Trays formed from multi-layer fiber sheets

Abstract

Trays can be used to hold and cushion items. Multiple fiber-based sheets are laminated into multilayer fiber sheets, wherein the multilayer fiber sheets are substantially planar. The multilayer fiber sheets are then formed into a tray, wherein the tray is substantially not planar. Forming the tray includes forming at least one protrusion within the tray. The sum of the basis weights of the multiple fiber-based sheets is in the range of 500 gsm to 700 gsm.

Description

Technical Field

[0001] This disclosure pertains to the technical field of trays for holding and cushioning objects. More particularly, this disclosure relates to trays formed from multilayer fiber sheets, which have been formed to have protrusions. Background Technology

[0002] A wide variety of materials and designs are used in cushioning for packaging. Packaging cushioning includes paper cushioning, open-cell foam and closed-cell foam cushioning, as well as cushioning articles made of membranes, such as air-porous cushioning. In some cases, cushioning may include a tray, at least a portion of which is positioned between an object and a container in which the object is situated. Paper products are cheaper than plastics by weight, and most paper products are more biodegradable than most plastic products. Traditionally, paper cushioning includes crepe paper, embossed paper, slit paper, and corrugated paper. It is desirable to provide a paper-based tray that exhibits cushioning performance comparable to that of a plastic-based tray. Summary of the Invention

[0003] This overview is provided to introduce, in a simplified form, some concepts that will be further described in the detailed description below. This overview is not intended to identify key features of the claimed subject matter, nor is it intended to serve as an aid in determining the scope of the claimed subject matter.

[0004] In a first embodiment, a method includes laminating a plurality of fiber-based sheets into a multilayer fiber sheet and forming the multilayer fiber sheet into a tray. The multilayer fiber sheet is substantially planar. The tray is not substantially planar. The forming includes forming at least one protrusion in the tray. The sum of the basis weights of the fiber-based sheets in the plurality of fiber-based sheets is in the range of 500 gsm to 700 gsm.

[0005] In the second embodiment, each of the plurality of fiber-based sheets in the first embodiment has one or more of the following: when tested according to ISO 19243, the longitudinal tensile percentage is at least 13% and the transverse tensile percentage is at least 9%; and / or when tested according to ISO 19243, the longitudinal tensile strength is at least 14 kN / m and the transverse tensile strength is at least 7 kN / m; and / or when tested according to ISO 1974, the longitudinal tear strength is at least 3300 mN and the transverse tear strength is at least 4800 mN.

[0006] In the third embodiment, forming a multilayer fiber sheet into a tray according to any of the preceding embodiments includes at least one of the following: cold-forming the multilayer fiber sheet into a tray or pressing the multilayer fiber sheet into a tray.

[0007] In the fourth embodiment, the method of any of the foregoing embodiments further includes at least one of the following: forming fold lines in the multilayer fiber sheet and / or cutting off a portion of the multilayer fiber sheet.

[0008] In a fifth embodiment, the method of any of the foregoing embodiments further includes forming a plurality of fold lines in a multilayer fiber sheet. Each of the plurality of fold lines is located between the main board of the tray and one of the plurality of side panels of the tray.

[0009] In a sixth embodiment, the method of the fifth embodiment further includes folding a tray along each of the plurality of fold lines such that each of the plurality of side panels is substantially perpendicular to the main board.

[0010] In a seventh embodiment, the method of the sixth embodiment further includes placing a tray in a container, wherein the main board of the tray is substantially parallel to the bottom of the container, and each of the plurality of side panels of the tray is substantially parallel to the side of the container.

[0011] In the eighth embodiment, forming at least one protrusion in the tray of any of the fifth to seventh embodiments includes: forming at least one protrusion on the main board and forming at least one protrusion on each of the plurality of side panels.

[0012] In the ninth embodiment, the at least one protrusion in the tray of any of the preceding embodiments includes a pattern of smaller and larger shapes.

[0013] In the tenth embodiment, the tray of any of the preceding embodiments includes a marking area.

[0014] In the eleventh embodiment, the method of the tenth embodiment further includes printing information in the marked area.

[0015] In the twelfth embodiment, forming a tray from a multilayer fiber sheet as described in any of the tenth to eleventh embodiments includes: imprinting information onto a marking area.

[0016] In the thirteenth embodiment, the marking area of ​​any of the tenth to twelfth embodiments is located on one of the at least one protrusion or on the tray area outside the at least one protrusion.

[0017] In the fourteenth embodiment, the tray is formed by the method described in any of the preceding embodiments.

[0018] In the fifteenth embodiment, the tray includes a plurality of fiber substrate sheets laminated into a multilayer fiber sheet and at least one protrusion formed in the multilayer fiber sheet. Due to said at least one protrusion, the tray is substantially not planar. The sum of the basis weights of the fiber substrate sheets in the plurality of fiber substrate sheets is in the range of 500 gsm to 700 gsm.

[0019] In the sixteenth embodiment, the tray of the fifteenth embodiment further includes multiple fold lines in a multilayer fiber sheet. Each of the multiple fold lines is located between the main body of the tray and one of the multiple side panels of the tray.

[0020] In the seventeenth embodiment, the tray of the sixteenth embodiment can be folded along each of the plurality of fold lines, such that each of the plurality of side panels is substantially perpendicular to the main board.

[0021] In the eighteenth embodiment, at least one protrusion described in any of the sixteenth and seventeenth embodiments includes at least one protrusion on the motherboard and at least one protrusion on each of the plurality of side plates.

[0022] In the nineteenth embodiment, the tray of any of the embodiments in the fifteenth to eighteenth embodiments further includes a marking area. The marking area includes at least one of information printed in the marking area or information embossed into the marking area.

[0023] In the twentieth embodiment, the system includes a tray according to the seventeenth embodiment and a container having a bottom and sides. The tray is placed in the container, wherein the main plate of the tray is substantially parallel to the bottom of the container, and each of the plurality of side plates of the tray is substantially parallel to one of the sides of the container. Attached Figure Description

[0024] When taken in conjunction with the accompanying drawings, the foregoing aspects and numerous accompanying advantages of the disclosed subject matter will become more readily understood and appreciated by referring to the following detailed description, wherein:

[0025] Figure 1 A to 1D depict embodiments of the process for manufacturing a tray that can be used to cushion objects, according to the embodiments described herein;

[0026] Figures 2A to 2C Each one depicts Figure 1 The top and side views of the tray shown in Figure D, and Figures 2A to 2C Examples of embodiments of a further method of manipulating a tray according to the embodiments described herein are shown;

[0027] Figure 3 A perspective view of another embodiment of the tray according to the embodiments described herein is depicted;

[0028] Figures 4A to 4C A perspective view depicting a system and method for packaging objects according to embodiments described herein;

[0029] Figure 5 A perspective view of another embodiment of the tray according to the embodiments described herein is depicted;

[0030] Figure 6 A perspective view depicting an embodiment of a tray without side panels or fold lines according to the embodiments described herein;

[0031] Figure 7 A perspective view depicting another embodiment of a tray without side panels or fold lines according to the embodiments described herein;

[0032] Figure 8 A perspective view depicting yet another embodiment of a tray without side panels or fold lines according to the embodiments described herein; and

[0033] Figure 9A and 9B An embodiment according to the description herein is depicted. Figure 3 A perspective view of the tray and the container used to pack the object. Detailed Implementation

[0034] This disclosure describes embodiments of trays that can hold and / or cushion objects. In particular, this disclosure describes trays formed from fiber-based sheets (e.g., paper sheets). To give the tray sufficient rigidity, multiple layers of fiber-based sheets are laminated to form a multilayer fiber sheet. The tray is formed by shaping (e.g., pressing, cold forming, etc.) the multilayer fiber sheet into a tray having at least one protrusion. When the tray is placed in a container, between an object and the side of the container, the protrusion provides cushioning for the object in the container.

[0035] Figure 1 Examples of the process for manufacturing a tray that can be used to cushion objects are depicted in A to 1D. Figure 1 A describes a collection 10 of fiber-based sheets 12. In some embodiments, the fiber-based sheet 12 may be paper, paperboard, newspaper, or any other kind of fiber-based material. A non-limiting list of possible fiber-based materials includes those examples shown in Table 1. In some embodiments, the fiber-based sheet 12 has one or more of the following properties: a longitudinal tensile strength percentage of at least 13% and a transverse tensile strength percentage of at least 9% when tested according to ISO 1924-3; and / or a longitudinal tensile strength of at least 14 kN / m and a transverse tensile strength of at least 7 kN / m when tested according to ISO 1924-3; and / or a longitudinal tear strength of at least 3300 mN and a transverse tear strength of at least 4800 mN when tested according to ISO 1974. An example of a fiber-based sheet having all the properties described in the preceding sentence is Example A in Table 1.

[0036]

[0037] In the depicted embodiment, set 10 includes four fiber substrate sheets 12. In other embodiments, set 10 may include any number of fiber substrate sheets 12. In other words, set 10 may include two or more fiber substrate sheets 12. In some embodiments, the fiber substrate sheets 12 may be fiber substrate sheets of the same type having similar properties. For example, each fiber substrate sheet 12 may have the same dimensions, basis weight, thickness, longitudinal and transverse tensile percentages, longitudinal and transverse tensile strengths, etc. In other embodiments, any two fiber substrate sheets 12 may have at least one property that is different from each other. For example, the fiber substrate sheets 12 in the set may include two fiber substrate sheets with different basis weights.

[0038] from Figure 1 The example shown in A is... Figure 1 In the example shown in B, an assembly 10 of fiber-based sheets 12 has been laminated together to form a multilayer fiber sheet 20. Lamination may include applying an adhesive between each pair of sheets in the assembly 10 of fiber-based sheets 12, and then pressing the fiber-based sheets 12 together. In some embodiments, the fiber-based sheets 12 are coated with a heat-sealable material (e.g., a polymer-based coating), and lamination includes applying heat and pressure to soften the coating due to the heat, and then bonding it to adjacent sheets due to the forces applied as the coating cools. In the depicted embodiments, the multilayer fiber sheet 20 is substantially planar. The multilayer fiber sheet 20 may be flexible and capable of bending or twisting without permanent physical deformation, but despite its flexibility, it remains substantially planar because it can maintain a substantially planar shape.

[0039] exist Figure 1 In the example shown in C, the multilayer fiber sheet 20 is formed by a press 30. In the depicted embodiment, the press 30 includes an upper tool 32 and a lower tool 34, which are pressed together with the multilayer fiber sheet 20 located between them. The lower surface of the upper tool 32 and the upper surface of the lower tool 34 can be shaped such that the pressing of the multilayer fiber sheet 20 forms the multilayer fiber sheet 20 into a desired non-planar shape. In particular, the forming process can form the multilayer fiber sheet 20 into a tray 40 (see below). Figure 1 (As discussed in D). The formation process may include pressing a multilayer fiber sheet 20, such as... Figure 1 As depicted in C. In some embodiments, the forming process is a cold forming process that does not heat the multilayer fiber sheet 20 to temperatures exceeding the ambient temperature at which the forming process occurs.

[0040] Figure 1D depicts a tray 40 formed of a multilayer fiber sheet 20. The tray 40 is not substantially planar. The tray 40 includes at least one protrusion. In the depicted embodiment, the tray 40 includes a flat portion 42, a central protrusion 44, and side protrusions 46. It will be apparent that the flat portion 42, central protrusion 44, and side protrusions 46 of the tray 40 are not the only possible embodiments of protrusions in the tray 40. In some embodiments, the size, shape, arrangement, location, number, and other characteristics of the protrusions in the tray 40 may be selected based on the desired structural stability of the tray 40, the desired cushioning to be provided for the objects packaged on the tray, the desired dimensions of the tray 40 for holding the objects, or any other reason.

[0041] Figure 1 The tray 40 depicted in D can be further manipulated to transform the tray 40 into a desired shape for cushioning and / or holding objects. Figures 2A to 2C Each depicts a top view and a side view of tray 40, and Figures 2A to 2C An example of an embodiment of a method for further manipulating tray 40 is shown. Figure 2A Depicting and Figure 1 The tray 40 shown in D is essentially the same in form. Figure 2A As can be seen in the side view, in the depicted embodiment of tray 40, the central protrusion 44 extends upward from the flat portion 42 to a greater extent than the side protrusions 46 extend upward from the flat portion 42. (As shown in...) Figure 2A As can be seen in the top view, each of the central protrusion 44 and the side protrusions 46 has a pattern of smaller and larger shapes. In one example, the central protrusion 44 has smaller sides and larger corners, which alternate in a certain pattern. In another example, the side protrusions 46 are essentially linear, with larger and smaller rectangles alternating in a pattern. Compared to protrusions with a single shape, these patterns of smaller and larger shapes allow the central protrusion 44 and the side protrusions 46 to provide structural stability and improved cushioning.

[0042] from Figure 2A The example shown is to Figure 2B In the example shown, portions of the multilayer fiber sheet 20 have been cut off from the tray 40. In the depicted embodiment, cuts 48 have been made in the multilayer fiber sheet 20 to remove corners of the tray 40. Also in the specific embodiment shown, the flat portion 42 of the tray is the portion of the multilayer fiber sheet 20 that has been cut off from the tray 40. Cuts 48 can be made using any type of cutting tool, such as blades, knives, dies, water jets, or any other tool capable of cutting the multilayer fiber sheet 20.

[0043] Figure 2BFold lines 50 formed in the multilayer fiber sheet 20 are also shown. As used herein, "fold line" refers to a line along which the material (e.g., multilayer fiber sheet 20) is creased, curled, embossed, perforated, scored, or otherwise weakened to enhance the foldability of the material along the fold line. In the depicted embodiment, four fold lines 50 have been formed in the multilayer fiber sheet 20. Each fold line 50 is substantially aligned with two of the cutouts 48. In the illustrated embodiment, the fold lines 50 mark the boundary between the main board 54 of the tray 40 and the side panel 56 of the tray 40. In the particularly depicted embodiment, each fold line 50 is located between one of the main board 54 of the tray 40 and one of the side panel 56 of the tray 40.

[0044] The tray 40 can be folded into a shape that helps hold and / or cushion objects. From Figure 2B The example shown is to Figure 2C In the example shown, tray 40 is folded along each fold line 50 such that side panels 56 are substantially perpendicular to main board 54. In this arrangement, tray 40 can hold an object and provide cushioning on the five sides of the object. For example, the object can be positioned on the central protrusion 44 of main board 54, with the object situated between the side protrusions 46 of side panels 56. The central protrusion 44 and the side protrusions 46 provide cushioning on the five sides of the object.

[0045] The tray 40 can be used to hold and / or cushion objects of any type. As used herein, "object" can include a single item or a group of several different items. In some cases, when the object is a group of several different items, the different items of the object are intended to be packaged in a single container. In some embodiments, the object can include electronic devices such as laptops, tables, mobile phones, etc. In some embodiments, the object can include peripheral items for use with electronic devices, such as power cords, batteries, keyboards, mice, etc. In some embodiments, the paper trays formed herein provide a more aesthetically pleasing and functional improvement over conventional fiber-based packaging materials used for packaging objects such as electronic devices and / or peripherals. For example, molded fiber trays tend to shed fibers and leave dusty residues on the object, and molded fiber trays tend to wear and damage the external finish of the object. In contrast, the paper trays formed herein have a smooth surface that does not affect the finish of the object and leaves no residues on the object.

[0046] Figure 3A perspective view depicting another embodiment of tray 140 is shown. Tray 140 is formed from a multilayer fiber sheet 120. The multilayer fiber sheet 120 has been formed (e.g., pressed, cold-formed, etc.) into tray 140 such that tray 140 includes a central protrusion 144 and side protrusions 146. The multilayer fiber sheet 120 has been cut, and fold lines 150 have been added to the multilayer fiber sheet 120 such that tray 140 includes a main plate 154 and side plates 156. In the depicted embodiment, the central protrusion 144 is located on the main plate 154, and each side protrusion 146 is located on one of the side plates 156. In the depicted embodiment, the main plate 154 is rectangular, and the central protrusion 144 is rounded rectangular. Each of the central protrusion 144 and the side protrusions 146 has a pattern of smaller and larger shapes. In the case of the central protrusion 144, the shorter side and corners of the rounded rectangle are larger shapes, and the longer side of the rounded rectangle includes a smaller shape. In the case of lateral protrusion 146, the protrusion is linear, with larger and smaller rectangles alternating in a pattern.

[0047] The tray 140 can be folded for use in containers. Figures 4A to 4C A perspective view depicting a system and method for packaging objects 170. Figure 4A The image depicts a tray 140 after the side panel 156 has been folded around the fold line 150 until the side panel 156 is substantially perpendicular to the main board 154.

[0048] Figure 4A Container 160 is also depicted. Any container described herein may be formed from a rigid or semi-rigid material suitable for use as a transport container. The container may be formed from a fiber-based material (e.g., cardboard, corrugated cardboard, paperboard), plastic, compressed foam, or any other material. In one example, the container may be formed from corrugated cardboard, such as single-wall B-groove, C-groove, and / or E-groove corrugated cardboard, B / C double-wall corrugated cardboard, E / B double-wall corrugated cardboard, or any combination thereof.

[0049] In the depicted embodiment, container 160 includes a bottom 164 and sides 166. In some embodiments, container 160 is formed from a single sheet of material (e.g., a single sheet of cardboard) that has been cut and folded to form the shape. Figure 4AThe shape of the depicted container 160. In other embodiments, the container 160 may be formed from multiple sheets of material joined together. In the depicted embodiment, the container 160 is a five-sided container with an open top. The container 160 may also include a separate lid that can be placed on top of the container 160 to close it. In other embodiments, the container 160 may have a lid integrated with the rest of the container 160. In either the separate lid or the integrated lid, a tray formed from multiple layers of fiber sheet and having protrusions may be attached to the underside of the lid.

[0050] Figure 4B The image depicts the tray 140 after it has been placed into the container 160. In the depicted embodiment, the tray 104 has been placed in the container 160, with the main plate 154 of the tray 140 substantially parallel to the bottom 164 of the container 160. Similarly, the tray 104 has been placed in the container 160, with each side plate 156 of the tray 140 substantially parallel to one of the sides 166 of the container 160. Thus, the central protrusion 144 is located above the bottom 164 of the container 160, and each side protrusion 146 is located inside one of the sides 166 of the container 160.

[0051] Figure 4C The illustration depicts a tray 140 and a container 160 after an object 170 has been placed in the tray 140. In the illustrated embodiment, the object 170 has been placed in the tray 140 above a main board 154, with the bottom of the object 170 resting on a central protrusion 144. The object is positioned between side panels 156. In some embodiments, one or more side protrusions 146 may contact the sides of the object 170. Thus, the central protrusion 144 may provide cushioning between the bottom 164 of the container 160 and the bottom of the object 170, and the side protrusions 146 may provide cushioning between the sides 166 of the container 160 and the sides of the object 170.

[0052] As discussed above, container 160 may have a lid for closing container 160. The lid may be separate from container 160 or integrated into container 160. In some embodiments, the lid may have a tray formed of multiple layers of fiber sheet located on the underside of the lid. For example, the tray may be similar in shape and size to the main board 154 of tray 140 and include protrusions similar to a central protrusion 144. In other words, the tray on the underside of the lid may be identical to tray 140 except for the absence of side panels 156 and side protrusions 146. The tray on the lid may be arranged such that when the lid closes container 160, the protrusions of the tray on the lid contact the top of object 170. In this way, the tray on the lid also provides cushioning between the lid and the top of the object.

[0053] exist Figure 4C In the illustrated embodiment, object 170 is a single item. This single item can be an electronic device, such as a laptop or tablet. In other embodiments, the object can be multiple items. For example, multiple objects can include a laptop and mouse, a tablet and charging cable, a mobile phone and case, or any other combination of multiple items. In some embodiments where the object includes multiple items, the tray can be formed with multiple compartments, each compartment capable of holding one item. In other embodiments, multiple formed trays can be placed in a single container, wherein each tray is capable of holding one item. Any other variations of containers, trays, and compartments can be used to accommodate an object having multiple items.

[0054] Figure 5 A perspective view depicting another embodiment of tray 240 is shown. Tray 240 is formed from a multilayer fiber sheet 220. The multilayer fiber sheet 220 has been formed (e.g., pressed, cold-formed, etc.) into tray 240 such that tray 240 includes a central protrusion 244 and side protrusions 246. The multilayer fiber sheet 220 has been cut, and fold lines 250 have been added to the multilayer fiber sheet 220 such that tray 240 includes a main plate 254 and side plates 256. In the depicted embodiment, the central protrusion 244 is located on the main plate 254, and each side protrusion 246 is located on one of the side plates 256. In the depicted embodiment, the main plate 254 is rectangular, and the central protrusion 244 is rectangular. Each of the central protrusion 244 and the side protrusions 246 has a pattern of smaller and larger shapes. In the case of the central protrusion 244, the protrusion has smaller sides and larger corners, which alternate in a certain pattern. In the case of lateral protrusion 246, the protrusion is linear, wherein larger rectangles and smaller rectangles alternate in a pattern.

[0055] Figure 6 and 7 Perspective views depicting embodiments of trays 340 and 440 without side panels or fold lines are shown. Figure 6 In this embodiment, tray 340 is formed from a multilayer fiber sheet 320. The multilayer fiber sheet 320 has been formed (e.g., pressed, cold-formed, etc.) into tray 340 such that tray 340 includes protrusions 344 extending from a flat portion 342 of tray 340. In the depicted embodiment, the multilayer fiber sheet 320 is rectangular in shape. The protrusions 344 are also rectangular in shape. Figure 7 In this embodiment, tray 440 is formed from a multilayer fiber sheet 420. The multilayer fiber sheet 420 has been formed (e.g., pressed, cold-formed, etc.) into tray 440 such that tray 440 includes protrusions 444 extending from a flat portion 442 of tray 440. In the depicted embodiment, the multilayer fiber sheet 420 is rectangular in shape. The protrusions 444 are also rectangular in shape.

[0056] When comparing trays 340 and 440, protrusion 444 extends further from the flat portion 442 of tray 440 than protrusion 344 extends from the flat portion 342 of tray 340. The angle of the side of protrusion 444 relative to the flat portion 442 of tray 440 is greater than the angle of the side of protrusion 344 relative to the flat portion 342 of tray 340. These differences in the size and shape of protrusions 344 and 444 give trays 340 and 440 different properties. For example, the higher aspect of protrusion 444 allows it to fill a larger void space, but the steeper angle produced by the side of protrusion 444 increases the likelihood that the multilayer fiber sheet 420 will break at the bend forming protrusion 444.

[0057] As mentioned above, trays 340 and 440 do not have side panels or fold lines. Trays 340 and 440 can be used in containers where folding is not required. For example, see reference [link to reference]. Figure 4C One of the containers 160, trays 340 and 440 shown can be placed on the underside of the lid of the closed container 160. When the container 160 is closed, one of the trays 340 and 440 on the underside of the lid will provide cushioning between the lid and the top of the object 170.

[0058] Any embodiment of the tray described herein may have a marking area that includes information. For example, tray 340 includes a marking area 322, and tray 422 includes a marking area. In those examples, marking areas 322 and 422 are located in areas outside of protrusions 344 and 444, respectively. Specifically, marking area 322 is located in the area of ​​flat portion 342 defined by protrusion 344, and marking area 422 is located in the area of ​​flat portion 442 defined by protrusion 444. It will be understood that the marking area may also be located on a protrusion, outside a protrusion, or in any location on the multilayer fiber sheet that has been formed into the tray. In some embodiments, the marking area may include information printed on the marking area. In other embodiments, the marking area may include information embossed into the multilayer fiber sheet during the formation of the multilayer fiber sheet into the tray. In other embodiments, information may be applied (marking, smearing, etc.) in any other manner. The information in the marking area may include any type of information, such as logos, brand names, advertisements, instructions for use of the object, warnings, personalized messages to the recipient, any other type of information, or any combination thereof.

[0059] Figure 8A perspective view depicting another embodiment of a tray 540 without side panels or fold lines is shown. The tray 540 is formed from a multilayer fiber sheet 520. The multilayer fiber sheet 520 has been formed (e.g., pressed, cold-formed, etc.) into the tray 540 such that the tray 540 includes a protrusion 544 extending from a flat portion 542 of the tray 540. In the depicted embodiment, the multilayer fiber sheet 520 is rectangular in shape. The protrusion 544 has a non-polygonal shape. The tray 540 also includes a marking area 522. In this example, the marking area 522 is located on the protrusion 544. In some embodiments, the marking area may include information printed on the marking area. In other embodiments, the marking area may include information embossed into the multilayer fiber sheet during the formation of the multilayer fiber sheet into a tray. For example, the marking area 522 may include information embossed upwards or downwards from the top of the protrusion 544. The information in the marking area may include any type of information.

[0060] Figure 9A and 9B A perspective view is depicted of a pallet 140 and a container 760 used for packaging an object 170. The container 760 is formed of a rigid material and has a bottom, sides 766, and a top 772 (or lid). In the depicted embodiment, the top 772 is integrally formed with the container 760. The container 760 also includes a folding closure 774 that is foldably attached to the top 772.

[0061] When observing Figure 9A At this time, tray 140 has been placed in container 760, with main plate 154 substantially parallel to the bottom of container 760, and each side plate 156 substantially parallel to one of the sides 766 of container 760. Object 170 has been placed in tray 140, with the bottom of object 170 contacting central protrusion 144, and one or more sides of object 170 contacting one or more side protrusions 146. Figure 9A At the point shown, the top 772 of the container 760 is open. The lower surface of the top 772 has a tray 640 connected thereto. The tray 640 is formed of a multilayer fiber sheet 642, which is formed into a tray 640 by forming (e.g., pressing, cold forming, etc.) protrusions 644. The protrusions 644 extend away from the lower surface of the top 772.

[0062] from Figure 9A The position shown is to Figure 9BAs shown, the top 772 has been closed. The closing flap 774 has also been removed, and the protrusion is tucked into the side 766 of the container 760. With the top 772 in this position, the protrusion 644 provides cushioning between the top of the object 170 and the top 772 of the container 760. In this orientation, the object 170 can be transported within the container 760, where pallets 140 and 640 provide cushioning for the object 170.

[0063] Figure 9A and 9B Various physical features of the container 760 are also depicted. The container 760 includes sides 766, a long edge 782, a middle edge 784, a short edge 786, and corners 788. In some embodiments, when observed... Figure 9B In this case, the side of container 760 including the closing flap 774 is considered the front of the packaging, and the side opposite the front of the packaging is the rear of the packaging. The top 772 of container 760 is the top of the packaging, and the side opposite the top 772 is considered the bottom of the packaging. The remaining two sides 766 are considered the right and left sides of the packaging.

[0064] One method for testing the effectiveness of different pallets in packaging is to drop the test package and measure the G-value. The G-value is the ratio of the acceleration due to gravity to the measured acceleration. (Using...) Figure 9B The packaging shown is similar to that used to perform tests on different types of pallets, where sensors (e.g., accelerometers) are attached to object 170 to measure the acceleration experienced during drop tests on different sides, edges, and corners of the packaging.

[0065] One characteristic of the pallet being tested is the basis weight of the fiber base sheet used to form the multilayer fiber sheet, which is then formed into the pallet. Tests were performed on pallets with different combinations of layer number and layer basis weight. Drop tests were performed on several different orientations of the packaging, including (1) the corners of the packaging, (2) the short edges of the packaging, (3) the middle edges of the packaging, (4) the long edges of the packaging, (5) the bottom of the packaging, (6) the top of the packaging, (7) the right side of the packaging, (8) the left side of the packaging, (9) the front of the packaging, and (10) the back of the packaging. For testing purposes, a G-value of 150 was determined to be the maximum permissible value for a successful test in any drop. If all drops have a G-value below 150, the test is classified as positive. If any drop exceeds a G-value of 150, the test is classified as a failed test. Additionally, any visible physical damage to the pallet caused by the drop force is classified as a failed test.

[0066] Table 2 shows examples of different types of pallets, each with the same paper basis weight in each layer. Specifically, it is assumed that there exists a minimum basis weight of pallet that will effectively cushion the object during the drop test. A very low basis weight may not provide sufficient rigidity to maintain the structural integrity of the protrusion, thus reducing the amount of cushioning provided by the pallet and increasing the force applied to the object during the drop. As can be seen in Table 2, failed tests tended to have fewer layers and / or lower basis weights, including pallets with four layers of 100gsm paper, three layers of 150gsm paper, and two layers of 200gsm paper. In contrast, pallets with more layers and / or higher basis weights tended to pass the test, including pallets with five layers of 100gsm paper, six layers of 100gsm paper, four layers of 150gsm paper, and three layers of 200gsm paper.

[0067]

[0068]

[0069] *Note “4L×100gsm” means four layers of paper, each with a basis weight of 100gsm. The note “XL×Ygsm” used in this article means X layers of paper, each with a basis weight of Ygsm.

[0070] While all layers of a pallet can have the same basis weight, it is also possible for the pallet to be formed from layers with different basis weights. Similar tests were performed on pallets formed from multi-layer fiber sheets, where at least two layers have different basis weights. Table 3 shows examples of such pallets where the basis weights of the layers in a multi-layer fiber sheet differ. As can be seen, all tested pallet examples passed the tests, including pallets with two layers of 100gsm paper and two layers of 150gsm paper, pallets with three layers of 100gsm paper and one layer of 200gsm paper, pallets with two layers of 150gsm paper and one layer of 200gsm paper, and pallets with one layer of 100gsm paper and two layers of 200gsm paper.

[0071]

[0072] After testing pallets with lower basis weights in each layer, it was assumed that higher basis weights would also be feasible, as higher levels would provide even greater rigidity than the basis weights that passed the drop test. However, pallets composed of more layers and / or higher basis weights were tested to confirm this assumption. Table 4 shows examples of different types of pallets, each with the same paper basis weight in each layer. As can be seen in Table 4, pallets with seven layers of 100gsm paper passed the test. However, pallets with eight or more layers of 100gsm paper, pallets with five or more layers of 150gsm paper, and pallets with four or more layers of 200gsm paper failed the test. It was determined that the pallets that failed the test were so rigid that they could not provide sufficient flexibility to cushion the forces applied to objects.

[0073]

[0074] Based on these results for pallets with the same basis weight in each layer, pallets with different basis weights in each layer were tested to see if similar results were obtained. Table 5 shows examples of such pallets with different basis weights in each layer of multilayer fiber sheet. As can be seen in Table 5, all tested pallets passed the test, including pallets with two 100gsm paper layers, two 150gsm paper layers and one 200gsm paper layer, pallets with two 150gsm paper layers and two 200gsm paper layers, pallets with one 100gsm paper layer and three 200gsm paper layers, and pallets with four 100gsm paper layers and two 150gsm paper layers.

[0075]

[0076] After all such tests, the results for all tested pallets were compared. Table 6 shows the comparison for all tested pallets, regardless of whether the multiple layers of fiber sheet constituting the pallet had the same basis weight. The sum of the basis weights of each layer in the pallet was compared with whether the pallet passed the test.

[0077]

[0078]

[0079] The comparison in Table 6 makes it clear that pallets with a total basis weight between 500 gsm and 700 gsm passed the drop test. Pallets with a total basis weight of 450 gsm or less failed the drop test, as did pallets with a total basis weight of 750 gsm or more. Therefore, in all embodiments of the pallets discussed herein, the total basis weight of the layers of the multilayer sheet forming the pallet can be in the range of 500 gsm to 700 gsm.

[0080] For the purposes of this disclosure, terms such as “upper,” “lower,” “vertical,” “horizontal,” “inward,” “outward,” “internal,” “external,” “front,” and “back” should be interpreted as descriptive and not as limiting the scope of the claimed subject matter. Furthermore, the use of “including,” “comprising,” or “having,” and variations thereof herein is intended to cover the items listed thereafter and their equivalents and appendages. Unless otherwise specified, the terms “connection,” “link,” and “installation,” and variations thereof, are used extensively herein and cover direct and indirect connections, links, and installations. Unless otherwise stated, the terms “substantially,” “approximately,” etc., are used to mean within 5% of the target value.

[0081] The principles, representative embodiments, and modes of operation of this disclosure have been described in the foregoing description. However, the aspects intended to be protected by this disclosure should not be construed as limited to the specific embodiments disclosed. Furthermore, the embodiments described herein are to be considered illustrative rather than restrictive. It will be appreciated that variations and modifications can be made and equivalents can be employed without departing from the spirit of this disclosure. Therefore, all such variations, modifications, and equivalents are clearly intended to fall within the spirit and scope of this disclosure as described in the claims.

Claims

1. A method comprising: Multiple fiber-based sheets are laminated into a multilayer fiber sheet, wherein the multilayer fiber sheet is substantially planar; and The multilayer fiber sheet is formed into a tray, wherein the tray is substantially non-planar, and wherein the forming includes forming at least one protrusion in the tray; The total basis weight of the fiber-based sheets in the plurality of fiber-based sheets is in the range of 500 gsm to 700 gsm.

2. The method according to claim 1, wherein, Each of the plurality of fiber-based sheets has one or more of the following: When tested according to ISO 1924-3, the longitudinal tensile strength percentage is at least 13%, and the transverse strength percentage is at least 9%; and / or When tested according to ISO 1924-3, the longitudinal tensile strength is at least 14 kN / m and the transverse tensile strength is at least 7 kN / m; and / or When tested according to ISO 1974, the longitudinal tear strength is at least 3300 mN and the transverse tear strength is at least 4800 mN.

3. The method according to claim 1, wherein, Forming the multilayer fiber sheet into a tray includes at least one of the following: cold-forming the multilayer fiber sheet into a tray, or pressing the multilayer fiber sheet into a tray.

4. The method of claim 1, further comprising at least one of the following: Fold lines are formed in the multilayer fiber sheet; or Cut off a portion of the multilayer fiber sheet.

5. The method of claim 1, further comprising: Multiple fold lines are formed in the multilayer fiber sheet, wherein each of the multiple fold lines is located between the main board of the tray and one of the multiple side panels of the tray.

6. The method of claim 5, further comprising: The tray is folded along each of the plurality of fold lines such that each of the plurality of side panels is substantially perpendicular to the main board.

7. The method of claim 6, further comprising: A tray is placed in a container, wherein the main plate of the tray is substantially parallel to the bottom of the container, and each of the plurality of side plates of the tray is substantially parallel to the side of the container.

8. The method according to claim 5, wherein, Forming the at least one protrusion in the tray includes forming at least one protrusion on the main board and forming at least one protrusion on each of the plurality of side panels.

9. The method according to claim 1, wherein, The at least one protrusion in the tray includes patterns of smaller and larger shapes.

10. The method according to claim 1, wherein, The tray includes a marking area.

11. The method of claim 10, further comprising: Information is printed in the marked area.

12. The method according to claim 10, wherein, Forming the multilayer fiber sheet into a tray includes imprinting information onto the marking area.

13. The method according to claim 10, wherein, The marked region lies on one of the following: The at least one protrusion; or The tray area outside of the at least one protrusion.

14. A tray formed by a method according to any one of the preceding claims.

15. A pallet comprising: Multiple fiber-based sheets are laminated into multi-layer fiber sheets; and At least one protrusion is formed in the multilayer fiber sheet, wherein the tray is substantially not planar due to the at least one protrusion; The total basis weight of the fiber-based sheets in the plurality of fiber-based sheets is in the range of 500 gsm to 700 gsm.

16. The pallet of claim 15, further comprising: The multilayer fiber sheet contains multiple fold lines, wherein each of the multiple fold lines is located between the main board of the tray and one of the multiple side panels of the tray.

17. The tray according to claim 16, wherein, The tray is foldable along each of the plurality of fold lines, such that each of the plurality of side panels is substantially perpendicular to the main board.

18. The tray according to claim 16, wherein, The at least one protrusion includes: At least one protrusion on the motherboard; and At least one protrusion on each of the plurality of side plates.

19. The tray according to claim 15, wherein, The tray includes a marking area, wherein the marking area includes at least one of information printed in the marking area and information embossed in the marking area.

20. A system comprising: The tray according to claim 17; and Containers with a bottom and sides; The tray is placed in the container, wherein the main plate of the tray is substantially parallel to the bottom of the container, and each of the plurality of side plates of the tray is substantially parallel to one of the sides of the container.

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