first top wing 615, second top wing 616, first bottom wing 617, and second bottom wing 618 discussed above. Each of these protrusions 641, 642, 643, 644, 645, 646, 647, and 648 is a segment containing a protrusion 320 (e.g., a cylindrical protrusion 331).

[0194] The foldable molded cushioning panel 640 also includes a connecting portion 649, which is similar to the one described above. Figure 21A and Figure 21B The first connecting portion 172 is discussed. Connecting portion 649 is positioned between adjacent protruding segments 641, 642, 643, 644, 645, 646, 647, and 648 to allow protruding segments 641, 642, 643, 644, 645, 646, 647, and 648 to fold relative to each other in the manner discussed above, as with... Figure 21A and Figure 21B Similar to the foldable molded buffer panel 170 in this paper, the additional layers discussed herein can be attached to each of the protrusions 641, 642, 643, 644, 645, 646, 647 and 648 to form the various buffer blocks discussed herein.

[0195] Figure 30A and Figure 30C Another shipping container 604 is shown. Figure 30C ). Figure 30A and Figure 30C The transport container 604 shown is similar to the one mentioned above. Figure 29A and Figure 29B The transport container 603 under discussion. Figures 30A to 30C The transport container 603 shown is formed by multiple foldable molded cushioning panels, not by a single foldable molded cushioning panel. Figure 30A The first foldable molded buffer panel 652 is shown, and Figure 30B A second foldable molded cushioning panel 654 is shown. Each of the first foldable molded cushioning panel 652 and the second foldable molded cushioning panel 654 can be any of the cushioning panels 300 discussed herein (e.g., Figures 3A to 3G For example, a cushioning panel 301 having cylindrical protrusions 331. A first foldable molded cushioning panel 652 can be positioned relative to a second foldable molded cushioning panel 654 to form a cushioning layer 650 as described above. Figure 30C ), which is similar to the first buffer panel 220 ( Figure 2 ) and second buffer panel 230 ( Figure 2 The first foldable molded cushioning panel 652 is an internal cushioning panel that can be positioned with respect to product 10. Figure 30C Adjacent to each other, and can be irregularly shaped cushioning sheets, similar to the first cushioning panel 512 discussed above. Figure 16A ).exist Figure 30A The image shows a first foldable molded buffer panel 652 in a flat configuration, and... Figure 30B The image shows a second foldable molded buffer panel 654 in a flat configuration.

[0196] Figure 30C A first foldable molded cushioning panel 652 and a second foldable molded cushioning panel 654 are shown in a folded configuration to form a shipping container 604. The first foldable molded cushioning panel 652 can be folded to form a product cavity 122. A cushioning layer 650, including each of the first foldable molded cushioning panel 652 and the second foldable molded cushioning panel 654, can be folded to surround the product 10. The first foldable molded cushioning panel 652 and the second foldable molded cushioning panel 654 can each be folded independently to form the cushioning layer 650. For example, the first foldable molded cushioning panel 652 can be folded, and then the second foldable molded cushioning panel 654 can be folded around the first foldable molded cushioning panel 652 to form the cushioning layer 650 and the shipping container 604. Alternatively, the first foldable molded cushioning panel 652 and the second foldable molded cushioning panel 654 can be placed together in a flat configuration and then folded together. Whether the first foldable molded cushioning panel 652 is separate or attached to the second foldable molded cushioning panel 654, the first foldable molded cushioning panel 652 can be folded around the product 10.

[0197] Figure 31 An alternative buffer panel 700 is shown. In the buffer block 200 discussed above ( Figure 2 The buffer layer 210 used in ) Figure 2 The cushioning panel 700 is formed using molded pulp sheet as the cushioning panel, but other cushioning panels can be used to form the cushioning block. The cushioning panel 700 is formed from a sheet including protrusions 720, which are allowed to deform when a load is applied thereon. More specifically, in Figure 31 In the middle, the buffer panel 700 includes a plurality of grooves 722 formed in a sheet that also includes a base layer 712. The base layer 712 is similar to the base layer 310 discussed above. Figure 3B The grooves 722 form protrusions 720 of the cushioning panel 700. These grooves 722 are spaced apart from each other, and this spaced configuration allows the grooves 722 to deform relative to the base layer 712, thereby providing cushioning. The cushioning panel 700 can be formed from various cellulose sheets discussed above. Corrugated fiberboard sheets 710 can be folded or otherwise formed into the grooves 722. The grooves 722 are elongated and extend parallel to each other. The grooves 722 can have various shapes, as will be discussed further below.

[0198] Figure 31The cushioning panel 700 shown includes a triangular recess 722, referred to herein as a triangular recess 732. For clarity, other cushioning panels discussed herein are referred to as cushioning panels with triangular recesses 730. The triangular recess 732 includes a plurality of unit walls defining a triangular-shaped unit, referred to herein as a triangular unit 734. The plurality of unit walls include a distal wall 742 forming the base of the triangle, and is similar to the distal end 322 discussed above (see [link to original text]). Figure 3B The first transverse wall 744 is located on the distal side of the base layer 712. The plurality of individual wall units also include the first transverse wall 744 and the second transverse wall 746. The first transverse wall 744 and the second transverse wall 746 may be part of a corrugated fiberboard sheet 710, a portion of which extends transversely from the base layer 712 or its surface. The corrugated fiberboard sheet 710 may be a continuous sheet, and each of the first transverse wall 744 and the second transverse wall 746 connects one of the base layers 712 to the distal wall 742, thereby forming a side of one of the triangular individual units 734. The ends of the first transverse wall 744 and the second transverse wall 746 are closer to each other on the base layer 712 side than the ends on the distal wall 742, thereby forming the apex 736 of the triangular individual unit 734. The first transverse wall 744 and the second transverse wall 746 may abut against each other at the second transverse wall 746, but... Figure 31 As shown, for example, the ends of each of the first transverse wall 744 and the second transverse wall 746 can be spaced apart from each other to form a gap in the base layer 712. The size and spacing of the grooves 722 (e.g., triangular grooves 732), including the gap at the apex 736, can be varied to provide different cushioning properties.

[0199] Figure 32 A buffer panel 730 with triangular grooves is shown, serving as a buffer layer 210 for buffer block 208. The buffer panel 730 with triangular grooves can be used in a manner similar to any of the buffer panels described above. Figure 32 As shown, for example, a buffer panel 730 with triangular grooves is used to form a composite buffer block having a rigid layer 270 formed by a honeycomb panel 410.

[0200] Figure 33 A rigid sheet panel 400 is shown, and more specifically, a shaped corrugated fiberboard rigid sheet panel 402 is shown. Figure 33The formed corrugated fiberboard rigid sheet panel 402 shown includes a first surface and a second surface. For ease of reference herein, the first surface will be referred to as the top surface 432 and the second surface as the bottom surface 434, but depending on the use, these surfaces may have different orientations, for example, an outer surface and an inner surface. The formed corrugated fiberboard rigid sheet panel 402 may be formed from a corrugated fiberboard sheet 436 that is folded or otherwise shaped to form a plurality of triangular-shaped monomers, and more specifically, a plurality of first triangular monomers 440 and a plurality of second triangular monomers 450. First triangular units 440 and second triangular units 450 are arranged in an alternating pattern, wherein each first triangular unit 440 is adjacent to two second triangular units 450, and more specifically, each first triangular unit 440 is located between two second triangular units 450. Similarly, except for end units, each second triangular unit 450 is adjacent to two first triangular units 440, and more specifically, each second triangular unit 450 is located between two first triangular units 440. However, an end unit is adjacent to only one unit. If one of the first triangular units 440 is on an end (end unit), then the end unit of the first triangular unit 440 is adjacent to one of the second triangular units 450, and similarly, if one of the second triangular units 450 is on an end (end unit), then the end unit of the second triangular unit 450 is adjacent to one of the first triangular units 440. Each of the plurality of triangular units (i.e., the first triangular unit 440 and the second triangular unit 450) has a longitudinal axis that, in the illustrated embodiment, extends in a direction parallel to the top surface 432, the bottom surface 434, or both.

[0201] Each of the first triangular monomers 440 includes a base portion, referred to herein as a first base portion 442. The first base portion 442 is part of the corrugated fiberboard sheet 436, and multiple first base portions 442 collectively form a top wall. A top surface 432 is the outer surface of the top wall. Similarly, each of the second triangular monomers 450 includes a base portion, referred herein as a second base portion 452. The second base portion 452 is part of the corrugated fiberboard sheet 436, and multiple second base portions 452 collectively form a bottom wall. A bottom surface 434 is the outer surface of the bottom wall. Thus, the first triangular monomers 440 and the second triangular monomers 450 are arranged in an interlocking pattern.

[0202] The formed corrugated fiberboard rigid sheet panel 402 also includes a plurality of transverse walls 438. The transverse walls 438 may be part of a corrugated fiberboard sheet 436 extending transversely to a top surface 432 and a bottom surface 434. The formed corrugated fiberboard rigid sheet panel 402 may be formed from a continuous sheet (i.e., corrugated fiberboard sheet 436), and each transverse wall 438 connects one of a first base portion 442 to one of a second base portion 452, thereby forming a side of one of the triangular monomers. The transverse walls 438 separate a first triangular monomer 440 from an adjacent second triangular monomer 450. Two transverse walls 438 are joined together opposite the base portions to form the vertices of the triangular monomers. More specifically, two transverse walls 438 may be joined together opposite the first base portion 442 to form a first vertices 444 of one of the first triangular monomers 440, and two transverse walls 438 may be joined together opposite the second base portion 452 to form a second vertices 454 of one of the second triangular monomers 450. A transverse wall 438 is attached to the ends of the first base portion 442 and the second base portion 452. In the illustrated embodiment, each end of the first base portion 442 abuts against the end of an adjacent first base portion 442 at a second vertex 454, and each end of the second base portion 452 abuts against the end of an adjacent second base portion 452 at a first vertex 444. In some embodiments, an adhesive may be located at each first vertex 444 and each second vertex 454.

[0203] In the illustrated embodiment, the transverse walls 438 have the same length, and thus the first triangular unit 440 and the second triangular unit 450 can be isosceles triangles or equilateral triangles. In some embodiments, the length of the first base portion 442 and / or the second base portion 452 is the same as the length of each transverse wall 438, but in other embodiments, the length of the first base portion 442 and / or the second base portion 452 is greater than or less than the length of each transverse wall 438. Figure 1 In this configuration, both the first triangular monomer 440 and the second triangular monomer 450 are acute isosceles triangles, but other shapes, such as obtuse triangles, can also be used. The number, size, and density of the monomers can be varied to determine the desired overall extrusion, bursting, and flexibility. The angles and lengths of the vertices of the first base portion 442, the second base portion 452, and the transverse wall 438 of the triangular monomers can be varied to adjust the properties of the formed corrugated fiberboard rigid sheet panel 402.

[0204] Figure 34 A formed corrugated fiberboard rigid sheet panel 402 is shown, serving as the rigid layer 270 for the buffer block 209. The formed corrugated fiberboard rigid sheet panel 402 can be used in a manner similar to any of the rigid sheet panels described above. Figure 34 As shown, for example, a shaped corrugated fiberboard rigid sheet panel 402 is used together with a cushioning panel 730 with triangular grooves to form a composite cushioning block.

[0205] Figure 35 Another alternative buffer panel 700 is shown. As mentioned above, the recess 722 can have various shapes, and Figure 35 The cushioning panel 700 shown has V-shaped or wavy protrusions 720. For clarity, this cushioning panel is referred to as V-shaped cushioning panel 750 for other cushioning panels discussed herein. V-shaped cushioning panel 750 can be formed from cellulose sheets (e.g., corrugated fiberboard sheet 752) discussed herein. V-shaped cushioning panel 750 includes a plurality of macro-grooves 760 arranged parallel to each other. These macro-grooves 760 will be referred to as macro-grooves 760 to distinguish them from the internal grooves of the corrugated fiberboard sheet 752 forming V-shaped cushioning panel 750. The macro-grooves 760 of V-shaped cushioning panel 750 are parallel to the internal grooves.

[0206] The macro-grooves 760 may have a generally triangular (or V-shaped) shape, with their first plane 762 connecting to a second plane 764 at a apex 766. Adjacent macro-grooves 760 connect to each other at valleys 768, thus providing a structure of multiple alternating ridges (apex 766) and grooves (valve 768). The macro-grooves 760 are shown to have the same height and spacing, but they are not limited to this and may have different heights and spacings.

[0207] Figure 36 A V-shaped buffer panel 750 is shown, serving as the buffer layer 210 for buffer block 754. The V-shaped buffer panel 750 can be used in a manner similar to any of the buffer panels described above. Figure 36 As shown, for example, a V-shaped buffer panel 750 is used to form a composite buffer block having a rigid layer 270 formed by a honeycomb panel 410.

[0208] Figure 37A and Figure 37B Another alternative buffer panel 700 is shown. For clarity, this buffer panel is referred to as the finned buffer panel 770 for the other buffer panels discussed herein. Figure 11A This is a perspective view of the finned buffer panel 770, and Figure 37B These are detailed images, showing... Figure 37ADetail 37B of the finned cushioning panel 770A is shown. The protrusions 720 of the finned cushioning panel 770 are fins 780 arranged parallel to each other. The finned cushioning panel 770 can be formed from a cellulose sheet (e.g., corrugated fiberboard sheet 772) discussed herein. The fins 780 of the finned cushioning panel 770 can be parallel to the internal grooves of the corrugated fiberboard sheet 772 used to form the finned cushioning panel 770. The fins 780 can be separated from each other by a base section 774 of the finned cushioning panel 770. The base section 774 is generally planar. The base section 774 can be similar to the base layer described above. Each fin 780 is attached to the base section 774, and the fin 780 protrudes from the base section 774.

[0209] like Figure 37B As shown, the fins 780 of this embodiment have a U-shape or horseshoe shape, and each fin 780 includes a first protrusion 782, which is connected to a second protrusion 784 at a peak 786. The peak 786 is similar to the distal end of the protrusions discussed above. The end of each of the first protrusion 782 and the second protrusion 784 connected to the base segment 774 is a base end portion 788. The base end portion 788 is the end of the first protrusion 782 or the second protrusion 784 opposite to the peak 786. The first protrusion 782 and the second protrusion 784 may be continuously connected to each other at the peak 786, and may be a continuation of the same corrugated material at the peak 786 without being cut or separated.

[0210] Other portions of the first protrusion 782 and the second protrusion 784 (beyond the peak 786) can also be connected to each other. For example, an adhesive can be applied to the inner surface of the first protrusion 782, the inner surface of the second protrusion 784, or between the two. Although the adhesive can be applied along the entire length of the inner surfaces of the first protrusion 782 and / or the second protrusion 784, the adhesive can be applied between the base end portion 788 of the inner surface of the first protrusion 782 and / or the base end portion 788 of the inner surface of the second protrusion 784. In this way, the first protrusion 782 and the second protrusion 784 are also connected to each other at the base end portion 788. For example, connecting the first protrusion 782 and the second protrusion 784 at the base end portion 788 helps prevent the fin 780 from spreading out when a force is applied to the peak 786, and thus provides rigidity to the fin 780 and provides an overall protective (cushioning) effect to the finned buffer panel 770. In addition, the spacing between the fins 780 (e.g., the length of the base segment 774) can be changed to adjust the cushioning performance of the finned buffer panel 770.

[0211] Figure 38A finned buffer panel 770 is shown, serving as the buffer layer 210 for buffer block 776. The finned buffer panel 770 can be used in a manner similar to any of the buffer panels described above. Figure 36 As shown, for example, a finned buffer panel 770 is used to form a composite buffer block having a rigid layer 270 formed by a honeycomb panel 410.

[0212] Figure 39A and Figure 39B A buffer block 460 is shown having a buffer layer 210 (e.g., the buffer layer 211 discussed above) and a rigid layer 270. Figure 39A This is an exploded view of buffer block 460, and Figure 39B This is a perspective view of buffer block 460. Although the above reference is shown... Figure 4A and Figure 4B The buffer layer 211 is discussed, but one of the buffer layers discussed herein may be used. The rigid layer 270 includes one or more rigid sheet panels 400. Figure 39A and Figure 39B The rigid sheet panel 400 shown herein is referred to herein as a lattice-structured rigid sheet panel 404. The lattice-structured rigid sheet panel 404 can be used in any of the buffer blocks discussed herein.

[0213] The rigid sheet panel 404 with a lattice structure includes a plurality of strips, including a first strip 462 and a second strip 464 laterally positioned relative to each other to form a lattice structure 466 having a plurality of units 468. The first strip 462 and the second strip 464 have widths oriented in the thickness direction of the cushioning block 460. The first strip 462 and the second strip 464 can be positioned such that the units 468 are oriented in the thickness direction of the cushioning block 460. The first strip 462 and the second strip 464 can be orthogonally positioned with respect to the outer side 238 of the second cushioning panel 230. The units 468 are shown as rectangular units, with the first strip 462 orthogonally positioned relative to the second strip 464, but other angles may also be used.

[0214] The lattice structure 466 can be formed in different ways. The lattice structure 466 can be formed as a molded pulp structure, wherein the first strip 462 and the second strip 464 are integrally formed with each other. Alternatively, the first strip 462 and the second strip 464 can be formed as separate strips and then interlocked with each other. For example, the first strip 462, the second strip 464, or both can have slits formed therein to interlock with other strips. The first strip 462 and the second strip 464 can be corrugated fiberboard strips that interlock with each other. When the first strip 462 and the second strip 464 are corrugated fiberboard strips, the grooves of the corrugated fiberboard can be oriented in the thickness direction of the buffer block 460.

[0215] As mentioned above, adhesives can be used in a variety of situations. Any suitable adhesive can be used, but throughout the embodiments discussed herein, the adhesive is preferably a biodegradable adhesive.

[0216] Throughout the embodiments discussed herein, various features are described as being similar to one another. Therefore, a discussion of one feature also applies to features similar to it. In some cases, the same reference numerals are used throughout the document to describe the same or similar features. Additionally, while various layers have been described separately above, as mentioned above, these layers can be combined in various ways, including those not explicitly shown, to form packaging materials, and more specifically, to form various different cushioning blocks.

[0217] Although the present invention has been described with reference to certain exemplary embodiments, many additional modifications and variations will be apparent to those skilled in the art from this disclosure. Therefore, it should be understood that the invention may be practiced in ways other than those specifically described. Consequently, the exemplary embodiments of the invention should be considered illustrative in all respects and not restrictive, and the scope of the invention should be determined by any claims supported by this application and its equivalents, rather than by the foregoing description.

Claims

1. A packaging material, said packaging material comprising: One or more buffer layers, each buffer layer comprising: A first cushioning panel, the first cushioning panel having a first base layer, the first base layer having a plurality of first protrusions extending therefrom, each of the first protrusions having a distal end distal to the first base layer, the first cushioning panel being a molded pulp panel; and A second cushioning panel has a second base layer, the second base layer having a plurality of second protrusions extending therefrom, each of the second protrusions having a distal end distal to the second base layer, the second cushioning panel being a molded pulp panel. Wherein, the first buffer panel is positioned such that the plurality of first protrusions protrude toward the second buffer panel, and The second buffer panel is positioned such that the plurality of second protrusions protrude toward the first buffer panel, and at least a portion of the plurality of second protrusions are second contact protrusions, the distal ends of which contact the first buffer panel.

2. The packaging material according to claim 1, wherein, The first buffer panel and the second buffer panel are the first and second portions of a foldable molded pulp panel, the foldable molded pulp panel having a connecting portion that connects the first portion and the second portion.

3. The packaging material according to claim 1, wherein, At least a portion of the second contact protrusion is an internal second contact protrusion, and each internal second contact protrusion is positioned between two or more adjacent first protrusions among the plurality of first protrusions.

4. The packaging material according to claim 1, wherein, At least a portion of the plurality of first protrusions are first contact protrusions, the distal end of which contacts the second buffer panel.

5. The packaging material according to claim 4, wherein, At least a portion of the second contact protrusion is an internal second contact protrusion, and each internal second contact protrusion is positioned between two or more adjacent first protrusions among the plurality of first protrusions.

6. The packaging material according to claim 4, wherein, The first contact protrusion contacts the second buffer panel by having the distal end of each first contact protrusion contact at least one of the plurality of second protrusions, and The second contact protrusion contacts the first buffer panel by having the distal end of each second contact protrusion contact at least one of the plurality of first protrusions.

7. The packaging material according to claim 6, wherein, The first contact protrusion and the second contact protrusion are positioned directly opposite each other, wherein the distal end of each first contact protrusion contacts the distal end of the corresponding second contact protrusion.

8. The packaging material according to claim 1, comprising two or more cushioning layers, wherein the two or more cushioning layers include a first cushioning layer and a second cushioning layer. in, For each buffer layer, the first base layer has an inner side and an outer side, the inner side of the first base layer is positioned opposite the second buffer panel and the plurality of first protrusions extend from the inner side of the first base layer, and the second base layer has an inner side and an outer side, the inner side of the second base layer is positioned opposite the first buffer panel and the plurality of second protrusions extend from the inner side of the second base layer, and Wherein, the outer side of one of the first base layer or the second base layer of the first buffer layer abuts against the outer side of one of the first base layer or the second base layer of the second buffer layer.

9. The packaging material according to claim 1, wherein, The first protrusion, the second protrusion, or both are elongated ridges extending parallel to each other.

10. The packaging material according to claim 1, wherein, Each of the plurality of first protrusions has a first geometric shape, and Each of the plurality of second protrusions has a second geometric shape, which is different from the first geometric shape.

11. The packaging material according to claim 1, wherein, Each of the plurality of first protrusions has a first geometric shape, and Each of the plurality of second protrusions has a second geometric shape, which is the same as the first geometric shape.

12. The packaging material according to claim 1, wherein, For each buffer layer, the second base layer has an inner side and an outer side, the inner side of the second base layer is positioned opposite the first buffer panel and the plurality of second protrusions extend from the inner side of the second base layer, each of the plurality of second protrusions having a tip and a length from the inner side to the tip, the plurality of second protrusions having a plurality of different lengths.

13. A composite packaging material, said composite packaging material comprising: One or more buffer layers, the one or more buffer layers being arranged to have a product side and an outer side, each buffer layer comprising: A first cushioning panel, the first cushioning panel having a first base layer, the first base layer having a plurality of first protrusions extending therefrom, the first cushioning panel being a molded pulp panel; and A second cushioning panel, the second cushioning panel having a second base layer, the second base layer having a plurality of second protrusions extending therefrom, the second cushioning panel being a molded pulp panel. Wherein, the first buffer panel and the second buffer panel are positioned in contact with each other, wherein the plurality of first protrusions protrude toward the second buffer panel and the plurality of second protrusions protrude toward the first buffer panel; and A cellulose sheet, which is positioned on the outside of one or more buffer layers.

14. The composite packaging material according to claim 13, wherein, The cellulose sheet is a corrugated fiberboard sheet.

15. The composite packaging material of claim 14, further comprising a rigid panel positioned between one of the cushioning layers and the cellulose sheet, the rigid panel being formed of a cellulose material, wherein, When a load is applied in the thickness direction of the rigid panel or the buffer layer, the stiffness of the rigid panel is greater than the stiffness of each buffer layer.

16. The composite packaging material according to claim 13, wherein, The cellulose sheet is a honeycomb panel, which includes a plurality of monomers extending in the thickness direction of the packaging material, and the plurality of first protrusions and the plurality of second protrusions extending in the thickness direction of the packaging material.

17. A composite packaging material, said composite packaging material comprising: A buffer layer, the buffer layer including a buffer panel having a base layer having a plurality of protrusions extending therefrom, each of the protrusions having a distal end distal to the base layer, the buffer panel being a molded pulp panel; and A rigid panel, which contacts the cushioning layer, is formed of a cellulose material. Specifically, when a load is applied in the thickness direction of the rigid panel or the buffer panel, the stiffness of the rigid panel is greater than that of the buffer panel.

18. The composite packaging material according to claim 17, wherein, The rigid panel is a honeycomb panel, which comprises a plurality of monomers extending in the thickness direction of the packaging material.

19. The composite packaging material according to claim 17, wherein, The rigid panel is a lattice-structured panel having monomers oriented in the thickness direction of the rigid panel.

20. The composite packaging material according to claim 17, wherein, The plurality of protrusions extend from the base layer in a direction away from the rigid panel.

21. The composite packaging material according to claim 17, wherein, The plurality of protrusions extend from the base layer toward the rigid panel, the rigid panel including a first surface, and the distal ends of the plurality of protrusions contact the first surface.

22. A packaging material, said packaging material comprising: One or more buffer blocks, each capable of being positioned on the product side of the buffer block around the object to be transported, each buffer block comprising: One or more buffer layers, each buffer layer comprising: A first cushioning panel, the first cushioning panel having a first base layer, the first base layer having a plurality of first protrusions extending therefrom, each of the first protrusions having a distal end distal to the first base layer, the first cushioning panel being a molded pulp panel; and A second cushioning panel has a second base layer, the second base layer having a plurality of second protrusions extending therefrom, each of the second protrusions having a distal end distal to the second base layer, the second cushioning panel being a molded pulp panel. The first buffer panel is positioned such that the plurality of first protrusions protrude toward the second buffer panel, and the second buffer panel is positioned such that the plurality of second protrusions protrude toward the first buffer panel.

23. The packaging material according to claim 22, wherein, Each buffer block also includes a rigid panel that contacts one of the buffer layers.

24. The packaging material according to claim 23, wherein, The rigid panel is a honeycomb panel having multiple monomers extending in a direction toward the product side of the buffer block, and the honeycomb panel is formed of cellulose material.

25. The packaging material according to claim 23, wherein, The one or more buffer layers are positioned closer to the product side of each buffer block than the rigid panel.

26. The packaging material according to claim 22, wherein, Each buffer block also includes a cellulose outer sheet, which is a corrugated fiberboard sheet.

27. The packaging material according to claim 26, wherein, Each buffer block also includes a rigid panel that contacts one of the buffer layers, and the corrugated fiberboard sheet contacts either one of the buffer layers or the rigid panel.

28. The packaging material according to claim 22, wherein, The one or more buffer blocks include a first buffer block and a second buffer block, the first buffer block and the second buffer block being arranged laterally to form an L-shape and forming a product cavity between them.

29. The packaging material of claim 22 further comprises a corrugated fiberboard sheet, the corrugated fiberboard sheet comprising a first portion, a second portion, and a connecting portion connecting the first portion and the second portion. in, The one or more buffer blocks include a first buffer block and a second buffer block, the first buffer block including a first portion of the corrugated fiberboard sheet, and the second buffer block including a second portion of the corrugated fiberboard sheet.

30. The packaging material according to claim 22, further comprising: A corrugated fiberboard sheet comprising a plurality of backing portions connected to each other by a plurality of connecting portions, each connecting portion connecting one backing portion to another. and Multiple buffer blocks, each buffer block further comprising one of the multiple backing portions, The plurality of backing sections are connected to each other in a manner that allows them to be folded into a shipping container.

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