Packaging material and method for manufacturing the same

Abstract

These are cellulose-based packaging materials, layers for cellulose-based packaging materials, and panels using them. These panels can be cushioning panels, more specifically cellulose-based cushioning panels such as cushioning panels formed from molded pulp or corrugated fiberboard sheets. These panels can be rigid panels, more specifically cellulose-based rigid panels. Cellulose-based cushioning panels can form a cushioning layer, and rigid panels can form a rigid layer. Cushioning blocks and packaging materials can be formed from the cushioning layer and the rigid layer.

Description

Technical Field

[0001] Cross-Reference to Related Applications This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 673,406, filed July 19, 2024, entitled "Packaging Material and Method for Manufacturing the Same". This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 624,460, filed January 24, 2024, entitled "Packaging Material and Method for Manufacturing the Same". This application claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63 / 538,629, filed September 15, 2023, entitled "Packaging Material and Method for Manufacturing the Same". Each of the above applications is incorporated herein by reference in its entirety.

[0002] The present invention relates to a packaging material and a method for manufacturing the same.

Background Art

[0003] Various packaging materials including cardboard boxes are used to fix and protect articles in shipping containers, which prevents articles from moving within the container during shipping and suffering damage caused by external forces during transportation (air transportation and land transportation) such as dropping and impact. Such packaging materials include bubble wrap, expanded polystyrene (EPS foam), other plastic foams molded into blocks or other shapes, so-called packing peanuts, and inflatable bags (also called air pillows), among others. These plastic products may be disposed of as waste after being used for shipping. Plastic waste takes an extremely long time to decompose, and generates carbon dioxide during its decomposition process. Furthermore, EPS foam is not readily biodegradable and may take an extremely long number of years to decompose completely.

Summary of the Invention

[0004] In one embodiment of the present invention, the present invention relates to a cushioning panel, and more specifically to a cellulose-based cushioning panel such as a cushioning panel formed from molded pulp or a corrugated fiberboard sheet.

[0005] In another embodiment, the present invention relates to rigid panels, more specifically, cellulose-based rigid panels.

[0006] In yet another embodiment, the present invention relates to a packaging material comprising multiple layers, such as a buffering layer formed from a buffering panel, a rigid panel, or both.

[0007] In yet another embodiment, the present invention relates to a packaging material comprising one or more buffer layers. Each buffer layer comprises a first buffer panel and a second buffer panel. The first buffer panel has a first base layer from which a plurality of first projections extend. Each of the first projections has a distal end distal to the first base layer. The first buffer panel is a molded pulp panel. The second buffer panel has a second base layer from which a plurality of second projections extend. Each of the second projections has a distal end distal to the second base layer. The second buffer panel is a molded pulp panel. The first buffer panel is arranged such that a plurality of first projections project toward the second buffer panel. The second buffer panel is arranged such that a plurality of second projections project toward the first buffer panel, and at least a portion of the plurality of second projections are second contacting projections. The distal end of the second contact projection contacts the first buffer panel.

[0008] In yet another embodiment, the present invention relates to a composite packaging material comprising one or more buffer layers arranged to have a product side and an outer side, and a cellulose sheet disposed outside the one or more buffer layers. Each buffer layer comprises a first buffer panel and a second buffer panel. The first buffer panel has a first base layer from which a plurality of first protrusions extend. The first buffer panel is a molded pulp panel. The second buffer panel has a second base layer from which a plurality of second protrusions extend. The second buffer panel is a molded pulp panel. The first buffer panel and the second buffer panel are arranged to be in contact with each other such that a plurality of first protrusions project toward the second buffer panel and a plurality of second protrusions project toward the first buffer panel.

[0009] In yet another embodiment, the present invention relates to a composite packaging material comprising a buffer layer and a rigid panel. The buffer layer comprises a buffer panel having a base layer from which a plurality of projections extend. Each projection has a distal end located away from the base layer. The buffer panel is a molded pulp panel. The rigid panel is in contact with the buffer layer. The rigid panel is formed from a cellulose-based material. The rigid panel has higher rigidity than the buffer panel when a load is applied in the thickness direction of the rigid panel or the buffer panel.

[0010] In yet another embodiment, the present invention relates to a packaging material comprising one or more cushioning blocks on the product side of each cushioning block, which can be positioned around the product to be shipped. 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 from which a plurality of first projections extend. Each of the first projections 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 from which a plurality of second projections extend. Each of the second projections has a distal end distal to the second base layer. The second cushioning panel is a molded pulp panel. The first cushioning panel is arranged such that a plurality of first projections project toward the second cushioning panel, and the second cushioning panel is arranged such that a plurality of second projections project toward the first cushioning panel.

[0011] These and other aspects of the present invention will become apparent from the following disclosure. [Brief explanation of the drawing]

[0012] [Figure 1] Figure 1 shows packaging material formed by this disclosure for protecting goods to be shipped. [Figure 2] Figure 2 is a schematic diagram of a cushioning block that can be used to form packaging material. [Figure 3A] Figure 3A is a top view of a cushioning panel that can be used to form a cushioning layer in packaging materials. [Figure 3B] Figure 3B is a cross-sectional view of the buffer panel shown in Figure 3A, along the line 3B-3B in Figure 3A. [Figure 3C] Figure 3C is a cross-sectional view of the buffer panel from the same viewpoint as in Figure 3B. [Figure 3D] Figure 3D is a cross-sectional view of the buffer panel from the same viewpoint as Figure 3B. [Figure 3E] Figure 3E is a cross-sectional view of the buffer panel from the same viewpoint as in Figure 3B. [Figure 3F] Figure 3F is a cross-sectional view of the buffer panel from the same viewpoint as in Figure 3B. [Figure 3G] Figure 3G is a schematic diagram of another cushioning panel that may be used to form a cushioning layer in packaging materials. [Figure 3H] Figure 3H is a schematic diagram showing the compressed state of the buffer panel shown in Figure 3G. [Figure 4A] Figure 4A is a top view of the buffer layer formed by arranging the first buffer panel relative to the second buffer panel. [Figure 4B] Figure 4B is a cross-sectional view of the buffer layer shown in Figure 4A, along the line 4B-4B in Figure 4A. [Figure 4C] Figure 4C is a cross-sectional view of the multiple buffer layers shown in Figures 4A and 4B, with the same viewpoint as Figure 4B. [Figure 5A] Figure 5A is a top view of the buffer layer formed by arranging the first buffer panel relative to the second buffer panel. [Figure 5B] Figure 5B is a cross-sectional view of the buffer layer shown in Figure 5A, along the line 5B-5B in Figure 5A. [Figure 5C] Figure 5C is a cross-sectional view of the multiple buffer layers shown in Figures 5A and 5B, with the same viewpoint as Figure 5B. [Figure 6A] Figure 6A is a top view of the buffer layer formed by arranging the first buffer panel relative to the second buffer panel. [Figure 6B] Figure 6B is a cross-sectional view of the buffer layer shown in Figure 6A, along the line 6B-6B in Figure 6A. [Figure 6C] Figure 6C is a cross-sectional view of the multiple buffer layers shown in Figures 6A and 6B, with the same viewpoint as Figure 6B. [Figure 7A] Figure 7A is a top view of the buffer layer formed by arranging the first buffer panel relative to the second buffer panel. [Figure 7B] Figure 7B is a cross-sectional view of the buffer layer shown in Figure 7A, along the line 7B-7B in Figure 7A. [Figure 8A] Figure 8A is a cross-sectional view of the buffer layer, with the same viewpoint as Figure 4B. [Figure 8B] Figure 8B is a cross-sectional view of the buffer layer, with the same viewpoint as Figure 4B. [Figure 8C] FIG. 8C is a cross-sectional view of a cushioning layer, taken from the same viewpoint as FIG. 4B. [Figure 9A] FIG. 9A is a top view of a cushioning layer formed by arranging a first cushioning panel relative to a second cushioning panel. [Figure 9B] FIG. 9B is a cross-sectional view of the cushioning layer shown in FIG. 9A, taken along line 9B-9B in FIG. 9A. [Figure 9C] FIG. 9C is a cross-sectional view of the plurality of cushioning layers shown in FIGS. 9A and 9B, taken from the same viewpoint as FIG. 9B. [Figure 10A] FIG. 10A shows a first step of a method for molding a cushioning layer. [Figure 10B] FIG. 10B shows a second step of a method for molding a cushioning layer. [Figure 11A] FIG. 11A shows a first step of an alternative method for molding a cushioning material. [Figure 11B] FIG. 11B shows a second step of an alternative method for molding a cushioning material. [Figure 11C] FIG. 11C shows an optional additional step of an alternative method for molding a cushioning material. [Figure 11D] FIG. 11D shows another optional additional step of an alternative method for molding a cushioning material. [Figure 11E] FIG. 11E shows an alternative optional additional step of an alternative method for molding a cushioning material. [Figure 12] FIG. 12 is an exploded view of a cushioning block that can be used for molding a packaging material. [Figure 13] FIG. 13 is an exploded view of a cushioning block that can be used for molding a packaging material. [Figure 14A] FIG. 14A is a schematic diagram of a rigid sheet panel, more specifically a honeycomb panel that can be used for molding a cushioning block. [Figure 14B] FIG. 14B is a schematic diagram showing a core of a honeycomb panel. [Figure 15A] FIG. 15A is a cross-sectional view of a cushioning block including a rigid layer using a honeycomb panel, taken from the same viewpoint as FIG. 4B. [Figure 15B] Figure 15B is a cross-sectional view of a buffer block with a rigid layer using honeycomb panels, and is from the same viewpoint as Figure 4B. [Figure 15C] Figure 15C is a cross-sectional view of a buffer block with a rigid layer using honeycomb panels, and is from the same viewpoint as Figure 4B. [Figure 15D] Figure 15D is a cross-sectional view of a buffer block with a rigid layer using honeycomb panels, and is from the same viewpoint as Figure 4B. [Figure 16A] Figure 16A is a schematic diagram of a rectangular packaging material. [Figure 16B] Figure 16B is an exploded view of the rectangular packaging material shown in Figure 16A. [Figure 17] Figure 17 is a schematic diagram of a U-shaped packaging material. [Figure 18] Figure 18 is a schematic diagram of two rectangular packaging materials and two U-shaped packaging materials placed next to each other. [Figure 19A] Figure 19A is a schematic diagram of a rectangular packaging material. [Figure 19B] Figure 19B is an exploded view of the rectangular packaging material shown in Figure 19A. [Figure 20A] Figure 20A is a schematic diagram of a rectangular packaging material in a flat state. [Figure 20B] Figure 20B is a schematic diagram of the rectangular packaging material shown in Figure 20A in its folded state. [Figure 21A] Figure 21A is a schematic diagram of a rectangular packaging material in a flat state. [Figure 21B] Figure 21B is a schematic diagram of the rectangular packaging material shown in Figure 21A in its folded state. [Figure 22A] Figure 22A is a top view of a rectangular packaging material. [Figure 22B] Figure 22B is a schematic diagram of the rectangular packaging material shown in Figure 22A. [Figure 23] Figure 23 is a schematic diagram of a rectangular packaging material. [Figure 24A] Figure 24A is a schematic diagram of a U-shaped packaging material. [Figure 24B] Figure 24B is a schematic diagram of a U-shaped packaging material. [Figure 25A] Figure 25A is a cross-sectional view of the irregular buffer layer, with the same viewpoint as Figure 4B. [Figure 25B] Figure 25B is a cross-sectional view of the irregular buffer layer, with the same viewpoint as Figure 4B. [Figure 25C] Figure 25C is a cross-sectional view of the irregular buffer layer, with the same viewpoint as Figure 4B. [Figure 26A] Figure 26A is a schematic diagram of a shipping container in which the buffer block has a flat configuration. [Figure 26B] Figure 26B is a schematic diagram of the shipping container shown in Figure 26A in a folded state. [Figure 27A] Figure 27A is a schematic diagram of a shipping container in which the buffer block has a flat configuration. [Figure 27B] Figure 27B is a schematic diagram of the shipping container shown in Figure 27A in a folded state. [Figure 28A] Figure 28A is a schematic diagram of a shipping container in which the buffer block has a flat configuration. [Figure 28B] Figure 28B is a schematic diagram of the shipping container shown in Figure 28A in a folded state. [Figure 29A] Figure 29A is a schematic diagram of a shipping container in which the buffer block has a flat configuration. [Figure 29B] Figure 29B is a schematic diagram of the shipping container shown in Figure 29A in a folded state. [Figure 30A] Figure 30A is a cross-sectional view of the first foldable molded buffer panel, with the same viewpoint as Figure 3B. [Figure 30B] Figure 30B is a schematic diagram of the second foldable molded buffer panel, with the same viewpoint as Figure 3B. [Figure 30C] Figure 30C is a schematic end view of a shipping container molded using the first foldable molded cushioning panel of Figure 30A and the second foldable molded cushioning panel of Figure 30B. [Figure 31] Figure 31 is a schematic diagram of the buffer panel. [Figure 32] Figure 32 is a schematic diagram of a buffer block using the buffer panel shown in Figure 31. [Figure 33] Figure 33 is a schematic diagram of a rigid sheet panel, more specifically a rigid sheet panel made of corrugated cardboard fiberboard. [Figure 34] Figure 34 is a schematic diagram of a buffer block using the rigid sheet panel of corrugated cardboard fiberboard formed in Figure 33. [Figure 35] Figure 35 is a schematic diagram of the buffer panel. [Figure 36] Figure 36 is a schematic diagram of a buffer block using the buffer panel shown in Figure 35. [Figure 37A] Figure 37A is a schematic diagram of the buffer panel. [Figure 37B] Figure 37B is a detailed view of a portion of the buffer panel shown in Figure 37A. [Figure 38] Figure 38 is a schematic cross-sectional view of a buffer block using the buffer panel shown in Figure 37A. [Figure 39A] Figure 39A is an exploded view of a buffer block having a rigid layer, more specifically a lattice structure rigid sheet panel. [Figure 39B] Figure 39B is a schematic diagram of the buffer block shown in Figure 35A. [Modes for carrying out the invention]

[0013] As mentioned above, with increasing awareness of the negative environmental impacts of plastics and EPS foams, businesses and consumers are increasingly demanding environmentally friendly, recyclable, and biodegradable packaging materials. The packaging materials discussed herein are environmentally friendly, recyclable, and biodegradable, while also providing sufficient protection and cushioning at an affordable cost. In particular, the embodiments discussed herein can serve as environmentally friendly, recyclable, and biodegradable alternatives to EPS and other plastic foams (e.g., expanded polyethylene, or EPE, foam).

[0014] Figure 1 shows packaging material 100 formed according to this disclosure, which is used to protect a shipment item, such as a flat-panel television, during transport. In this specification, the shipment item is referred to as product 10. The packaging material 100 can be arranged in various configurations around product 10 to protect product 10 during transport. However, as will be discussed later, the packaging material 100 can be arranged so that certain characteristic shapes are closer to product 10 than other parts. The packaging material 100 has a product side and may include a product side surface. The product side surface may be in contact with product 10 in some configurations.

[0015] The packaging material 100 is placed around the product 10, and the product 10, with the packaging material 100 placed around it, can be placed in a shipping container, such as a shipping box 20. The shipping box 20 shown in Figure 1 is a cardboard shipping box, but the packaging material 100 discussed herein can also be used in other shipping containers. The shipping box 20 comprises a plurality of walls 22 defining an internal cavity 24. More specifically, each wall 22 may have an inward-facing surface 26 defining the internal cavity 24. As will be described later, the packaging material 100 can be positioned such that certain features are located closer to the shipping box 20 than other parts. The packaging material 100 has a container side and may include a container side surface. The container side surface may be in contact with an inward-facing surface 26 of the shipping container (e.g., shipping box 20). The shipping box 20 may also include a plurality of flaps 28 that can be used to open and close the shipping box 20 in order to allow access to the internal cavity 24 through an opening.

[0016] Figure 1 shows multiple packing materials 100 arranged around product 10. The packing materials 100, or a portion thereof, can be arranged around product 10 before it is placed in the shipping box 20. Other packing methods include placing the packing materials 100 in the internal space 24 of the shipping box 20 before product 10, after product 10, together with product 10, or in a combination thereof.

[0017] As will be described later, the packaging material 100 may consist of a plurality of buffer blocks arranged in different configurations to constitute the packaging material 100. The packaging material 100 shown in Figure 1 includes, for example, a corner-shaped packaging material 102 and a U-shaped packaging material 104. As shown in Figure 1, in an embodiment used to protect a television (product 10), the U-shaped packaging material 104 may be elongated, and the packaging material 100 may be arranged to form an elongated packaging material.

[0018] Figure 2 shows a buffer block 200, more specifically a buffer block 201 that can be used to form the packaging material 100 (Figure 1) described herein. As previously stated, the packaging material 100 discussed herein can be formed from one or more buffer blocks 200. The buffer blocks 200 discussed herein may have several different structures, but reference numeral 200 is used to refer collectively to any of the buffer blocks 200 discussed herein. The buffer blocks 200 discussed herein may include multiple layers. In some buffer blocks 200, at least some of the layers may differ from each other in terms of material, structure, or both, and these different layers may have a variety of different structures, resulting in different strengths, stiffnesses, and buffering properties. Buffer blocks 200 and packaging materials 100 having these different layers may be referred to herein as composite buffer blocks and composite packaging materials. A composite buffer block and composite packaging material is, for example, a combination of a buffer layer 210 (described later) and at least one other different layer.

[0019] The constituent materials also directly affect these properties. As will be described later, the buffer block 200 can be formed from cellulosic materials. Some layers, or parts thereof, are formed by combining molded pulp (also called molded fibers), fiberboard (including corrugated fiberboard sheets (also called corrugated cardboard)), and paper sheets in various arrangements. The inventors found that certain arrangements and structures of these different layers are effective in protecting the product 10 in transit, while other arrangements, including the use of only certain layers, do not provide equivalent protection.

[0020] A buffer block 200 may include one or more buffer layers. The buffer block 201 shown in Figure 2 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 layer 210 will be described later, but in this specification, reference numeral 300 is used to refer collectively to these various different buffer panels. More specifically, in Figure 2, the buffer layer 210 is formed from a first buffer panel 220, such as a top buffer panel, and a second buffer panel 230, such as a bottom buffer panel. As will be described later, the buffer layer 210 can be used in various different arrangements to form the buffer block 200, but the buffer layer 210 can also be used as a buffer block 201 on its own.

[0021] Figure 3A is a top view of a buffer panel 301 that can be used as a buffer panel 300 for forming the buffer layer 210 (Figure 2) described herein. Figure 3B is a cross-sectional view of the buffer panel 301 along the line 3B-3B in Figure 3A. The buffer panel 301 shown in Figures 3A and 3B can be used to form the buffer layer 210 shown in Figure 2, and more specifically, the buffer panel 301 can be used to form either or both of the first buffer panel 220 or the second buffer panel 230.

[0022] The buffer panel 300 (e.g., buffer panel 301) discussed herein is formed from a cellulosic material, such as a natural cellulose material, which is recyclable and biodegradable. The buffer panel 301 can be formed using a molded pulp method (also called a molded fiber method). The pulp or fiber used in this process is preferably a cellulosic pulp and fiber, and more preferably a pulp produced from used recycled paper, including newsprint, recycled cardboard / fiberboard, recycled cardboard, and recycled corrugated cardboard (OCC). Recycled paper, including cardboard / fiberboard, recycled corrugated cardboard, and OCC, can be dissolved in water to defibrillate the paper fibers and form an aqueous slurry of paper (cellulose) fibers. Other suitable sources of cellulose (paper) fibers may also be used, and in some embodiments, recycled paper fibers may be mixed with other cellulose (paper) fibers. Depending on the raw materials of the cellulosic fibers, other suitable defibrillation and pulping methods (such as Kraft methods) may be used. Therefore, the cushioning panel 300 formed using this process is also called a molded cushioning panel.

[0023] One such molded pulp process is the vacuum-forming process or the web fiber molding process. A molding tool having a surface shaped to correspond to the buffer panel 300 described herein, for example, a surface having a plurality of cylindrical protrusions, can be placed in an aqueous slurry of paper (cellulose) fibers. This formed surface is called a mold or molding surface. A vacuum is drawn through the molding surface to remove moisture and allow the paper fibers to accumulate on the molding surface, taking the shape of the molding surface. Once the desired thickness of paper fibers has accumulated, the molding surface is removed from the aqueous slurry and the molded paper fibers are dried. The molded paper fibers can be removed from the molding surface to be completely dried in a drying oven or the like.

[0024] Other suitable fiber molding processes, such as dry fiber molding processes, may be used. In such dry fiber molding processes, paper pulp / fibers are defibrated, for example, by grinding, and then molded dry (e.g., without using an aqueous slurry). The dried defibrated paper fibers can be molded in a press- and heated press die to form a desired shape, such as the shapes discussed herein. In some processes, the dried defibrated paper fibers may be loosely molded into a sheet (hereinafter referred to as a fiber sheet) by vacuum, rolled (or otherwise formed) to a desired thickness, and then fed into a press die. Before being fed into the press die, the fiber sheet may have a tissue sheet attached to at least one of its top or bottom surface, if necessary.

[0025] The buffer panel 301 shown in Figures 3A and 3B is formed by 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 protrusion side having a protrusion-side surface 312. Each protrusion 320 may extend from the protrusion-side surface 312. The opposite side of the base layer 310 is referred to herein as the back side, and therefore the base layer 310 may include a back side surface 314. In Figures 3A and 3B, all protrusions 320 extend from the protrusion-side surface 312, and the back side surface 314 of the buffer panel 301 is a generally flat surface.

[0026] Each projection 320 has a distal end 322 distal to the base layer 310. Each projection 320 has a specific geometric shape. As shown in Figures 3A and 3B, the projections 320 are cylindrical, more specifically cylindrical. As will be discussed later, the projections 320 may have other geometric shapes such as cylinders, cuboids, pyramids, or cones. Although all the projections 320 of the buffer panel 301 shown in Figures 3A and 3B have the same geometric shape, the buffer panel 301 may have multiple projections 320 having different geometric shapes. That is, one of the multiple projections 320 may have a first geometric shape, and another of the multiple projections 320 may have a second geometric shape different from the first geometric shape.

[0027] Each projection 320 may be a hollow projection with a cavity 324 formed inside it. Therefore, each projection 320 may include one or more side walls extending from the base layer 310 and defining the cavity 324. Each projection 320 may be closed at one end. For example, in Figures 3A and 3B, the distal end 322 is closed and has an end wall that defines part of the cavity 324. The distal end 322, more specifically the end wall, can have a variety of suitable shapes. As shown in Figure 3B, the distal end 322 is rounded. The distal end 322 may have a spherical dome shape, such as hemispherical. Alternatively, the distal end 322 may be flat, for example, and the projection 320 may have a U-shaped cross-section.

[0028] In the illustrated embodiment, the cavity 324 of the projection 320 is an open cavity, with an opening 326 formed in the base layer 310, more specifically in the back surface 314 of the base layer 310. The opening 326 is an opening leading to the cavity 324. Depending on how the buffer panel 301 is arranged relative to the other components of the buffer block 200, the cavity 324 may be a closed cavity 324. For example, this may occur when multiple buffer panels 301 are arranged back to back, with the back surface 314 of one buffer panel 301 in contact with another buffer panel 301. The opening 326 can also be seen, for example, in Figure 2.

[0029] The base layer 310 has a specific thickness. The thickness of the base layer 310 may be less than the length of the projection 320. The length of each projection 320 can be considered as the distance from the projection-side surface 312 to the tip 328 of the distal end 322. In Figure 3B, all projections 320 have the same length, but as will be described later, the projections 320 may have multiple different lengths.

[0030] Multiple protrusions 320 can be arranged as a two-dimensional (2D) array consisting of multiple rows and columns. The buffer panel 301 has a length and width corresponding to the length and width directions. Multiple protrusions 320 can be arranged in an array in both the length and width directions. In Figure 3A (see also Figure 2), the protrusions 320 in each row are spaced equally apart from each other, and the protrusions 320 in each column are also spaced equally apart from each other. However, other arrangements are also possible.

[0031] As mentioned above, the projection 320 can take on other shapes, including other geometric shapes. Figures 3C to 3F show buffer panels having projections 320 of different geometric shapes. Except for the shape of the projection 320, these buffer panels have the same or similar features as the buffer panel 301 described above with reference to Figures 3A and 3B, and the description applies here as well. For clarity, in the case of the other buffer panels described herein, the projection shown in Figures 3A and 3B will be referred to as the cylindrical projection 331.

[0032] Figure 3C is a cross-sectional view of the buffer panel 303 from the same viewpoint as in Figure 3B. The projection 320 of the buffer panel 303 shown in Figure 3C has a dome shape. This dome shape may be a spherical dome shape, such as a hemispherical shape. For clarity, as with other buffer panels described later in this specification, the projection shown in Figure 3C will be referred to as the dome-shaped projection 333.

[0033] Figure 3D is a cross-sectional view of the buffer panel 305 from the same viewpoint as in Figure 3B. The projection 320 of the buffer panel 305 shown in Figure 3D is pyramidal or conical. The base can take various appropriate shapes, such as a circular base with corresponding curved side walls, or a rectangular base such as a square with corresponding triangular or trapezoidal side walls. For clarity, as with other buffer panels described later in this specification, the projection shown in Figure 3D is referred to as the pyramidal projection 335. The pyramidal projection 335 shown in Figure 3D has a flat distal end 322 rather than a pointed tip.

[0034] Figure 3E is a cross-sectional view of the buffer panel 307 from the same viewpoint as in Figure 3B. The projection 320 of the buffer panel 307 shown in Figure 3E has an arc-shaped side wall. Similar to the pyramidal projection 335, the base can take various appropriate shapes, such as circular or square. For clarity, as with other buffer panels described later in this specification, the projection shown in Figure 3E is referred to as the arc-shaped projection 337. The arc-shaped projection 337 shown in Figure 3E has a flat distal end 322.

[0035] Figure 3F is a cross-sectional view of the buffer panel 309 from the same viewpoint as in Figure 3B. The projection 320 of the buffer panel 309 shown in Figure 3F has a rectangular geometric shape. The base can take various rectangular shapes, including squares. For clarity, as with other buffer panels described later in this specification, the projection shown in Figure 3F is referred to as the rectangular projection 339. The rectangular projection 339 shown in Figure 3F has a flat distal end 322.

[0036] Figure 3G shows another buffer panel 302 that can be used as one of the buffer panels 300 described herein. The buffer panel 302 is similar to the buffer panel 300 described above, but instead of having multiple rows or columns of projections 320, the projections 320 are replaced by ridges 332. The ridges 332 are elongated and extend parallel to each other. The ridges 332 can take on various shapes, including dome-shaped or arc-shaped distal ends 322 as shown in Figure 3G.

[0037] Figure 3H shows the state in which the buffer panel 302 shown in Figure 3G is compressed. When a force is applied perpendicular to the buffer panel 302, the ridge 332 deforms, for example by spreading at the distal end 322 or by parts of the base layer 310 moving closer together, and the size of the opening 326 is reduced.

[0038] As described above, the buffer layer 210 (Figure 2) can be formed by arranging two or more buffer panels 300. In the following description, we refer to the specific buffer panel 300 described above (for example, buffer panel 302 having a dome-shaped projection 333), but this description also applies to other buffer panels 300 having projections 320 of other shapes. In general, reference numeral 210 is used to refer to any of the buffer layer 210, regardless of the specific configuration described below. Similarly, the first buffer panel 220 and the second buffer panel 230 are used to refer collectively to the buffer panels constituting the buffer layer 210, regardless of the specific shape of the projections.

[0039] Figures 4A and 4B show a buffer layer 211 formed by positioning a first buffer panel 220 relative to a second buffer panel 230. Figure 4A is a top view of the buffer layer 211, and Figure 4B is a cross-sectional view of the buffer layer 211 along the line 4B-4B in Figure 4A. The first buffer panel 220 and the second buffer panel 230 are shown as buffer panels 303 having dome-shaped protrusions 333, respectively. However, as mentioned above, the first buffer panel 220 and the second buffer panel 230 may be other buffer panels 300 (Figures 3A-3F) having protrusions 320 of different shapes. 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 multiple first projections 224 has a first geometric shape, and each of the multiple second projections 234 has a second geometric shape. In Figures 4A and 4B, the second geometric shape is the same as the first geometric shape and is shown as a dome-shaped projection 333. However, the second geometric shape may be different from the first geometric shape.

[0040] The first buffer panel 220 is arranged such that a plurality of first protrusions 224 project toward the second buffer panel 230, and the second buffer panel 230 is arranged such that a plurality of second protrusions 234 project toward the first buffer panel 220. The first base layer 222 has an inner 226 and an outer 228. The inner 226 of the first base layer 222 is arranged to face the second buffer panel 230, and the plurality of first protrusions 224 extend from the inner 226 of the first base layer 222. The second base layer 232 also has an inner 236 and an outer 238. The inner 236 of the second base layer 232 is arranged to face the first buffer panel 220, and the plurality of second protrusions 234 extend from the inner 236 of the second base layer 232.

[0041] In Figures 4A and 4B, the first projection 224 and the second projection 234 face each other, more specifically, they face each other directly. When the first projection 224 and the second projection 234 face each other directly, the distal end 322 of the first projection 224 can contact the distal end 322 of the second projection 234. A projection that contacts another surface, such as another buffer panel (more specifically, a projection whose distal end 322 contacts another surface) is referred to herein as a “contact projection.” Therefore, at least a portion of the first projection 224 and at least a portion of the second projection 234 are contact projections. At least a portion of the first projection 224 is a first contact projection, the distal end 322 of the first contact projection contacts the second buffer panel 230, and at least a portion of the second projection 234 is a second contact projection, the distal end 322 of the second contact projection contacts the first buffer panel 220. More specifically, in Figures 4A and 4B, the first and second contact projections are positioned directly opposite each other, with the distal end 322 of each first contact projection contacting the corresponding distal end 322 of the second contact projection. In this case, both the first projection 224 and the second projection 234 are contact projections, but as will be described later, in other cases, only one of the first projection 224 or the second projection 234 is a contact projection.

[0042] Figure 4C is a cross-sectional view of multiple buffer layers 211, viewed from a similar viewpoint as in Figure 4B. As previously mentioned, the packaging material 100 (Figure 1) may include a buffer block 200 (Figure 2) having a single buffer layer 210, such as the buffer layer 211 shown in Figure 5B. Other packaging materials 100 may include a buffer block 200 having multiple buffer layers 210. For example, Figure 5C shows four buffer panels 300 arranged to form two buffer layers 210, more specifically a first buffer layer 211a and a second buffer layer 211b. The first buffer layer 211a and the second buffer layer 211b shown in Figure 4C are both the buffer layers 211 described above with reference to Figure 4B, and that description also applies here. Although the figures show the same arrangement, the first buffer layer 211a and the second buffer layer 211b can be arranged differently from each other.

[0043] Figure 4D is a perspective view of the buffer layer 211c formed by positioning the first buffer panel 220 relative to the second buffer panel 230. In Figure 4D, each of the first buffer panel 220 and the second buffer panel 230 is a buffer panel 302 arranged so that the ridges 332 directly face each other, similar to the buffer layer 211 described above with reference to Figures 4A and 4B.

[0044] As shown in Figure 5C, a packaging material 100 (Figure 1), such as a buffer block 200, may have two or more buffer layers, including a first buffer layer 211a and a second buffer layer 211b. The outer surface 238 of either the first base layer 222 or the second base layer 232 of the first buffer layer 211a abuts against the outer surface 238 of either the first base layer 222 or the second base layer 232 of the second buffer layer 211b. In Figure 4C, the outer surface 238 of the second base layer 232 of the first buffer layer 211a abuts against the outer surface 238 of the first base layer 222 of the second buffer layer 211b.

[0045] Figures 5A and 5B show a buffer layer 212 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 5A is a top view of the buffer layer 212, and Figure 5B is a cross-sectional view of the buffer layer 212 along the line 6B-6B in Figure 6A. Figures 5A and 5B show the first projection 224 and the second projection 234 facing each other directly, but as mentioned above, other arrangements of the first buffer panel 220 and the second buffer panel 230, such as an offset arrangement, may be used to form the buffer layer 210 discussed herein. Figures 5A and 5B show a buffer layer 212 having one such offset arrangement.

[0046] The first projection 224 and the second projection 234 are offset from each other. More specifically, the first projection 224 and the second projection 234 are offset from each other in either the longitudinal or widthwise direction of the buffer panel 303, but are aligned in the other longitudinal or widthwise direction of the buffer panel 303. In Figure 5A, the first projection 224 is shown by a solid line and the second projection 234 is shown by a dashed line. As shown in Figure 5A, the rows of projections on the first buffer panel 220 and the second buffer panel 230 are aligned from each other, but the columns of projections on the first buffer panel 220 and the second buffer panel 230 are offset from each other.

[0047] More specifically, at least some of the second projections 234 are positioned between two adjacent first projections 224, and at least some of the first projections 224 are positioned between two adjacent second projections 234. In the illustrated embodiment, portions of the first projections 224 on the edge of the first buffer panel 220 are referred to herein as “edge projections.” Edge projections are positioned only next to one second projection 234, rather than between two adjacent second projections 234. Each of the first projections 224 and the second projections 234 may include edge projections. More specifically, at least some of the first projections 224 may be edge projections, and / or at least some of the second projections 234 may be edge projections. Other projections of the first projections 224 and the second projections 234 may be internal projections. More specifically, at least a portion of the first projection 224 may be an internal projection, and / or at least a portion of the second projection 234 may be an internal projection. Each internal projection of the first projection 224 is positioned between two adjacent second projections 234, and each internal projection of the second projection 234 is positioned between two first projections 224. In Figures 5A and 5B, the internal projections of the first projection 224 are in contact with two adjacent second projections 234, and the internal projections of the second projection 234 are in contact with two adjacent first projections 224.

[0048] Figure 5C is a cross-sectional view of multiple buffer layers 212, viewed from a similar viewpoint as in Figure 5B. Two or more buffer layers 212 shown in Figures 5A and 5B can be arranged adjacent to each other in the same manner as the first buffer layer 211a and the second buffer layer 211b described above with reference to Figure 4C. More specifically, the multiple buffer layers 213 shown in Figure 5C include a first buffer layer 212a and a second buffer layer 212b. In Figure 6C, the outer surface 238 of the second base layer 232 in the first buffer layer 212a is in contact with the outer surface 238 of the first base layer 222 in the second buffer layer 212b. These can be arranged in various ways, but the opening 326 of the second projection 234 in the first buffer layer 212a aligns with the opening 326 of the first projection 224 in the second buffer layer 212b, forming a closed cavity between the cavity 324 of the second projection 234 in the first buffer layer 212a and the cavity 324 of the first projection 224 in the second buffer layer 212b.

[0049] Figures 6A and 6B show a buffer layer 213 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 6A is a top view of the buffer layer 213, and Figure 6B is a cross-sectional view of the buffer layer 213 along the line 6B-6B in Figure 6A. Figures 6A and 6B show a buffer layer 213 with a different offset arrangement.

[0050] The first projection 224 and the second projection 234 are offset from each other. More specifically, the first projection 224 and the second projection 234 are offset from each other in both the longitudinal and widthwise directions of the buffer panel 303. In Figure 6A, the first projection 224 is shown by a solid line and the second projection 234 is shown by a dashed line. As can be seen from Figure 6A, at least a portion of the second projection 234 (e.g., the internal projection) is located in the interstitial locations between the first projections 224. In Figure 6A, these interstitial locations are located between four adjacent first projections 224. This arrangement means that at least a portion of the first projection 224 (e.g., the internal projection) is also located in the interstitial locations between the second projections 234. In Figure 6A, these interstitial locations are located between four adjacent second projections 234. In Figures 6A and 6B, the internal protrusions of the first projection 224 are in contact with four adjacent second projections 234, and the internal protrusions of the second projections 234 are in contact with four adjacent first projections 224.

[0051] Figure 6C is a cross-sectional view of multiple buffer layers 213, viewed from the same viewpoint as in Figure 6B. Two or more buffer layers 213 shown in Figures 6A and 6B can be arranged adjacent to each other in the same manner as the first buffer layer 212a and the second buffer layer 212b described above with reference to Figure 5C. The description of the features in Figure 5C also applies to the first buffer layer 213a and the second buffer layer 213b shown in Figure 7C, but the offset arrangement described above is adopted for Figures 6A and 6B.

[0052] Figures 7A and 7B show a buffer layer 214 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 7A is a top view of the buffer layer 213, and Figure 7B is a cross-sectional view of the buffer layer 214 along the line 7B-7B in Figure 7A. Figures 7A and 7B show the buffer layer 213 with a different offset arrangement. In Figures 6A and 6B, the contact protrusions of the first projection 224 and the second projection 234 were in contact with other protrusions, but other arrangements are also possible. In Figures 7A and 7B, the contact protrusions of the first projection 224 and the second projection 234 are not in contact with each other, but rather are in contact with other parts of the second buffer panel 230 and the first buffer panel 220, respectively. More specifically, the distal end 322 of the first projection 224 is in contact with the projection-side surface 312 of the second base layer 232, and the distal end 322 of the second projection 234 is in contact with the projection-side surface 312 of the second projection 234.

[0053] The buffer layer 210 discussed herein can provide a certain degree of cushioning to the product 10. The buffer layer 210 has some degree of elastic deformability and not only provides a first level of cushioning but also absorbs energy by wrinkling and deforming. These different arrangements of the buffer layer 210 provide different levels of energy absorption, which can be adjusted as needed. Furthermore, as mentioned above, the first protrusions 224 and the second protrusions 234 can have a variety of shapes, including various geometric shapes. These different geometric shapes can take on different configurations to provide different cushioning and elasticity. For example, Figure 8A shows a buffer layer 215 formed by arranging a first buffer panel 220 relative to a second buffer panel 230. Figure 8A is a cross-sectional view of the buffer layer 214 from a similar viewpoint to that of Figure 4B mentioned above, but each of the first buffer panel 220 and the second buffer panel 230 in the buffer layer 215 is a buffer panel 305 having the pyramidal protrusions 335 shown in Figure 3D. Similarly, Figure 8B shows a buffer layer 216 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 8B is a cross-sectional view of the buffer layer 216 from a similar viewpoint to that of Figure 4B, but each of the first buffer panel 220 and the second buffer panel 230 within the buffer layer 216 is a buffer panel 307 having the arc-shaped projection 337 shown in Figure 3E. In Figures 8A and 8B, the first projection 224 and the second projection 234 are depicted directly opposite each other, but other arrangements are also possible, including the offset arrangement described above.

[0054] Figure 8C also shows a buffer layer 217 formed by positioning the first buffer panel 220 in a predetermined position relative to the second buffer panel 230. Figure 8C is a cross-sectional view of the buffer layer 216 from the same viewpoint as in Figure 4B described above. In the buffer layer 210 described above, the first buffer panel 220 and the second buffer panel 230 are arranged such that the first projection 224 protrudes toward the second buffer panel 230 and the second projection 234 protrudes toward the first buffer panel 220. However, as shown in Figure 8C, the first buffer panel 220 and the second buffer panel 230 are arranged such that the first projection 224 protrudes toward the second buffer panel 230 and the second projection 234 protrudes toward the first buffer panel 220. Similar to the explanation regarding multiple layers, the same explanation applies here, but the first buffer panel 220 and the second buffer panel 230 are arranged such that the back surface 314 of the first buffer panel 220 is in contact with the back surface 314 of the second buffer panel 230.

[0055] Figures 9A and 9B show a buffer layer 218 formed by positioning the first buffer panel 220 relative to the second buffer panel 230. Figure 9A is a top view of the buffer layer 213, and Figure 9B is a cross-sectional view of the buffer layer 218 along the line 9B-9B in Figure 9A. As mentioned above, the second projection 234 may have a different geometric shape from the first projection 224. In Figures 9A and 9B, the first buffer panel 220 is formed using a buffer panel 305 having a pyramidal projection 335 as shown in Figure 4D, and the second buffer panel 230 is formed using a buffer panel 309 having a rectangular projection 339 as shown in Figure 4F. Other arrangements are also possible, but Figures 9A and 9B show a buffer layer 218 with the offset arrangement described above, with reference to Figures 5A and 5B. In the aforementioned buffer layer 210, both the first projection 224 and the second projection 234 included contact protrusions. However, depending on the arrangement and geometric shape, only one of the first projection 224 or the second projection 234 may include contact protrusions. For example, as shown in Figures 9A and 9B, the second projection 234 includes a contact protrusion at its distal end 322 that contacts the first buffer panel 220, while the distal end 322 of the first projection 224 does not contact the second buffer panel 230.

[0056] Figure 9C is a cross-sectional view of multiple buffer layers 218, viewed from a similar viewpoint as in Figure 9B. Two or more buffer layers 218 shown in Figures 9A and 9B can be arranged adjacent to each other in the same manner as the first buffer layer 212a and the second buffer layer 212b described above with reference to Figure 5C. The description of the features in Figure 5C also applies to the first buffer layer 218a and the second buffer layer 218b shown in Figure 9C.

[0057] Figure 9D shows several different types of cushioning panels in a different configuration. Different rigidity can be obtained for each sheet depending on the shape of the protrusions and their arrangement relative to each other. As will be described later, using a combination of the first cushioning layer 219a and the second layer 219b, which has higher rigidity than the first cushioning layer 219a, is particularly advantageous when the first cushioning layer 219a is positioned closer to the product 10 than the second layer 219b, which is a more rigid layer as shown in Figure 9D. In Figure 9D, the first cushioning layer 219a is shown as using the cushioning layer 211 described above with reference to Figures 4A and 4B, and the second layer 219b is shown as a cushioning panel 309 having the rectangular protrusions 339 shown in Figure 3F. However, other cushioning panels can also be used to form these layers, as long as the rigidity is as described above.

[0058] Figures 10A and 10B illustrate a method for forming a buffer layer 210, such as the buffer layer 211 described above. Figure 10A shows the first step, and Figure 10B shows the second step. After forming the first buffer panel 220 and the second buffer panel 230, respectively, using the molded pulp method described above, adhesive 241 can be applied to the first buffer panel 220, the second buffer panel 230, or both. Figure 10A shows the adhesive 241 being applied to the second buffer panel 230. More specifically, the adhesive 241 is shown being applied to the projection side of the second buffer panel 230, including the distal end 322 of the second projection 234. Next, the first buffer panel 220 is positioned relative to the second buffer panel 230. As shown in the figure, this arrangement involves positioning the first projection 224 directly opposite the second projection 234, such that the distal end 322 of the first projection 224 contacts the distal end 322 of the second projection 234. The adhesive 241 is then dried to bond the distal end 322 of the first projection 224 to the distal end 322 of the second projection 234.

[0059] Figures 11A and 11B show another method for forming a buffer layer 210, similar to the buffer layer 211 described above. Figure 11A shows the first step, and Figure 11B shows the second step. In this method, the first buffer panel 220 and the second buffer panel 230 are formed as a single buffer panel 240, with the first buffer panel 220 becoming the first portion 243 of the buffer panel 240, and the second buffer panel 230 becoming the 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 where the projection 320 is not formed. The connecting portion 247 may be a flat sheet portion of the buffer panel 240. After applying the adhesive 241 in the manner described above, the first portion 243 can be rotated relative to the second portion 245 in the direction of the arrow, as shown in Figure 11B, similar to the method described above with respect to Figure 10B.

[0060] Figure 11C shows optional additional steps. As will be described later, the buffer layer 210 and buffer blocks 200 can be arranged in a variety of packaging materials by adjusting their relative positions. As will be described later with reference to Figures 16A and 16B, the third buffer block 116 and the fourth buffer block 118 can be arranged laterally to form an L-shape, with a product cavity 122 between them. One way to arrange them laterally is to further fold the buffer panel 240 after the steps shown in Figure 11B. For example, two buffer blocks (e.g., the third buffer block 116 and the fourth buffer block 118) can be arranged laterally to each other by rotating one end of the buffer panel 240 relative to the other end. The buffer panel 240 may include corner portions 249, and the first base portion 222 and the second base portion 232 can be folded or otherwise cut to facilitate rotation before rotating either of them. Furthermore, instead of stopping the bend to form an L-shape, one end of the buffer panel 240 can be further rotated to form multiple buffer layers (for example, the first buffer layer 211a and the second buffer layer 211b described above, with reference to Figure 4C).

[0061] Figure 11D shows another optional additional step. The buffer panel 240 can be further rotated in the manner described above with reference to Figure 11C, for example, to form a U-shape having a first buffer block 112, a second buffer block 114, and a third buffer block 116, which will be described later. One end of the L-shape shown in Figure 11C can also be further rotated to position it laterally on another part of the buffer panel 240.

[0062] Figure 11E shows another selective additional step for forming multiple layers. In Figure 11B, the buffer panel 240 is folded once to form a buffer layer, and then one end of the buffer layer is folded in the opposite direction to the other end. Here, in Figure 11E, the buffer panel 240 is folded multiple times in the opposite direction to itself to form multiple buffer layers. Therefore, the base layer of the buffer panel 240 will have a meandering structure after being folded.

[0063] Figure 12 shows a buffer block 202 that can be used as a buffer block 200 of the packaging material 100 (Figure 1) described herein. As previously stated, the buffer block 202 may be a composite buffer block that combines one or more buffer layers 210 with at least one other layer having a different configuration, such as having a different material or a different structure. The other layer shown in this embodiment is a cellulose sheet 250. The cellulose sheet 250 may be a paper sheet of various basis weights. For example, a thicker, more rigid cellulose sheet 250, including a fiberboard sheet, may be used. The cellulose sheet 250 can be in contact with and fixed to the buffer layer 210. More specifically, the cellulose sheet 250 can be in contact with and directly fixed to either the outer surface 228 of the first buffer panel 220 or the outer surface 238 of the second buffer panel 230. The cellulose sheet 250 may include a first surface 252 and a second surface 254. The first surface 252 can abut against and be directly fixed to either the outer surface 228 of the first buffer panel 220 or the outer surface 238 of the second buffer panel 230. The cellulose sheet 250 can be directly attached to the buffer layer 210 by applying an adhesive to either the first surface 252 of the cellulose sheet 250, the outer surface 228 of the first buffer panel 220, the outer surface 238 of the second buffer panel 230, or both.

[0064] Multiple cellulose sheets 250 can be used in various arrangements. In one arrangement, the first cellulose sheet and the second cellulose sheet may be in contact with each other and directly attached to the outside 228 of the first buffer panel 220 and the outside 238 of the second buffer panel 230, respectively. In some embodiments, the cellulose sheets 250 are formed on the outside of the buffer block 202 and may be called a cover layer.

[0065] Figure 13 shows a cushioning block 203 that can be used as a cushioning block 200 for the packaging material 100 (Figure 1) described herein. The cushioning block 203 shown in Figure 13 is also a composite cushioning block, but instead of using a cellulose sheet 250, the cushioning block 203 may be a corrugated fiberboard sheet 260, also called corrugated cardboard. The corrugated fiberboard sheet 260 shown in Figure 13 is a single-wall corrugated fiberboard sheet, but other corrugated fiberboard sheets 260 can also be used, for example, a double-wall corrugated fiberboard sheet or a triple-wall corrugated fiberboard sheet. The corrugated fiberboard sheet 260 includes a top sheet 261, a bottom sheet 263, and a corrugated sheet 265 sandwiched between the top sheet 261 and the bottom sheet 263. If the corrugated fiberboard sheet 260 is a double-walled or triple-walled 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, and may have an intermediate sheet or middle layer sheet separating the corrugated sheets 265.

[0066] Each liner (e.g., top sheet 261, bottom sheet 263, and middle sheet) and corrugated sheet 265 can be a suitable sheet made from cellulosic fibers commonly used in the manufacture of cardboard shipping boxes. Each corrugated sheet 265 has multiple flutes (corrugated cores). Any suitable standard flute shape commonly used in the manufacture of cardboard shipping boxes can be used. These flutes are referred to herein as “internal flutes” to distinguish them from other flutes formed in the packaging material described later.

[0067] The corrugated fiberboard sheet 260 can be positioned and arranged in the same manner as the cellulose sheet 250 described above. More specifically, the corrugated fiberboard sheet 260 may include a first surface 267 that faces outward from the top sheet 261 and a second surface 269 that faces outward from 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 the same manner as 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 outside of the buffer block 202 and may be called a cover layer, similar to the cellulose sheet 250. Alternatively, the corrugated fiberboard sheet 260 may be a structural layer of the buffer block 203.

[0068] In some applications, including the television applications described above, a structure is required that combines both robust and rigid protective and cushioning functions. Therefore, in some embodiments, one or more cushioning panels 300 (Figures 3A-3G) arranged and configured in the manner described above can be used in combination with an additional layer having a stronger and more rigid structure. For example, a composite cushioning block can be formed using a cushioning layer 210 (Figure 2) having one or more cushioning panels 300 and another panel or sheet panel having a stronger and more rigid structure than the cushioning panels 300 and the cushioning layer 210. These sheet panels are referred to herein as rigid sheet panels 400 (Figure 14A) to distinguish them from the cushioning panels 300. The rigid sheet panels 400 have higher rigidity than the cushioning panels 300, the cushioning layer 210, or both, when a load is applied in the thickness direction of the rigid sheet panels 400, the cushioning panels 300, or the cushioning layer 210. The composite cushioning block may include one or more rigid layers 270 (Figures 15A-15D) formed from one or more rigid sheet panels 400. Various rigid sheet panels 400 that can be used to form the rigid layer 270 will be described in more detail below, but in this specification, reference numeral 400 is used to refer collectively to various different rigid panels.

[0069] Figure 14A shows a rigid sheet panel 400 that can be used to form the buffer block 200 and the packaging material 100 (Figure 1). The rigid sheet panel 400 shown in Figure 14A 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 which is the outward-facing surface of the top sheet 412 and a second surface 418 which is the outward-facing surface of the bottom sheet 414. The top sheet 412 and the bottom sheet 414 are each cellulose sheets, and the description of the cellulose sheet 250 above also applies to these sheets. The honeycomb panel 410 also includes a core 420 sandwiched between the top sheet 412 and the bottom sheet 414.

[0070] Figure 14B shows the core 420 of the honeycomb panel 410. The core 420 includes a plurality of bands 422. The bands 422 are cellulose bands made of cellulose sheet material, and the description of the cellulose sheet 250 above also applies to these cellulose bands. The core 420 is formed by joining the bands 422 to each other using an adhesive or the like, forming a plurality of cells 424 defined by the bands 422. In Figure 14B, the cells 424 are hexagonal, but other shapes may be used. The bands 422 can be oriented laterally with respect to the top sheet 412 and the bottom sheet 414, for example, in a direction perpendicular to the top sheet 412 and the bottom sheet 414. The cells 424 are also oriented laterally with respect to the top sheet 412 and the bottom sheet 414, for example, in a direction perpendicular to the top sheet 412 and the bottom sheet 414. The top sheet 412 and the bottom sheet 414 may have a thickness greater than that of the band 422.

[0071] Figures 15A to 15D show a buffer block 200, more specifically a composite buffer block formed by combining one or more buffer layers 210 and one or more rigid layers 270. Figure 15A shows a buffer block 204 having the aforementioned buffer layer 212 and a rigid layer 270 formed using one honeycomb panel 410. The rigid layer 270, more specifically the honeycomb panel 410, is shown in Figure 15A as being 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 to abut against a second buffer panel 230 of the buffer layer 210. The first surface 416 of the top sheet 412 abuts against and is directly attached to either the outer surface 228 of the first buffer panel 220 or the outer surface 238 of the second buffer panel 230. The honeycomb panel 410 can be directly attached to the buffer layer 210 by applying adhesive to either the outer surface 228 of the first buffer panel 220, either the outer surface 238 of the second buffer panel 230, or both, on the first surface 416 of the honeycomb panel 410. In Figure 15A, the top sheet 412 is in contact with the second base layer 232 of the buffer layer 210.

[0072] The protrusions 320, such as the first protrusion 224, the second protrusion 234, or both, can be positioned in the same direction as the cells 424 of the honeycomb panel 410 (Figure 14B). The first protrusion 224, the second protrusion 234, the cells 424, or any combination thereof, can be positioned in the thickness direction of the buffer block 204.

[0073] Figure 15B shows a buffer block 205 having a rigid layer 270 formed using a single honeycomb panel 410. The buffer block 205 is similar to the buffer block 204 described above with reference to Figure 15A, but as shown in Figure 15B, the buffer layer 210 is formed using a single buffer panel 300, such as the buffer panel 303 described above. The buffer panel 303 can be positioned in various directions, such as in which the projections 320 extend toward the honeycomb panel 410, for example, in which the distal end 322 of the projections 320 contacts the first surface 416 of the upper sheet 412.

[0074] Figure 15C shows another buffer block 206 in which the rigid layer 270 is a honeycomb panel 410. The buffer block 206 shown in Figure 15C is similar to the buffer block 205 described above with reference to Figure 15B, but here the protrusions 320 project outward from the honeycomb panel 410. The base layer 310 can be brought into contact with the honeycomb panel 410 (e.g., the top sheet 412). More specifically, the back surface 314 can be brought into contact with the first surface 416 and positioned to make direct contact.

[0075] Figure 15D shows another buffer block 207. The buffer block 207 is similar to the buffer block 204 described above with reference to Figure 15A. The buffer block 207 comprises a corrugated fiberboard sheet 260 in addition to the buffer layer 210 and the rigid layer 270. The corrugated fiberboard sheet 260 can be incorporated at various positions within the buffer block 207. The corrugated fiberboard sheet 260 can be positioned adjacent to the buffer layer 210, the rigid layer 270, or both, for example, in contact with them. The corrugated fiberboard sheet 260 can also be positioned on the outer surface of the buffer block 207, for example, outside the buffer layer 210 or the rigid layer 270, or it can be positioned between the buffer layer 210 and the rigid layer 270. For example, as shown in Figure 15D, the corrugated fiberboard sheet 260 is positioned adjacent to the rigid layer 270, more specifically, in contact with the honeycomb panel 410 of the rigid layer 270.

[0076] As described above, the packaging material 100 (Figure 1) discussed herein can be formed from one or more cushioning blocks 200. The cushioning blocks 200 can be arranged around the product 10 (Figure 1) in various ways and combinations. In the following description, the cushioning material 100 is assumed to be formed as a single structure comprising cushioning blocks 200 connected to each other, for example, by corrugated fiberboard sheets 260. The cushioning blocks 200 can be arranged around the product 10 in the manner described later, even if they are not connected to each other.

[0077] Figures 16A and 16B show a rectangular packaging material 110 that can be used as one of the rectangular packaging materials 102 described above, for example with reference to Figure 1. Figure 16B is an exploded view of the rectangular packaging material 110. The rectangular packaging material 110 includes one or more cushioning blocks that can be placed around the product 10. More specifically, the rectangular 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, more specifically, two cushioning layers 210, as shown in Figures 16A and 16B. The buffer layers shown in Figures 16A and 16B are the buffer layers 211 described above with reference to Figures 4A to 4C, but other buffer layers 210 can also be used, and these buffer blocks 112, 114, 116, and 118 include a first buffer layer 211a and a second buffer layer 211b.

[0078] The first buffer block 112 and the second buffer block 114 are positioned facing each other, with a product cavity 122 in between them. The first buffer block 112 and the second buffer block 114 may be positioned parallel to each other, and their respective thickness directions may be aligned in the same direction. The first buffer block 112 may be a front buffer block, and the second buffer block 114 may be a back buffer block. The first buffer block 112 and the second buffer block 114 may have different shapes, but as shown in Figures 16A and 16B, the first buffer block 112 and the second buffer block 114 may each have the same shape, i.e., an L-shape.

[0079] The third buffer block 116 is positioned along one edge of each of the first buffer block 112 and the second buffer block 114, forming a bottom buffer block. The third buffer block 116 can 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 perpendicularly, to the first buffer block 112 and the second buffer block 114.

[0080] The fourth buffer block 118 is positioned along one end of each of the first buffer block 112 and the second buffer block 114, forming a lateral buffer block. The fourth buffer block 118 can be positioned on the short side of the first buffer block 112 and the second buffer block 114. The fourth buffer block 118 is positioned laterally, and more specifically orthogonally, 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 positioned laterally, and more specifically orthogonally, to each other.

[0081] The third buffer block 116 and the fourth buffer block 118 also define the boundaries of the product cavity 122. The product cavity 122 shown in Figure 16A is slot-shaped, but other shapes can be formed by the arrangement of the product cavities 122. In the illustrated configuration, each buffer block 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 have a product side and a product side surface 124. The product side surface 124 is the surface facing the product cavity 122 in each buffer block 112, 114, 116, and 118.

[0082] The cushioning blocks 112, 114, 116, and 118 also have a container side and a container-side surface 126 located outside the rectangular packaging material 110 and away from the product cavity 122. Each cushioning block 112, 114, 116, and 118 has a backing sheet, such as a corrugated fiberboard sheet 260, positioned on the container side of the cushioning block 112, 114, 116, and 118. More specifically, the rectangular packaging material 110 includes a first corrugated fiberboard sheet portion 132 corresponding to the first cushioning block 112, a second corrugated fiberboard sheet portion 134 corresponding to the second cushioning block 114, a third corrugated fiberboard sheet portion 136 corresponding to the third cushioning block 116, and a fourth corrugated fiberboard sheet portion 138 corresponding to the fourth cushioning block 118, and is arranged in the manner described above, corresponding to the second cushioning block 114, the third cushioning block 116, and the fourth cushioning block 118, respectively. The corrugated fiberboard sheet portions 132, 134, 136, and 138 can also be formed independently as separate sheets on the cushioning blocks 112, 114, 116, and 118, but in Figures 16A and 16B, the corrugated fiberboard sheet portions 132, 134, 136, and 138 are shown as part of a corrugated fiberboard sheet 130 that is connected to one another and folded to form an open box-like structure.

[0083] Figure 17 shows a U-shaped packaging material 142 that can be used, for example, as one of the U-shaped packaging materials 104 described above with reference to Figure 1. This U-shaped packaging material 142 is formed similarly to the rectangular packaging material 110 described above with reference to Figures 16A and 16B. The U-shaped packaging material 142 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 described above. The shape of each of the first cushioning block 112 and the second cushioning block 114 is shown as an elongated rectangular block, thereby forming an elongated product cavity 122.

[0084] Figure 18 shows two rectangular packaging materials 110 and one U-shaped packaging material 142 arranged next to each other. The product cavities 122 of the rectangular packaging material 110 and the U-shaped packaging material 142 can be aligned to form a continuous cavity for the product 10 (Figure 1). Although shown adjacent to each other in Figure 18 (and Figure 1), the packaging materials 100, such as the rectangular packaging material 110 and the U-shaped packaging material 142, can also be arranged with spaces between them.

[0085] Figures 19A and 19B show another rectangular packaging material 144 that can be used as one of the rectangular packaging materials 102 described above with reference to Figure 1, for example. Figure 19B is an exploded view of the rectangular packaging material 144. The rectangular packaging material 144 shown in Figures 19A and 19B is similar to the rectangular packaging material 110 described above with reference to Figures 16A and 16B, and the description applies thereto as well. In this rectangular packaging material 144, 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 are formed on the product-side surface 124 of each cushioning block 112, 114 and on the product-side surface 124 of 116 and 118, but not on the container-side surface 126. In this embodiment, the corrugated fiberboard sheet 130, more specifically the corrugated fiberboard sheet portions 132, 134, 136, and 138, define the void, rather than the surface of the buffer layer 210. In yet another embodiment, the corrugated fiberboard sheet portions 132, 134, 136, and 138 may be formed on either side of the buffer layer 210 (for example, by combining the features of Figures 16A and 16B with the features of Figures 19A and 19B).

[0086] Figures 20A and 20B show another rectangular packaging material 150 that can be used as one of the rectangular packaging materials 102 described above, for example with reference to Figure 1. The rectangular packaging material 150 shown in Figures 20A and 20B is similar to the rectangular packaging material 110 described above with reference to Figures 16A and 16B. 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. The advantage of using the corrugated fiberboard sheet 130 is that the cushioning blocks 112, 114, 116, and 118 can be attached to a surface such as the inner surface of the corrugated fiberboard sheet 130, and then the rectangular packaging material 150 can be formed by folding the corrugated fiberboard sheet 130 from a flat state to a folded state. Suitable mounting means include, for example, adhesives for attaching the cushioning blocks 112, 114, 116, and 118 (or parts thereof such as the cushioning layer) to the surface of the corrugated fiberboard sheet 130. The rectangular packaging material 150 shown in Figures 20A and 20B can be configured in a flat configuration and a folded configuration. The flat configuration is shown in Figure 20A, and the folded configuration is shown in Figure 20B. In the folded configuration, the rectangular packaging material 150 is formed as described above with reference to Figures 16A and 16B.

[0087] In the flat configuration shown in Figure 20A, the first buffer block 112 is positioned with a gap between it and the third buffer block 116, creating a space between them. The corrugated fiberboard sheet 130 includes a first connecting portion 152 that spans between the first buffer block 112 and the third buffer block 116. The connecting portion of the corrugated fiberboard sheet 130, such as the first connecting portion 152, is a portion of the corrugated fiberboard sheet 130 to which the buffer blocks are not attached, and allows the first buffer block 112 to be folded relative to the third buffer block 116. The first connecting portion 152 connects the first corrugated fiberboard sheet portion 132 and the third corrugated fiberboard sheet portion 136. Similarly, the second buffer block 114 is positioned at a distance from the third buffer block 116, and the second connecting portion 154 connects the second corrugated fiberboard sheet portion 134 to the third corrugated fiberboard sheet portion 136, allowing the second buffer block 114 to be folded relative to the third buffer block 116. Similarly, the fourth buffer block 118 is positioned at a distance from the third buffer block 116, and the third connecting portion 156 connects the fourth corrugated fiberboard sheet portion 138 to the third corrugated fiberboard sheet portion 136, thereby allowing the fourth buffer block 118 to be folded relative to the third buffer block 116.

[0088] To transition from the flat configuration in Figure 20A to the folded configuration in Figure 20B, 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 folded relative to the third buffer block 116 as shown, the buffer blocks 112, 114, 116, and 118 can also be connected to each other in other configurations and folded 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 and folded relative to the fourth buffer block 118. Furthermore, although a corrugated fiberboard sheet 130 has been described as an example, other backing or connecting materials such as paper sheets can also be used. More generally, a buffer block (e.g., a first buffer block 112) can be folded from a flat configuration to a folded configuration by connecting another buffer block (e.g., a third buffer block 116) with a connecting member and creating a gap between them.

[0089] To hold the rectangular packaging material 150 in a folded state, the corrugated layer 130 may be provided with tabs 158 connected to or part of the corrugated fiberboard sheet 130, for example, part of the fourth corrugated fiberboard sheet portion 138. A removable adhesive tape 159 may be attached to the inner surface of each tab 158 and used as an adhesive tape to hold the rectangular packaging material 150 in a folded state. Other means may be used to hold the rectangular packaging material 150 in a folded state instead of (or in addition to) the removable adhesive tape 159. For example, instead of the removable adhesive strip 159, adhesive may be applied to various parts of the rectangular packaging material 150, such as the inner surface of the tabs 158. Furthermore, or instead, an adhesive strip (e.g., tape) may be used. When an adhesive strip such as tape is used, the tabs 158 can be omitted.

[0090] Figures 21A and 21B show another rectangular packaging material 160, which can be used as one of the rectangular packaging materials 102 described above, for example with reference to Figure 1. This rectangular packaging material 160 is similar to the rectangular packaging material 150 shown in Figures 20A and 20B and can be formed in a flat configuration and a folded configuration. The flat configuration is shown in Figure 21A, and the folded configuration is shown in Figure 21B. As previously stated, a single molded pulp buffer panel can be used to form the rectangular packaging material 160, and the rectangular packaging material 160 shown in Figures 21A and 21B is formed from a single foldable molded buffer panel 170, such as the buffer panel 301 described above with reference to Figures 3A and 3B. Although buffer panel 301 (Figures 3A and 3B) has been described, any of the buffer panels 300 described herein (e.g., Figures 3A to 3G) can be used.

[0091] The foldable molded cushioning panel 170 comprises a first projection 162, a second projection 164, a third projection 166, and a fourth projection 168, arranged similarly to the first cushioning block 112, and arranged in the same configuration as the first cushioning block 112, second cushioning block 114, third cushioning block 116, and fourth cushioning block 118 described above with respect to Figures 20A and 20B. Each of these projections 162, 164, 166, and 168 is a portion containing a projection 320, such as a cylindrical projection 331.

[0092] The foldable molded cushioning panel 170 includes a first connecting portion 172 that spans between a first projection 162 and a third projection 166. Connecting portions of the foldable molded cushioning panel 170, such as the first connecting portion 172, may be portions on the surface of the cushioning panel 170 where the projections 320 are not formed. These connecting portions may be flat sheet portions of the foldable molded cushioning panel 170. The first connecting portion 172 connects the first projection 162 and the third projection 166, allowing the first projection 162 to be folded relative to the third projection 166 or bent in the opposite direction. Similarly, the second projection 164 is spaced apart from the third projection 166 and connected to the third projection 166 by the second connecting portion 174, thereby allowing the second connecting portion 174 to be folded relative to the third rectangular packaging material 146 or bent in the opposite direction. Similarly, the fourth projection 168 is positioned at a distance from the third projection 166 and is connected to the third projection 166 via a third connector 176, thereby allowing the fourth projection 168 to be folded or bent relative to the third projection 166.

[0093] The foldable molded cushioning panel 170 can be folded from a flat configuration to a folded configuration and can be held in the folded configuration, as described herein, in the same manner as the rectangular packaging material 150 described above with reference to Figures 20A and 20B. By attaching the additional layers described herein to the respective projections 162, 164, 166, and 168, various cushioning blocks described herein can be formed.

[0094] Figures 22A and 22B show another rectangular packaging material 146 that can be used, for example, as one of the rectangular packaging materials 102 described above with reference to Figure 1. Figure 22A is a top view of the rectangular packaging material 146, and Figure 22B is a perspective view of the rectangular packaging material 146. The rectangular packaging material 146 shown in Figures 22A and 22B is similar to the rectangular packaging material 110 described above with reference to Figures 16A and 16B, and the description thereof also applies here. However, in the rectangular packaging material 146 shown in Figures 22A and 22B, each cushioning block 112, 114, 116, and 118 is a composite cushioning block including a rigid layer 270. The rigid layer 270 shown in Figures 22A and 22B includes one or more honeycomb panels 410, but any rigid sheet panel 400 described herein can be used.

[0095] More specifically, the first buffer block 112 and the second buffer block 114 include the buffer block 205 described above with reference to Figure 15B. The third buffer block 116 and the fourth buffer block 118 include the buffer block 204 described above with reference to Figure 15A, but have multiple buffer layers 210, such as the first buffer layer 212a and the second buffer layer 212b described above with reference to Figure 5B. However, as mentioned above, different arrangements and numbers of buffer layers 210 can also be used.

[0096] In each of the buffer blocks 112, 114, 116, and 118, the buffer layer 210 can be placed on the product side. More specifically, the buffer layer 210 is placed adjacent to the product cavity 122 and is positioned to define the product cavity 122 as described above with reference to Figures 16A and 16B. In addition, the rigid layer 270, more specifically the honeycomb panel 410, is placed between the buffer layer 210 and the corrugated fiberboard sheet 130 that forms the container side of the rectangular packaging material 146.

[0097] In some embodiments, the third buffer block 116 and the fourth buffer block 118 form the periphery of the packaging material 100 (Figure 1). The inventors found it advantageous to place additional buffering material, such as an additional buffering layer 210, around the periphery of the product 10 rather than on its surface (Figure 1). Thus, the third buffer block 116 and the fourth buffer block 118 forming the periphery can have more buffering layers 210 than the first buffer block 112 and the second buffer block 114.

[0098] Figure 23 shows another rectangular packaging material 148, which can be used as one of the rectangular packaging materials 102 described above, for example, with reference to Figure 1. As previously mentioned, the additional cushioning layer 210 can be placed around the edges of the product 10 rather than on its surface (Figure 1). The rectangular packaging material 148 shown in Figure 23 is similar to the rectangular packaging material 146 shown in Figures 22A and 22B, but here the cushioning layer 210 is omitted from the first cushioning block 112 and the second cushioning block 114, leaving only the honeycomb panel 410 and the corrugated fiberboard sheet 130.

[0099] Figure 24A shows a U-shaped cushioning material 180 that can be used, for example, as one of the U-shaped cushioning materials 104 described above with reference to Figure 1. The U-shaped cushioning material 180 is formed similarly to the U-shaped cushioning material 142 described above with reference to Figure 17. The U-shaped cushioning material 180 includes a third cushioning block 116 arranged as described above with reference to Figure 17. Similar to the rectangular cushioning material 146 described above with reference to Figures 22A and 22B, 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 and the other cushioning blocks shown in Figure 24 includes one or more honeycomb panels 410, but any rigid sheet panel 400 described herein can be used. More specifically, the third cushioning block 116 includes the cushioning block 204 described above with reference to Figure 15A, but comprises multiple cushioning layers 210, such as the first cushioning layer 212a and the second cushioning layer 212b described above with reference to Figure 5B.

[0100] Furthermore, the U-shaped packaging material 180 includes a plurality of cushioning blocks arranged on the first side of the U-shaped packaging material 180, similar to the first cushioning block 112 described above with reference to Figure 17. More specifically, the U-shaped packaging material 180 has a first side first end cushioning block 181, a first side second end cushioning block 183, and a first side intermediate 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 intermediate cushioning block 185 shown in Figure 25 is a composite cushioning block formed by one or more cushioning layers 210, such as the cushioning layer 212 described above with reference to Figure 5B, and one or more rigid layers 270, such as a 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 a corrugated fiberboard sheet 130, more specifically, a first corrugated fiberboard sheet portion 132 positioned on the first surface 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 connection portion 187 of the corrugated fiberboard sheet 130.

[0101] Similarly, the U-shaped packaging material 180 comprises a plurality of cushioning blocks arranged on the second side of the U-shaped packaging material 180, similar to the second cushioning block 114 described above with reference to Figure 17. More specifically, the U-shaped packaging material 180 comprises a second side first end cushioning block 182, a second side second end cushioning block 184, and a second side intermediate cushioning block 186 on the first side. Each of the second side first end cushioning block 182, the second side second end cushioning block 184, and the second side intermediate cushioning block 186 shown in Figure 25 is formed by comprising one or more cushioning layers 210, such as the cushioning layer 212 described above with reference to Figure 5B. The second side first end cushioning block 182, the second side second end cushioning block 184, and the second side intermediate cushioning block 186 are connected to each other by a corrugated fiberboard sheet 130, more specifically, a second corrugated fiberboard sheet portion 134 arranged 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 the second side connecting portion 188 of the corrugated fiberboard sheet 130.

[0102] The first side first end buffer block 181 is positioned opposite the second side first end buffer block 182, with a product cavity 122 provided between them. The first side second end buffer block 183 is positioned opposite the second side second end buffer block 184, with a product cavity 122 provided between them. The first side intermediate buffer block 185 is positioned opposite the second side intermediate buffer block 186, with a product cavity 122 provided between them.

[0103] While the illustration shows a buffer block of a specific configuration, 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 fact, the cushioning protection provided by the first buffer layer 212a and the second buffer layer 212b of the third buffer block 116 may be sufficient, in which case the sides of the U-shaped packaging material 180 may include a rigid layer 270 such as a honeycomb panel 410 and have no buffer layer. Similarly, although shown as separate 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. 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.

[0104] Figure 24B shows a U-shaped cushioning material 190 that can be used as one of the U-shaped cushioning materials 104 described above with reference to Figure 1, for example. The U-shaped cushioning material 190 is formed similarly to the U-shaped cushioning material 180 described above with reference to Figure 24A. Instead of having multiple cushioning blocks on the first and second sides, the U-shaped packaging material 190 has one first side block 192 on the first side and one second side block 194 on the second side. Each of the first side block 192 and the second side block 194 includes a rigid panel 400, more specifically, a rigid panel without a cushioning layer. The rigid panel 400 shown in Figure 24B is a honeycomb panel 410, but any rigid panel discussed herein can be used. Although packaging materials consisting only of rigid panels such as honeycomb panels are known to break, it has been found that adding a cushioning layer (third cushioning block 116) to the back surface can provide sufficient cushioning for products 10 such as televisions. Although only the rigid panel 400 is shown in the illustration, the first side block 192 and the second side block 194 may include any buffer block, such as the composite buffer block described herein.

[0105] Figures 25A to 25C show another buffer layer, referred to herein as an irregular buffer layer 500, formed from a first buffer panel 512 and a second buffer panel 514. The irregular buffer layer 500 discussed herein can be used as any of the buffer layers described above and is particularly useful when the buffer layer abuts against or otherwise contacts the product 10. Figure 25A shows an irregular buffer layer 510 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, e.g., Figure 2) and the second buffer panel 230 (see, e.g., Figure 2). If a buffer panel such as the first buffer panel 512 is a molded buffer panel, the first buffer panel 512 can be molded into various shapes. For example, the product side and product side surface 124 of the first buffer panel 512, more specifically the buffer block formed using the irregular buffer layer 510, can be formed to conform to the shape of the product 10, such as an irregularly shaped product 12. Therefore, the irregular buffer layer 510, more specifically the first buffer panel 512 formed therefrom, can have product side recesses 516, product side protrusions 518, or both, formed on the product side of the buffer block formed using the irregular buffer layer 510. Thus, the product side recesses 516 and product side protrusions 518 can be molded on the back surface 314 of the first buffer panel 512.

[0106] Figure 25B shows another irregular buffer layer 520, similar to the irregular buffer layer 510 described above with reference to Figure 25A. The irregular buffer layer 520 is formed from a first buffer panel 522 and a second buffer panel 524, similar to the first buffer panel 512 and the second buffer panel 514. In the first buffer panel 512 and the second buffer panel 514 described above, the protrusions 320 on the protruding side of the first buffer panel 512 and the second buffer panel 514 (e.g., the first protrusion 224 and the second protrusion 234) can take the form of a repeating or regular pattern arrangement. However, as shown in Figure 25B, the first protrusion 224 may be omitted in the protruding portion 526 of the first buffer panel 522 (e.g., a portion of the first buffer panel 522 including the product-side recess 516), resulting in a non-repeating pattern.

[0107] Figure 25C shows another irregular buffer layer 530, similar to the irregular buffer layer 520 described above with reference to Figure 25B. The irregular buffer layer 530 is formed from a first buffer panel 532 and a second buffer panel 534, similar to the first buffer panel 522 and the second buffer panel 524. In Figure 25C, the first projection 224 of the first buffer panel 532 is omitted, and the second projection 234 of the second buffer panel 534 has a non-repeating pattern, such as an enlarged projection 536 that abuts against the portion without projections 526.

[0108] Figures 26A to 30C show various forms in which the buffer block described herein constitutes a shipping container. The packaging material 100 (Figure 1) described herein is separate from the shipping box 20 (Figure 1) and may be placed inside the shipping box 20, but other forms, as described below, can also be used to constitute a shipping container.

[0109] Figures 26A and 26B show a shipping container 600 formed using the buffer block 200 described herein (see, for example, Figure 2). The shipping container 600 can be configured in a flat configuration and a folded configuration. The flat configuration is shown in Figure 26A, and the folded configuration is shown in Figure 26B. The shipping container 600 includes a corrugated fiberboard sheet 610 similar to the corrugated fiberboard sheet 130 described above. The corrugated fiberboard sheet 610 can be folded from a flat state to a folded state and is partitioned to form multiple sections that form a box in the folded state. Various patterns can be used to partition the corrugated fiberboard sheet 610. The shipping container 600 may take on other shapes, but the shipping container 600 shown in Figure 26B is a rectangular shipping container, and the multiple sections of the corrugated fiberboard sheet 610 include a front section 611, a left side section 612, a right side section 613, a back section 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 attached to each section of the multiple sections of the fiberboard sheet 610 in a manner similar to that described above with reference to Figures 20A and 20B. More specifically, the shipping container 600 includes a front cushioning block 621, a left side cushioning block 622, a right side cushioning block 623, a rear cushioning block 624, a first top cushioning block 625, a second top cushioning block 626, a first bottom cushioning block 627, and a second bottom cushioning block 628, which are attached to the inner surfaces of the front section 611, the left side section 612, the right side section 613, the rear section 614, the first top flap 615, the second top flap 616, the first bottom flap 617, and the second bottom flap 618, respectively.

[0110] The buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 can be separated from each other with gaps between them. Thus, the corrugated fiberboard sheet 610 may include connecting portions 619 between adjacent buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628. The connecting portions 619 are similar to the aforementioned connecting positions, such as the first connecting portion 152. The connecting portions 619 allow adjacent buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 to fold relative to each other from a flat configuration shown in Figure 26A to a folded configuration shown in Figure 26B, thereby forming a shipping container 600 with a product cavity 122 for the product to be shipped. The shipping container 600 can be held in a folded configuration using methods for shipping boxes, such as strips of adhesive tape (e.g., tape) or adhesive applied to the overlapping parts of the shipping container 600.

[0111] Figures 27A and 27B show a shipping container 601 formed using the buffer block 200 described herein (see, for example, Figure 2). The shipping container 601 is similar to the shipping container 600 described above with reference to Figures 26A and 26B. The shipping container 601 can be configured in a flat configuration and a folded configuration. The flat configuration is shown in Figure 27A, and the folded configuration is shown in Figure 27B. An advantage of using the buffer block 200 described herein is that the buffer block 200 can be configured to fit more directly to the product 10, in particular to the product 10 that does not have a rectangular shape. Buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 may have positions where additional layers are added to better fit the shape of the product 10 and to form a product cavity 122 having a non-rectangular cross-section. For example, as shown in Figures 27A and 27B, the front buffer block 621 and the rear buffer block 624 each have a portion on which an additional layer 632, such as an additional buffer layer, is formed. To accommodate the additional layer 632, the other buffer blocks 621, 622, 623, 624, 625, 626, 627, and 628 (for example, 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 have a cutout 634 for accommodating the additional layer 632.

[0112] Figures 28A and 28B show a shipping container 602 formed using the buffer blocks 200 described herein (see, for example, Figure 2). The shipping container 602 is similar to the shipping container 601 described above with reference to Figures 27A and 27B. The shipping container 602 can be configured in a flat configuration and a folded configuration. The flat configuration is shown in Figure 28A, and the folded configuration is shown in Figure 28B. As previously stated, the irregular buffer layer 500 can be advantageously used to form irregular buffer blocks 636. As shown in Figures 28A and 28B, one or more buffer blocks can be irregular buffer blocks 636, such as a rear buffer block 624. Other buffer blocks, such as a second top buffer block 626 and a second bottom buffer block 628, can be formed to accommodate irregular buffer blocks 636 in a folded configuration.

[0113] Figures 29A and 29B show another shipping container 603. Shipping container 603 is similar to shipping container 602 shown in Figures 28A and 28B and can be configured in a flat configuration and a folded configuration. The flat configuration is shown in Figure 29A, and the folded configuration is shown in Figure 29B. Instead of using corrugated fiberboard sheets 610, shipping container 603 is formed from a single foldable molded cushioning panel 640, similar to the cushioning panel 301 described above with reference to Figures 3A and 3B, and the rectangular packaging material 160 described above with reference to Figures 21A and 21B. Although cushioning panel 301 (Figures 3A and 3B) has been described, any of the cushioning panels 300 described herein (e.g., Figures 3A to 3G) can be used.

[0114] The foldable molded cushioning panel 640 includes a front projection 641, a left side projection 642, a right side projection 643, a rear projection 644, a first top flap projection 645, a second top flap projection 646, a first bottom flap projection 647, and a second bottom flap projection 648, which are arranged in the same manner as the aforementioned front portion 611, left side portion 612, right side portion 613, rear portion 614, first top flap 615, second top flap 616, first bottom flap 617, and second bottom flap 618. Each of these projections 641, 642, 643, 644, 645, 646, 647, and 648 is a portion that includes a projection 320 such as a cylindrical projection 331.

[0115] The foldable molded cushioning panel 640 also includes a connector 649 similar to the first connector 172 described above with reference to Figures 21A and 21B. The connector 649 is positioned between adjacent protrusions 641, 642, 643, 644, 645, 646, 647, and 648, and is arranged such that, similar to the foldable molded cushioning panel 170 shown in Figures 21A and 21B, the protrusions 641, 642, 643, 644, 645, 646, 647, and 648 fold toward each other in the manner described above, and additional layers described herein can be attached to each of the protrusions 641, 642, 643, 644, 645, 646, 647, and 648 to form various cushioning blocks described herein.

[0116] Figures 30A and 30C show another shipping container 604 (Figure 30C). The shipping container 604 shown in Figures 30A and 30C is similar to the shipping container 603 described above with reference to Figures 29A and 29B. The shipping container 604 shown in Figures 30A to 30C is not formed from a single foldable molded cushioning panel, but from multiple foldable molded cushioning panels. Figure 30A shows a first foldable molded cushioning panel 652, and Figure 30B shows a second foldable molded cushioning panel 654. Each of the first foldable molded cushioning panel 652 and the second foldable molded cushioning panel 654 may be any of the cushioning panels 300 described herein (e.g., Figures 3A to 3G), such as a cushioning panel 301 having a cylindrical projection 331. The first foldable molded cushioning panel 652 can be positioned relative to the second foldable molded cushioning panel 654, similar to the method described above, to form a cushioning layer 650 (Figure 30C). The first foldable molded cushioning panel 652 is an inner cushioning panel that can be positioned adjacent to the product 10 (Figure 30C), and, similar to the first cushioning panel 512 (Figure 16A) described above, may be an irregularly shaped cushioning sheet. The first foldable molded cushioning panel 652 is shown in a flat state in Figure 30A, and the second foldable molded cushioning panel 654 is shown in a flat state in Figure 30B.

[0117] Figure 30C shows a first foldable molded cushioning panel 652 and a second foldable molded cushioning panel 654 in a folded state to form a shipping container 604. The first foldable molded cushioning panel 652 can be folded to form a product cavity 122. The 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 be folded independently to form the cushioning layer 650. For example, the buffer layer 650 and the shipping container 604 can be formed by folding the first foldable molded buffer panel 652, followed by folding the second foldable molded buffer panel 654 around the first foldable molded buffer panel 652. Alternatively, the first foldable molded buffer panel 652 and the second foldable molded buffer panel 654 can be stacked flat and then folded together. The first foldable molded buffer panel 652 can be folded around the product 10, either on its own or connected to the second foldable molded buffer panel 654.

[0118] Figure 31 shows another buffer panel 700. The buffer layer 210 (Figure 2) used in the buffer block 200 (Figure 2) described above is formed from a molded paper pulp panel, but other buffer panels can also be used to form the buffer block. This buffer panel 700 is formed from a sheet having protrusions 720 that deform when a load is applied. More specifically, in Figure 31, the buffer panel 700 has a plurality of flutes 722 formed on a sheet including a base layer 712. The base layer 712 is the same as the base layer 310 (Figure 3B) described above. The flutes 722 form the protrusions 720 of the buffer panel 700. These flutes 722 are spaced apart from each other, and this spaced configuration allows the flutes 722 to deform relative to the base layer 712, providing a buffering effect. The buffer panel 700 can be formed from the various cellulosic sheets described above. The corrugated fiberboard sheet 710 can be folded or otherwise shaped to form flutes 722. The flutes 722 are elongated and extend parallel to each other. The flutes 722 can take on various shapes, as will be described later.

[0119] The buffer panel 700 shown in Figure 31 is provided with triangular flutes 722, which are referred to herein as triangular flutes 732. For clarity, these buffer panels, along with other buffer panels described later, are referred to herein as "triangular flute buffer panels 730". The triangular flutes 732 include a plurality of cell walls that define triangularly formed cells, which are referred to as triangular cells 734. The plurality of cell walls include distal walls 742 that form the base of the triangles, which are similar to the distal end 322 (see Figure 3B) described above. The first transverse wall 744 is distal to the base layer 712. The plurality of cell walls 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 that extends laterally from the base layer 712 or its surface. The corrugated fiberboard sheet 710 is a continuous sheet, and each of the first transverse wall 744 and the second transverse wall 746 connects either of the base layers 712 to the distal wall 742 and forms one of the sides of the triangular cell 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 side, forming the vertices 736 of the triangular cell 734. The first transverse wall 744 and the second transverse wall 746 may be in contact with each other at the second transverse wall 746, but the ends of the first transverse wall 744 and the second transverse wall 746 may be spaced apart from each other, as shown in Figure 31, for example, to form a gap within the base layer 712. The dimensions and spacing of the flutes 722, such as the triangular flutes 732, including the gap at the vertices 736, can be varied to provide different cushioning properties.

[0120] Figure 32 shows a triangular flute buffer panel 730 used as the buffer layer 210 of the buffer block 208. This triangular flute buffer panel 730 can be used in a similar manner to any of the buffer panels described above. For example, as shown in Figure 32, the triangular flute buffer panel 730 is used in combination with a rigid layer 270 formed from a honeycomb panel 410 to form a composite buffer block.

[0121] Figure 33 shows a rigid sheet panel 400, more specifically, a shaped corrugated fiberboard rigid sheet panel 402. The shaped corrugated fiberboard rigid sheet panel 402 shown in Figure 33 comprises a first surface and a second surface. For ease of reference in this specification, the first surface is referred to as the top surface 432 and the second surface as the bottom surface 434, although depending on the application, these surfaces may have different orientations, such as being the outer or inner surface. The shaped corrugated fiberboard rigid sheet panel 402 can be manufactured by folding or otherwise shaping a corrugated fiberboard sheet 436 to form a plurality of triangular cells, more specifically, a plurality of first triangular cells 440 and a plurality of second triangular cells 450. The first triangular cells 440 and the second triangular cells 450 are arranged alternately, with each first triangular cell 440 adjacent to two second triangular cells 450, more specifically located between them, and similarly, with the exception of the end cells, each second triangular cell 450 adjacent to two first triangular cells 440, more specifically located between them, except for the end cells which are adjacent to only one cell. If any of the first triangular cells 440 are end cells, then the end cell of the first triangular cells 440 is adjacent to any of the second triangular cells 450, and similarly, if any of the second triangular cells 450 are end cells, then the end cell of the second triangular cells 450 is adjacent to any of the first triangular cells 440. Each of the multiple triangular cells (i.e., the first triangular cell 440 and the second triangular cell 450) has a longitudinal axis, which in the illustrated embodiment extends in a direction parallel to the top surface 432, the bottom surface 434, or both.

[0122] Each first triangular cell 440 includes a base, which is referred to herein as a first base 442. The first base 442 is part of a corrugated fiberboard sheet 436, and multiple first bases 442 come together to form a top wall. The top surface 432 is the outer surface of the top wall. Similarly, each second triangular cell 450 includes a base, which is referred to herein as a "second base 452". The second base 452 is part of a corrugated fiberboard sheet 436, and multiple second bases 452 come together to form a bottom wall. The bottom surface 434 is the outer surface of the bottom wall. Thus, the first triangular cells 440 and the second triangular cells 450 are arranged to interlock with each other.

[0123] The formed corrugated fiberboard rigid sheet panel 402 further comprises a plurality of lateral walls 438. The lateral walls 438 may be part of a corrugated fiberboard sheet 436 that extends laterally with respect to the top surface 432 and bottom surface 434. The formed corrugated fiberboard rigid sheet panel 402 may be formed from a continuous sheet (i.e., a corrugated fiberboard sheet 436), and each lateral wall 438 connects one of the first bases 442 and one of the second bases 452, forming one side of a triangular cell. The lateral wall 438 separates the first triangular cell 440 from the adjacent second triangular cell 450. Two lateral walls 438 are joined at a position opposite the bottom surface portion, forming the vertices of the triangular cell. More specifically, two side walls 438 can be brought together on opposite sides of the first base 442 to form one first vertex 444 of the first triangular cell 440, and two side walls 438 can be brought together on opposite sides of the second base 452 to form one second vertex 454 of the second triangular cell 450. The side walls 438 are connected to the ends of the first base 442 and the second base 452. In the illustrated embodiment, each end of the first base 442 abuts against the adjacent end of the first base 442 at the second vertex 454, and each end of the second base 452 abuts against the adjacent end of the second base 452 at the first vertex 444. In some embodiments, adhesive may be applied to each of the first vertices 444 and the second vertices 454.

[0124] In the illustrated embodiment, the side walls 438 are of the same length, so the first triangular cells 440 and the second triangular cells 450 can be isosceles or equilateral triangles. In some embodiments, the first base 442 and / or the second base 452 are the same length as each side wall 438, while in other embodiments, the length of the first base 442 and / or the second base 452 is either longer or shorter than each side wall 438. In Figure 1, the first triangular cells 440 and the second triangular cells 450 are acute isosceles triangles, but other shapes such as obtuse triangles can also be used. The number, size, and density of cells can be varied depending on the required overall compressibility, burst strength, and flexibility. The angles of the triangular cell vertices, and the lengths of the first base 442, the second base 452, and the side walls 438 can be modified to adjust the properties of the formed corrugated fiberboard rigid sheet panel 402.

[0125] Figure 34 shows a formed corrugated fiberboard rigid sheet panel 402 used as the rigid layer 270 of the buffer block 209. This formed corrugated fiberboard rigid sheet panel 402 can be used in the same manner as any of the rigid sheet panels described above. For example, as shown in Figure 34, the formed corrugated fiberboard rigid sheet panel 402 is used in combination with a triangular flute buffer panel 730 to form a composite buffer block.

[0126] Figure 35 shows another alternative buffer panel 700. As previously mentioned, the grooves 722 can take on various shapes, and the buffer panel 700 shown in Figure 35 has V-shaped or wavy protrusions 720. To clearly distinguish it from other buffer panels described herein, this buffer panel is referred to as the V-shaped buffer panel 750. The V-shaped buffer panel 750 can be formed from a cellulose sheet described herein, such as a corrugated fiberboard sheet 752. The V-shaped buffer panel 750 includes a plurality of macroflutes 760 arranged parallel to each other. These macroflutes 760 are referred to as macroflutes 760 to distinguish them from the internal flutes of the corrugated fiberboard sheet 752 that forms the V-shaped buffer panel 750. The macroflutes 760 of the V-shaped buffer panel 750 are parallel to the internal flutes.

[0127] The macroflutes 760 may generally have a triangular (or V-shaped) form, with the first plane 762 connected to the second plane 764 at vertex 766. Adjacent macroflutes 760 are connected to each other at valleys 768, forming a structure in which multiple ridges (vertices 766) and grooves (valleys 768) are arranged alternately. In the figure, the macroflutes 760 are shown to have the same height and spacing, but are not limited to this, and may have different heights and spacings.

[0128] Figure 36 shows a V-shaped buffer panel 750 used as the buffer layer 210 of the buffer block 754. The V-shaped buffer panel 750 can be used in the same manner as any of the buffer panels described above. For example, as shown in Figure 36, the V-shaped buffer panel 750 is used in combination with a rigid layer 270 formed from a honeycomb panel 410 to form a composite buffer block.

[0129] Figures 37A and 37B show another alternative buffer panel 700. To clearly distinguish it from other buffer panels described herein, this buffer panel is referred to as the "finned buffer panel 770". Figure 11A is a perspective view of the finned buffer panel 770, and Figure 37B is a detail view showing the detail 37B of the finned buffer panel 770 of Figure 37A. The projections 720 of the finned buffer panel 770 are fins 780 arranged parallel to each other. The finned buffer panel 770 can be molded from a cellulose sheet as described herein, such as a corrugated fiberboard sheet 772. The fins 780 of the finned buffer panel 770 can be arranged parallel to the inner flutes of the corrugated fiberboard sheet 772 used to form the finned buffer panel 770. The fins 780 may be separated from each other by a base 774 of the finned buffer panel 770. The base 774 is generally planar. The base 774 can have a structure similar to the base layer described above. Each fin 780 is connected to a base 774, and the fins 780 protrude from the base 774.

[0130] As shown in Figure 37B, the fins 780 in this embodiment are U-shaped or horseshoe-shaped, and each fin 780 has a first projection 782 connected to a second projection 784 at the apex 786. The apex 786 has a structure similar to the distal end of the projection described above. The end of each of the first projection 782 and the second projection 784 that is connected to the base 774 is the base end 788. The base end 788 is the end of the first projection 782 or the end of the second projection 784 that are opposite each other at the apex 786. The first projection 782 and the second projection 784 are connected to each other in a continuous manner at the apex 786 and can be an extension of the same corrugated cardboard material without being cut or separated at the apex 786.

[0131] Other parts of the first projection 782 and the second projection 784 (outside the vertex 786) may also be connected to each other. For example, adhesive can be applied to the inner surface of the first projection 782, the inner surface of the second projection 784, or between them. The adhesive may be applied along the entire length of the inner surface of the first projection 782 and / or the inner surface of the second projection 784, or it may be applied between the base end 788 of the inner surface of the first projection 782 and / or the base end 788 of the inner surface of the second projection 784. In this way, the first projection 782 and the second projection 784 are also connected to each other at the base end 788. Connecting the first projection 782 and the second projection 784 at the base end 788 helps to prevent the fin 780 from spreading when force is applied to the vertex 786, for example, thereby giving rigidity to the fin 780 and providing a protective (cushioning) effect to the entire finned cushioning panel 770. In particular, the cushioning characteristics of the finned cushioning panel 770 can be adjusted by changing the spacing between the fins 780 (for example, the length of the base section 774).

[0132] Figure 38 shows a finned buffer panel 770 used as the buffer layer 210 of a buffer block 776. The finned buffer panel 770 can be used in a similar manner to any of the buffer panels described above. For example, as shown in Figure 36, the finned buffer panel 770 is used in combination with a rigid layer 270 formed from a honeycomb panel 410 to form a composite buffer block.

[0133] Figures 39A and 39B show a buffer block 460 having a buffer layer 210, such as the buffer layer 211 described above, and a rigid layer 270. Figure 39A is an exploded view of the buffer block 460, and Figure 39B is a perspective view of the buffer block 460. The buffer layer 211 described above is shown with reference to Figures 4A and 4B, but any buffer layer described herein can be used. The rigid layer 270 includes one or more rigid sheet panels 400. The rigid sheet panels 400 shown in Figures 39A and 39B are referred to herein as lattice structure rigid sheet panels 404. Lattice structure rigid sheet panels 404 can be used in any buffer block described herein.

[0134] The rigid sheet panel 404 having a lattice structure comprises a plurality of strips, including a first strip 462 and a second strip 464 arranged laterally to each other, thereby forming a lattice structure 466 having a plurality of cells 468. The widths of the first strip 462 and the second strip 464 are oriented in the thickness direction of the buffer block 460. The first strip 462 and the second strip 464 can be arranged such that the cells 468 are oriented in the thickness direction of the buffer block 460. The first strip 462 and the second strip 464 can be arranged perpendicular to the outer surface 238 of the second buffer panel 230. The cells 468 are shown as rectangular cells with the first strip 462 positioned perpendicular to the second strip 464, but other angles may be used.

[0135] The lattice structure 466 can be formed in various ways. The lattice structure 466 can be formed as a molded pulp structure in which the first strip 462 and the second strip 464 are integrally molded 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, slits can be formed in the first strip 462, the second strip 464, or both, for interlocking with the other strip. The first strip 462 and the second strip 464 may be interlocked corrugated fiberboard strips. If the first strip 462 and the second strip 464 are corrugated strips, the flutes of the corrugated fiberboard can be oriented in the thickness direction of the buffer block 460.

[0136] As mentioned above, adhesives can be used for a variety of applications. Any suitable adhesive can be used, but in the embodiments discussed herein, the adhesive is preferably a biodegradable adhesive.

[0137] Throughout the embodiments discussed herein, various features are described as being similar to one another. Therefore, a description of one feature also applies to similar features. In some cases, the same reference numerals are used throughout to describe identical or similar features. Furthermore, although various layers are described individually above, as previously stated, these layers can be combined in various combinations, including those not explicitly illustrated, to form packaging materials, more specifically, various different cushioning blocks.

[0138] Although the present invention has been described based on specific embodiments, many further modifications and variations will become apparent to those skilled in the art in light of this disclosure. Therefore, it should be understood that the present invention may be carried out in ways other than those specifically described. Accordingly, the embodiments of the present invention should be considered in all respects to be illustrative and not limiting, and the scope of the invention is determined not by the foregoing description but by the claims and equivalents that may be supported by this application.

Claims

1. A packaging material that includes one or more buffer layers, Each buffer layer is It includes a first buffer panel having the first base layer from which a plurality of first protrusions extend, Each of the first projections has a distal end located distal to the first base layer, The first buffer panel is a molded pulp panel, Each of the aforementioned buffer layers also, It includes a second buffer panel having the second base layer from which a plurality of second protrusions extend, Each of the second projections has a distal end located distal to the second base layer, The second buffer panel is a molded pulp panel, The first buffer panel is arranged such that the plurality of first protrusions project toward the second buffer panel. The second buffer panel is arranged such that the plurality of second protrusions project toward the first buffer panel, and at least a portion of the plurality of second protrusions are second contact protrusions. The distal end of the second contact projection contacts the first buffer panel. Packing materials.

2. The first and second buffer panels are first and second parts of a foldable molded pulp panel, The foldable molded pulp panel has a connecting portion between the first portion and the second portion. The packaging material according to claim 1.

3. At least a portion of the second contact projection is an inner second contact projection, and each of the inner second contact projections is located between two or more adjacent first projections of the plurality of first projections. The packaging material according to claim 1.

4. At least a portion of the first projections among the plurality of first projections is a first contact projection, The distal end of the first contact projection contacts the second buffer panel. The packaging material according to claim 1.

5. At least a portion of the second contact projection is an inner second contact projection, and each of the inner second contact projections is located between two or more adjacent first projections of the plurality of first projections. The packaging material according to claim 4.

6. The first contact protrusions come into contact with the second buffer panel by the distal end of each first contact protrusion coming into contact with at least one of the plurality of second protrusions. The second contact projection contacts the first buffer panel by the distal end of each second contact projection contacting at least one of the plurality of first projections. The packaging material according to claim 4.

7. The first contact projection and the second contact projection are arranged to face each other directly. The distal end of each first contact projection is in contact with the corresponding distal end of the second contact projection. The packaging material according to claim 6.

8. It includes two or more buffer layers, including a first buffer layer and a second buffer layer. Each buffer layer has an inner and an outer layer, The inner side of the first base layer is positioned opposite the second buffer panel, and a plurality of first protrusions extend from the inner side of the first base layer. The second base layer has an inner and an outer layer, The inner side of the second base layer is positioned opposite the first buffer panel, and a plurality of second protrusions extend from the inner side of the second base layer. The outer side of either the first base layer or the second base layer of the first buffer layer is in contact with the outer side of either the first base layer or the second base layer of the second buffer layer. The packaging material according to claim 1.

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

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

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

12. Regarding each buffer layer, The second base layer has an inner and an outer layer, The inner side of the second base layer is positioned to face 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 has a tip and a length from the inside to the tip, and the plurality of second protrusions have a plurality of different lengths. The packaging material according to claim 1.

13. A composite packaging material comprising one or more buffer layers arranged to have a product side and an outer side, Each buffer layer is It includes a first buffer panel having a first base layer from which a plurality of first protrusions extend, The first buffer panel is a molded pulp panel, Each of the aforementioned buffer layers also, It includes a second buffer panel having a second base layer from which a plurality of second protrusions extend, The second buffer panel is a molded pulp panel, The first cushioning panel and the second cushioning panel are arranged to contact each other such that the plurality of first protrusions protrude toward the second cushioning panel, and the plurality of second protrusions protrude toward the first cushioning panel. Includes a cellulose-based sheet disposed on the outside of one or more buffer layers, Composite packaging material.

14. The aforementioned cellulose-based sheet is a corrugated fiberboard sheet. The composite packaging material according to claim 13.

15. The present invention further includes a rigid panel located between one of the buffer layers and the cellulose-based sheet, The rigid panel is formed from a cellulose-based material. The rigid panel has higher rigidity than each of the buffer layers when a load is applied in the thickness direction of the rigid panel or the buffer layer. The composite packaging material according to claim 14.

16. The cellulose-based sheet is a honeycomb panel containing a plurality of cells extending in the thickness direction of the packaging material. The plurality of first protrusions and the plurality of second protrusions extend in the thickness direction of the packaging material. The composite packaging material according to claim 13.

17. It is a composite packaging material, The buffer layer includes a buffer panel having a base layer with multiple protrusions extending therefrom, Each of the aforementioned protrusions has a distal end located away from the base layer, The aforementioned buffer panel is a molded pulp panel, The aforementioned composite packaging material also, The buffer layer includes a rigid panel in contact with the buffer layer, the rigid panel being formed from a cellulose-based material, The rigid panel has higher rigidity than the cushioning panel when a load is applied in the thickness direction of the rigid panel or the cushioning panel. Composite packaging material.

18. The rigid panel is a honeycomb panel containing a plurality of cells extending in the thickness direction of the packaging material. The composite packaging material according to claim 17.

19. The rigid panel is a lattice structure panel having cells oriented in the thickness direction of the rigid panel. The composite packaging material according to claim 17.

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

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

22. Each cushioning block has a product side containing one or more cushioning blocks that can be placed around the product to be shipped, and the packaging material includes these blocks. Each buffer block includes one or more buffer layers. Each buffer layer is It includes a first buffer panel having a first base layer from which a plurality of first protrusions extend, Each of the first projections has a distal end located distal to the first base layer, The first buffer panel is a molded pulp panel, Each of the aforementioned buffer layers also, It includes a second buffer panel having a second base layer from which a plurality of second protrusions extend, Each of the second projections has a distal end located distal to the second base layer, The second buffer panel is a molded pulp panel, The first cushioning panel is arranged such that the plurality of first protrusions project toward the second cushioning panel, and the second cushioning panel is arranged such that the plurality of second protrusions project toward the first cushioning panel. Packing materials.

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

24. The rigid panel is a honeycomb panel having a plurality of cells extending in the direction extending toward the product side of the buffer block, The aforementioned honeycomb panel is formed from a cellulose-based material. The packaging material according to claim 23.

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

26. Each buffer block further comprises a cellulose outer sheet, The aforementioned cellulose-based outer sheet is a corrugated fiberboard sheet. The packaging material according to claim 22.

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

28. The buffer blocks include a first buffer block and a second buffer block, which are arranged laterally to each other so as to form an L-shape and a product cavity between them. The packaging material according to claim 22.

29. The present invention further includes a corrugated fiberboard sheet comprising a first part, a second part, and a connecting portion connecting the first part and the second part, The one or more buffer blocks include a first buffer block and a second buffer block, The first buffer block includes the first portion of the corrugated fiberboard sheet, The second buffer block includes the second portion of the corrugated fiberboard sheet. The packaging material according to claim 22.

30. Packing materials, The corrugated fiberboard sheet further includes multiple backing sections connected to each other by multiple connecting sections, Each connection point connects one backing section to another backing section. The aforementioned packaging material further, Includes multiple buffer blocks, Each buffer block further includes one of the plurality of backing portions, The aforementioned multiple backing sections are connected to each other so that they can be folded into the shipping box. The packaging material according to claim 22.

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