Tension-activated expandable sheet with compound slits

Abstract

The present disclosure generally relates to tension-actuated expansion articles that include a compound slit pattern. In some embodiments, these articles are used as cushioning films and / or packaging materials. The present disclosure also generally relates to methods of making and using these tension-actuated expansion articles.

Description

[Technical field]

[0001] The present disclosure generally relates to tension-actuated expansion articles that include a compound slit pattern. In some embodiments, these articles are used as cushioning films and / or packaging materials. The present disclosure also generally relates to methods of making and using these tension-actuated expansion articles. [Background technology]

[0002] In 2016, consumers purchased more products online than in stores. (Consumers Are Now Doing Most of their Shopping Online, Fortune Magazine, June 8, 2016). Specifically, consumers did 51% of their shopping online and 49% in stores. Ibid. One result of this change in consumer behavior is the increase in the number of packages mailed and delivered per day. Over 13.4 billion packages are delivered to homes and businesses around the world each year (approximately 5.2 billion by the U.S. Postal Service, 3.3 billion by Fed Ex, and 4.9 billion by UPS). While non-package mail deliveries have declined year over year, package deliveries have grown at about 8% annually. This growth has resulted in package deliveries accounting for 25% of the U.S. Postal Service's business. (Washington Examiner, "For every Amazon package it delivers, the Postal Service loses $1.46," September 1, 2017). Amazon ships about 3 million packages per day, while Alibaba ships about 12 million packages per day.

[0003] It's not just businesses shipping packages. The growing maker movement creates opportunities for individuals to ship handmade products around the world through websites like Etsy™. Additionally, an increased focus on sustainability has led many consumers to resell used products on sites like eBay™ rather than tossing them in landfills. For example, over 25 million people sell items on eBay™, and over 171 million people buy those goods.

[0004] Individuals and businesses who ship these goods often ship those items in a shipping container, typically a box, that contains the product to be shipped, cushioning material, and air. Boxes have many advantages, such as being standable, being lightweight, storing flat, being recyclable, and being relatively low cost. However, boxes come in standard sizes that often do not match the size of the product to be shipped, requiring users to fill the boxes with large amounts of filler or cushioning material to protect the item from being damaged by being bumped into the surroundings while being shipped in a box that is too large.

[0005] Packaging cushioning protects goods during transportation. The effects of vibration and shock during transportation and loading / unloading are mitigated by the cushioning, reducing the possibility of damage to the product. Cushioning is often placed inside the shipping container, where it absorbs energy, for example, by buckling and deforming and / or by reducing vibration or by transferring shock and vibration to the cushioning instead of the goods being shipped. In other examples, packaging materials are used for functions other than cushioning, such as to immobilize and hold the goods being shipped in place inside the box. Alternatively, packaging materials are used to fill gaps, for example, when boxes are used that are significantly larger than the goods being shipped.

[0006] Some exemplary packaging materials include plastic bubble wrap™, bubble film, cushion wrap, air pillows, shredded paper, crinkled paper, shredded poplar, vermiculite, cradle, and corrugated bubble film. Many of these packaging materials are not recyclable.

[0007] One exemplary packaging material is shown in Figures 1A and 1B. The film 100 is made of a paper sheet containing a pattern of multiple cuts or slits 110, often referred to as a "skip slit pattern," which is a type of single slit pattern. When the film 100 is tension-activated (pulled along a pulling axis (T) that is substantially perpendicular to the cuts or slits 110), multiple beams 130 are formed. The beams 130 are the areas between adjacent, coaxial rows of slits. Collectively, the beams 130 formed by the slits 110 move upward and downward to some degree (see, for example, Figures 1B and 1C). This upward and downward movement causes the two-dimensional article (substantially flat sheet) of Figure 1A to become the three-dimensional article of Figures 1B and 1D when tension-activated. When this film is used as a packaging material, the three-dimensional structure provides some cushioning compared to a two-dimensional flat structure.

[0008] The cut or slit pattern for the film 100 is shown in FIG. 1A and described in U.S. Patent Nos. 4,105,724 (Talbot) and 5,667,871 (Goodrich et al.). The pattern includes a plurality of substantially parallel rows 112 of a plurality of individual linear slits 110. Each individual linear slit 110 in a given row 112 is out of phase with each individual linear slit 110 in an immediately adjacent substantially parallel row 112. In the particular configuration of FIGS. 1A-1C, adjacent rows 112 are out of phase with one-half the horizontal spacing. The pattern forms an array of slits 110 and rows 112 having a regular repeating pattern throughout the array. A beam 130 of material is formed between immediately adjacent rows 112 of slits 110.

[0009] FIG. 2A shows the cut or slit pattern of the film 100 of FIGS. 1A-1C rotated 90 degrees. Each linear slit 110 has a length (L) extending between a first end 114 and a second end 116. Each linear slit 110 also has a midpoint 118 that is halfway between the first end 114 and the second end 116. The midpoint 118 is indicated by a dot on two of the slits 110 in FIG. 2A. The midpoints 118 of parallel and aligned slits 110 are substantially aligned with one another. In other words, the midpoint 118 of an individual linear slit 110 is substantially aligned with the midpoint 118 of an individual linear slit 110 on an immediately adjacent beam 130 along the tensile axis (T). Such slits 110 are not within a row 112 of immediately adjacent slits; instead, they are on alternating rows 112. Additionally, the midpoint 118 of an individual slit 110 is between the ends 114 and 116 of immediately adjacent slits or incisions 110 along the tensile axis (T). The distance between the centers of two immediately adjacent slits 110 in a row 112 of the plurality of slits 110 is identified as the lateral spacing (H). The thickness of the beam 130, or the distance between two adjacent rows 112 of adjacent linear slits 110, is identified as the axial spacing (V).

[0010] More specifically, in the embodiment of FIG. 2A, the midpoint 118A of the slit 110A is axially aligned with the midpoint 118B of the slit 110B, meaning that the midpoints 118A, 118B are aligned along an axis extending in the axial direction. The slit 110B is on the beam 130B directly adjacent to the beam 130A on which the slit 110A is located. Also, the midpoint 118A of the slit 110A is between the end 114C of the slit 110C and the end 116D of the slit 110D. The slits 110C and 110D are directly adjacent to the slit 110A in the axial direction. FIG. 2A also shows the lateral pitch (H) between laterally adjacent midpoints 118, the axial pitch (V) or height of the beam 130, the slit length (L), and the tension axis (T) along which tension can be applied resulting in upward and downward movement of the beam 130.

[0011] FIG. 2B shows the primary tension lines (e.g., lines approximating the highest tensile stress path) that are formed when an article including the slit pattern of FIG. 2A is unfolded under tension along the tensile axis T. FIG. 2B shows the primary tension lines 140, where the maximum tensile stress occurs, in dotted lines. A tension line is an imaginary path through a material that transmits the maximum load when tension is applied to the material along the tensile axis. When tension is applied along the tensile axis (T), the primary tension lines 140 move to be approximately aligned with the axis along which tension is applied, distorting the patterned material or sheet. When the single slit pattern is unfolded, tension along the primary tension lines 140 causes substantially all areas of the pattern to experience some tension or compression (tensile or compressive stress) and then buckle and bend out of the plane of the original two-dimensional film. In some embodiments, when the film is fully unfolded and / or tension is applied to the desired extent, there are substantially no areas of the film that remain parallel to the original plane of the sheet. Summary of the Invention

[0012] The inventors of the present disclosure have invented novel composite slit patterns. These composite slit patterns can be used to form tension-activated expanding articles. In some embodiments, the articles can be used for transportation and packaging applications. However, the articles and patterns can also be used for many other uses or applications. Thus, the present disclosure is not meant to be limited to the use of transportation or packaging materials, which is merely one exemplary use or application.

[0013] Some embodiments relate to an expanding material that includes a material that includes a plurality of compound slits.

[0014] In some embodiments, the material is substantially planar in the pretensioned configuration, but when tension is applied along the tension axis, at least a portion of the material rotates 90 degrees or more out of the plane of the pretensioned configuration. In some embodiments, the compound slit includes three or more ends, and at least one of the ends is curved. In some embodiments, at least some of the compound slits include at least one of hooks, loops, sine waves, square waves, triangle waves, cross slits, or other similar features. In some embodiments, the slit pattern extends substantially to one or more of the edges of the material. In some embodiments, the material includes at least one of paper, corrugated cardboard, woven or nonwoven fabrics, plastics, elastic materials, non-elastic materials, polyesters, acrylics, polysulfones, thermoset polymers, thermoplastic polymers, biodegradable polymers, and combinations thereof. In some embodiments, the material is paper and has a thickness of about 0.003 inches (0.076 mm) to about 0.010 inches (0.25 mm). In some embodiments, the material is plastic and has a thickness of about 0.005 inches (0.13 mm) to about 0.125 inches (3.2 mm). In some embodiments, the material passes the interconnection test described herein. In some embodiments, the slits are approximately perpendicular to the tensile axis. In some embodiments, the slits of the plurality of slits are offset from each other by no more than 75% of the lateral length of the slits in adjacent rows. In some embodiments, the slits have a slit shape and a slit orientation, and the slit shape and / or orientation differs within a row of slits. In some embodiments, the slits have a slit shape and a slit orientation, and the slit shape and / or orientation differs between adjacent rows. In some embodiments, the material has a thickness of about 0.001 inches (0.025 mm) to about 5 inches (127 mm). In some embodiments, each slit of the plurality of slits has a slit length of about 0.25 inches to about 3 inches. In some embodiments, each slit of the plurality of slits has a slit length, the material has a material thickness, and the ratio of the slit length to the material thickness is from about 50 to about 1000.

[0015] Some embodiments relate to a die capable of forming any of the composite patterns described herein.

[0016] Some embodiments relate to packaging materials formed from any of the expanding materials described herein.

[0017] Some embodiments relate to methods of making any of the expanded materials described herein, comprising forming a compound slit pattern in the material by at least one of extrusion, molding, laser cutting, water jet machining, machining, stereolithography or other 3D printing techniques, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, other suitable negative or positive machining techniques, or combinations thereof.

[0018] Some embodiments relate to methods of using any of the expanding materials described herein, comprising applying tension to the expanding material along a tension axis to expand the material. In some embodiments, applying tension causes one or more of: (1) slits to form openings; and / or (2) material adjacent to the slits to form corrugations. In some embodiments, tension is applied by hand or machine. In some embodiments, applying tension to the expanding material along a tension axis changes the material from a two-dimensional structure to a three-dimensional structure. [Brief description of the drawings]

[0019] The present disclosure may be more fully understood from the following detailed description of various embodiments of the disclosure, taken in conjunction with the accompanying drawings, in which:

[0020] [Figure 1A] 1 is a top view line drawing of an exemplary single slit pattern.

[0021] [Figure 1B]1B is a top line drawing of a slit pattern used to form the packaging material of FIG. 1A.

[0022] [Figure 1C] FIG. 1C is an enlarged view of a portion of the view in FIG. 1B.

[0023] [Figure 2A] 1C is a top line drawing of a slit pattern used to form the packaging material of FIGS. 1A and 1B, rotated 90 degrees.

[0024] [Figure 2B] 2B shows the primary tension lines for the slit pattern shown in FIG. 2A.

[0025] [Figure 3A] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0026] [Figure 3B] 3B shows the primary tension lines in the compound slit pattern of FIG. 3A when tensioned.

[0027] [Figure 4A] FIG. 3B is a schematic top view illustrating the behavior of the slit patterned material of FIG. 3A when tension is applied. [Figure 4B] FIG. 3B is a schematic top view illustrating the behavior of the slit patterned material of FIG. 3A when tension is applied. [Figure 4C] FIG. 3B is a schematic top view illustrating the behavior of the slit patterned material of FIG. 3A when tension is applied.

[0028] [Figure 4D] FIG. 3B is a schematic perspective side view of a portion of the slit patterned material of FIG. 3A when the material is under tension.

[0029] [Figure 4E]FIG. 3B is a schematic perspective side view of the slit patterned material of FIG. 3A when under tension.

[0030] [Figure 4F] 4A-4F are images showing the slit patterned material of FIG. 3A when tensioned, FIG. 4F is a schematic side view created from a photograph, FIG. 4G is a top view created from a photograph, FIG. 4H is a schematic perspective photograph, and FIG. 4I is a top view created from a photograph. [Figure 4G] 4A-4F are images showing the slit patterned material of FIG. 3A when tensioned, FIG. 4F is a schematic side view created from a photograph, FIG. 4G is a top view created from a photograph, FIG. 4H is a schematic perspective photograph, and FIG. 4I is a top view created from a photograph. [Figure 4H] 4A-4F are images showing the slit patterned material of FIG. 3A when tensioned, FIG. 4F is a schematic side view created from a photograph, FIG. 4G is a top view created from a photograph, FIG. 4H is a schematic perspective photograph, and FIG. 4I is a top view created from a photograph. [Figure 4I] 4A-4F are images showing the slit patterned material of FIG. 3A when tensioned, FIG. 4F is a schematic side view created from a photograph, FIG. 4G is a top view created from a photograph, FIG. 4H is a schematic perspective photograph, and FIG. 4I is a top view created from a photograph.

[0031] [Figure 5A] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0032] [Figure 5B] 5B are line drawings made from photographs showing a schematic side view, a perspective view, and a schematic top view, respectively, of the pattern of FIG. 5A cut into a material and developed along the axis of tension. [Figure 5C] 5B are line drawings made from photographs showing a schematic side view, a perspective view, and a schematic top view, respectively, of the pattern of FIG. 5A cut into a material and developed along the axis of tension. [Figure 5D] 5B are line drawings made from photographs showing a schematic side view, a perspective view, and a schematic top view, respectively, of the pattern of FIG. 5A cut into a material and developed along the axis of tension.

[0033] [Figure 6] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0034] [Figure 7] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0035] [Figure 8] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0036] [Figure 9] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0037] [Figure 10A] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0038] [Figure 10B] 10B are line drawings made from photographs showing a perspective view, a schematic side perspective view, a schematic top view, and a top view, respectively, of the pattern of FIG. 10A cut into a material and developed along the axis of tension. [Figure 10C] 10B are line drawings made from photographs showing a perspective view, a schematic side perspective view, a schematic top view, and a top view, respectively, of the pattern of FIG. 10A cut into a material and developed along the axis of tension. [Figure 10D] 10B are line drawings made from photographs showing a perspective view, a schematic side perspective view, a schematic top view, and a top view, respectively, of the pattern of FIG. 10A cut into a material and developed along the axis of tension. [Figure 10E] 10B are line drawings made from photographs showing a perspective view, a schematic side perspective view, a schematic top view, and a top view, respectively, of the pattern of FIG. 10A cut into a material and developed along the axis of tension.

[0039] [Figure 11] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0040] [Figure 12] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0041] [Figure 13] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0042] [Figure 14] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0043] [Figure 15] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0044] [Figure 16] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0045] [Figure 17A] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0046] [Figure 17B] 17B are line drawings made from a photograph showing a schematic top view, a top view, and a schematic side view, respectively, of the pattern of FIG. 17A cut into a material and developed along the axis of tension. [Figure 17C] 17B are line drawings made from a photograph showing a schematic top view, a top view, and a schematic side view, respectively, of the pattern of FIG. 17A cut into a material and developed along the axis of tension. [Figure 17D] 17B are line drawings made from a photograph showing a schematic top view, a top view, and a schematic side view, respectively, of the pattern of FIG. 17A cut into a material and developed along the axis of tension.

[0047] [Figure 18A]1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0048] [Figure 18B] 18D-18E are line drawings made from photographs showing a perspective view, a view approximately 45 degrees from the lateral direction aligned with the tensile axis, a schematic top view, and a schematic side view of the pattern of FIG. 18A cut into the material and developed along the tensile axis. [Figure 18C] It is a line drawing created from a photograph. [Figure 18D] Photographs showing a perspective view, a view approximately 45 degrees from the transverse direction aligned with the tensile axis, a schematic top view, and a schematic side view of the pattern of FIG. 18A cut into the material and developed along the tensile axis. [Figure 18E] Photographs showing a perspective view, a view approximately 45 degrees from the transverse direction aligned with the tensile axis, a schematic top view, and a schematic side view of the pattern of FIG. 18A cut into the material and developed along the tensile axis.

[0049] [Figure 19] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0050] [Figure 20] 1 is a schematic top view of an exemplary composite slit pattern. FIG.

[0051] [Figure 21A] 1A and 1B are schematic top and front perspective views, respectively, of an exemplary composite slit pattern. [Figure 21B] 1A and 1B are schematic top and front perspective views, respectively, of an exemplary composite slit pattern.

[0052] [Figure 21C] 21A-21B are respectively a front view, a front view, a side view, and a top view of a portion of a sheet having the slit pattern of FIGS. 21A-21B formed thereon when the material is under tension. [Figure 21D]21A-21B are respectively a front view, a front view, a side view, and a top view of a portion of a sheet having the slit pattern of FIGS. 21A-21B formed thereon when the material is under tension. [Figure 21E] 21A-21B are respectively a front view, a front view, a side view, and a top view of a portion of a sheet having the slit pattern of FIGS. 21A-21B formed thereon when the material is under tension.

[0053] [Figure 22] 1 is an exemplary system for making materials consistent with the technology disclosed herein. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0054] Various embodiments of the present disclosure relate to composite slit patterns and articles that include composite slit patterns. A "slit" is defined herein as a narrow cut through an article that has at least two ends and forms at least one line, which may be straight or curved. The slits described herein are distinct, meaning that each individual slit does not intersect with other slits. A slit is generally not a notch. Here, a "notch" is defined as a surface area of ​​a sheet that is removed from the sheet when the slit intersects itself. However, in practice, many forming techniques result in some surface area of ​​the sheet being removed, which is not considered a "notch" for purposes of this application. Specifically, many cutting techniques create a "kerf" or a cut that has some physical width. For example, a laser cutter removes some surface area of ​​a sheet to create a slit, a router cuts out some surface area of ​​material to create a slit, and a crush cut also creates some deformation at the edge of the material and creates a physical gap across the surface area of ​​the material. Additionally, forming techniques require material between the opposing sides of the slit to create a gap or kerf at the slit. In various embodiments, the gap or kerf of the slit will be equal to or less than the thickness of the material. For example, a slit pattern cut into paper that is 0.007 inches thick may have slits with gaps of about 0.007 inches or less. However, it is understood that the width of the slits can be increased to many times the thickness of the material and be consistent with the technology disclosed herein.

[0055] As used herein, the term "single slit pattern" refers to a pattern of individual slits forming individual rows, each row extending laterally across the sheet, forming a repeating pattern of individual rows along the axial length of the sheet, where the pattern of slits in each row is different from the pattern of slits in immediately adjacent rows. For example, the slits in a row may be axially offset or out of phase with the slits in the immediately adjacent rows.

[0056] The term "multiple slit pattern" is defined herein as a pattern of individual slits forming a first set of adjacent rows across the lateral direction y of the sheet, where the individual slits in the first set of adjacent rows are aligned in the lateral direction y. In a multi-slit pattern, the first set of adjacent rows forms a repeating pattern with at least a second row along the axial length of the sheet, where the slits in the first set of adjacent rows are offset in the lateral direction y from the slits in the second row. The term "multiple slit pattern" includes double slit patterns, triple slit patterns, quadruple slit patterns, etc.

[0057] As used herein, the term "compound slit" refers to a slit with three or more ends, which is distinguished from a "simple slit," defined herein as a slit with exactly two ends. A compound slit has at least two slit segments with at least one segment intersection. Thus, a "compound slit pattern" is a pattern that includes a plurality of individual slits, at least some of which are compound slits. In some embodiments, the pattern includes rows of a plurality of slits that are phase offset from one another. In some embodiments, the slits are substantially perpendicular to the tensile axis (T).

[0058] A compound slit pattern can be configured to create significantly more out-of-plane rotation than a single slit pattern when tensioned along the tensile axis. This out-of-plane rotation of the material is of great value for many applications. For example, the rotated regions create out-of-plane material that can interconnect with other regions of out-of-plane material when portions of the material are placed adjacent to one another or wrapped together. In this manner, compound slit patterns are inherently interconnecting and / or include interconnecting features. When tensioned, these features and patterns interconnect and hold the material substantially in place.

[0059] Whether or not the materials are interconnected can be determined by the following test method: A sample 36 inches (0.91 m) long and 7.5 inches (19 cm) wide was obtained. The sample was fully unfolded without tearing and then placed directly adjacent to a smooth PVC pipe (e.g., an outside diameter (OD) of 3.15 inches (8 cm) and a length of 23 inches (58.4 cm)) so that the sample remained fully unfolded while wrapping. The sample was wrapped over the top of the pipe such that each subsequent layer was placed directly over the previous layer and the sample was centered (along the length) of the pipe. This resulted in a minimum of two complete wraps around the pipe. Once the entire sample was wrapped around the pipe, the sample was released and observed to see if it had unfolded / unraveled. After waiting one minute, if the sample had not unfolded / unraveled, the sample was slid off the pipe and placed on a smooth surface such as a table top. The sample was then lifted by the trailing edge to see if it had opened / unraveled or held its shape.

[0060] A sample was considered "not interconnected" if it opened / unfolded within one minute of release when it was slid off the pipe or when lifted by the trailing edge. A sample was considered "interconnected" if it retained its tubular shape during and after it was slid off the pipe and when lifted by the trailing edge. This test was repeated 10 times for each sample.

[0061] The out-of-plane rotation also creates a very rigid structure, so that it can resist large forces. This structure can absorb energy in a spring-like manner without significant plastic deformation, and can also buckle and absorb energy by plastic deformation. When a compound slit pattern is cut into a two-dimensional article (such as paper) and tension is applied to the article along the tensile axis (T), a portion of the two-dimensional article rotates and moves toward the z-axis (the axis perpendicular to the original plane of the two-dimensional article), resulting in the formation of a three-dimensional article. In some embodiments, the slit shapes described herein allow unique out-of-plane movement of the material or article, as compared to the prior art slit shapes and / or orientations of Figures 1A-2B. In some embodiments, the material in which the compound slit pattern is formed is substantially inextensible. In some embodiments, the compound slit pattern continues without interruption and change, and is terminated by at least one edge of the material. The resulting materials and / or articles provide a wide variety of advantages.

[0062] 3A is a schematic top view of an exemplary compound slit pattern 300. A compound slit pattern may be consistent with a single slit pattern or a multi-slit pattern. In this example, the pattern 300 includes a plurality of slits 310 in a row 312 of slits. Each slit 310 includes a first axial portion 321, a second axial portion 323 spaced from and generally parallel to the first axial portion 321, and a generally transverse portion 325 connecting the first axial portion 321 and the second axial portion 323. Each slit 310 includes four ends: a first end 314, a second end 315, a third end 316, and a fourth end 317. Each slit 310 has a midpoint 318.

[0063] The first end 314 and the second end 315 are opposite ends of the first axial portion 321 of the slit 310. The third end 316 and the fourth end 317 are opposite ends of the second axial portion 323 of the slit 310. The first end 314 is aligned with the third end 316 along an axial x axis (parallel to the first axial portion 321 in this embodiment), and the third end 316 is aligned with the fourth end 317 along an axial x axis (parallel to the second axial portion 323 in this embodiment). The first end 314 is aligned with the third end 316 along a transverse y axis i1, and the second end 315 is aligned with the fourth end 317 along a transverse axis i2. The spaces between immediately adjacent slits 310 in rows 312a, 312b can be referred to as axial beams 320. When tensioned, the axial beams 320 between adjacent slits 310 in rows 312a, 312b become non-rotating beams 320 (as can be seen in Figures 3C-E and 3G). The spaces defined by the generally lateral portions 325, excluding the non-rotating beams 320, define folded wall regions 330a, 330b.

[0064] The folded wall regions 330a, 330b may be further described as having two generally rectangular regions 331 and 333, where the rectangular region 331 is defined by (1) the generally lateral portions 325 of the immediately adjacent slits 310 perpendicular to the tensile axis, and (2) the adjacent axial portions 321 and 323 of the immediately adjacent opposing slits 310. The axial beam 320 is between adjacent slits 310 in a single row 312a, 312b, more specifically between adjacent axial portions 321 and 323. Immediately adjacent to the beam 320 is region 333, which is the remaining material of the folded wall regions 330a, 330b, defined axially by the beam 320 and the generally lateral portion 325, and laterally by the two generally rectangular regions 331, more specifically by the axial extensions of the adjacent axial portions 321 and 323. The slits 310 in immediately adjacent rows are phase offset from each other.

[0065] In the embodiment of Figure 3A, the tension axis T is substantially parallel to the axial direction x and substantially perpendicular to the transverse direction y. The tension axis T is approximately perpendicular to the direction of the rows 312a, 312b of slits 310. "Approximately perpendicular" is defined herein as an angle with a 5 degree margin of error or a 3 degree margin of error. The tension axis T is the axis along which tension can be applied to the material in which the pattern 300 is formed, resulting in rotation of portions of the material as well as upward and downward movement.

[0066] In this embodiment, unlike the other embodiments, there are no transverse beams extending in the transverse direction y across the width of the sheet of material. Rather, in this embodiment, there are folded wall regions 330a, 330b defined across the transverse width of the material 300 that alternate along the axial length of the sheet of material 300. As with some other embodiments, in this embodiment, the pattern of slits in the sheet of material defines first rows 312a and second rows 312b that alternate along the axial length of the sheet of material 300. The plurality of slits 310 in the sheet of material define columns and rows of beams in which each axial beam 320 extends from a first folded wall region 330a to an adjacent second folded wall region 330b. Additionally, each axial beam 320 defines two ends 324a, 324b that correspond to the ends of adjacent slits in the row.

[0067] FIG. 3B shows primary tension lines 340 (e.g., lines approximating the highest tensile stress path) that are formed when an article including the slit pattern of FIG. 3A is deployed under tension along the tension axis T. FIG. 3B shows the primary tension lines 340, where the maximum tensile stress occurs, in dotted lines. A tension line is an imaginary path through a material that transmits the maximum load when tension is applied to the material along the tension axis. When tension is applied along the tension axis (T), the primary tension lines 340 move to be approximately aligned with the axis along which tension is applied, distorting the sheet. The tension lines 340 are focused into axial beams 320 between adjacent slits in the same row. When tensioned, these beams 320 become non-rotating beams 320. In the embodiment of FIG. 3A, these non-rotating beams 320 are approximately parallel to the tension axis. In the embodiment of FIG. 3A, these non-rotating beams 320 are generally axial. When tension is applied along the tension axis T (which in this embodiment is an axis nominally parallel to the non-rotating beams 320), the tension (or the maximum concentration of stress caused by that tension) exists somewhat uniformly on all of the non-rotating beams 320, but across sections of the folded wall regions 330a, 330b, as shown by the dotted lines.

[0068] 4A-4E are schematic top views showing how the material containing the slit pattern of FIG. 3A moves in space when tension is applied along the tension axis T. When the composite slit pattern is unfolded, tension along the primary tension lines 340 causes substantially all regions of the pattern to experience some tension or compression (tensile or compressive stress), causing some of those regions to rotate and / or bend out-of-plane from the plane of the original two-dimensional film. The tension transmitted through the folding wall regions 330 simultaneously rotates and folds the beams, forcing the non-rotating beams 320 closer together and more aligned with the tension axis T. In FIG. 4A, the non-rotating beams 320 are represented as split and connected by force vectors (arrows). This helps visualize the force interaction in the separate regions and clarify the material motion. Because the material 300 under the force is relatively thin, the folding wall regions 330 rotate and fold out-of-plane at the base of the non-rotating beams 320 in response to the tension applied. Specifically, Figure 4A shows a non-rotating beam 320 with a force vector acting on a folding wall region 330. This action moves the material 300 to the position shown generally in Figure 4B, where folding wall regions 330a, 330b have rotated as a result of the force vector shown in Figure 4A. As shown in Figure 4C, folding wall region 330 also folds or bends in response to the force vectors shown in Figures 4A, 4B, and 4C. The degree of folding or bending will vary depending on many factors including, for example, the modulus of rigidity of the material, the amount of tension, the dimensions and scale of the elements, the width of the non-rotating beams, the distance between the non-rotating beams, etc.

[0069] FIG. 4B is a schematic top view of the folded wall regions 330 showing only the rotation from the top perspective view of FIG. 4A. FIG. 4C is a schematic showing the top view of the rotated and bent rotating beam when fully tensioned and deployed. From the top view, the folded wall regions 330, once rotated, form an accordion-like folded vertical wall that can resist large compressive forces in the Z axis (orthogonal to the xy plane). The energy required to buckle the folded wall is energy that can be absorbed by the structure to prevent damage to the object it is wrapped around. Non-rotating beams 320 connect the folded wall regions 330. The compound slit pattern in FIG. 3A causes the non-rotating beams 320 to alternate, which further contributes to the strength of the material when deployed. The movement of the non-rotating beams 320 and the folded wall regions 330a, 330b creates an open region 322, which can be seen in FIGS. 4E-I.

[0070] Returning to FIG. 3A, the generally rectangular region 333 has a width or lateral dimension that is equal to the width or lateral dimension of the non-rotating beam 320. In some embodiments, this width is preferably small compared to the width or lateral dimension of the rectangular region 331. If the lateral width of the rectangular region 333 is small compared to the lateral width of the rectangular region 331, the rectangular region 333 will be substantially folded when unfolded and will not be clearly and separately distinguishable from the rest of the folded wall regions 330a, 330b, as approximated by the view in FIG. 4D and as can be seen in FIG. 4G. Specifically, in the front view (top or bottom) of the material in FIG. 4G, the shape of the opening 322 appears to be generally hexagonal in shape compared to the model view in FIG. 4I, where it is more clearly visible in the front view that it is octagonal. If the rectangular region 333 were wide enough, there would be another flat vertical section at the fold of the rotating / folding beam shown in FIG. 4I. Visually, this means that the opening 322 appears to be an octagon rather than a hexagon.

[0071] Figures 4F-I are photographs and diagrams created from photographs showing the composite slit pattern of Figure 3A formed or cut into a paper sheet and tensioned along a tensile axis T. These figures provide a visual of how the principles described above work on a material. Figure 4F is a schematic side perspective view created from a photograph, Figure 4G is a schematic top view created from a photograph, Figure 4H is a perspective photograph, and Figure 4I is a top view created from a photograph.

[0072] In some embodiments, it may be preferable to make the height and width of the curved wall section or rectangular region 331 nominally equal to create a square section within the folded wall. Without wishing to be bound by theory, for a given cross-sectional area, a square plate has the greatest buckling resistance.

[0073] In some embodiments, the sharp creases in the folded walls and the interfaces between the walls and the non-rotating beams tend to generate sufficiently high (but not tearing) stresses to plastically deform (or crease) the slit patterned material. As a result, once deployed, the structure tends to stay in its deployed (honeycomb) shape with very little tension, often making it easier to wrap around an object.

[0074] Embodiments such as the specific implementations of FIGS. 3A - 4I have unique advantages. For example, FIGS. 3A - 4I illustrate a set of embodiments where when deployed or tension - actuated, a portion of the material rotates up to the z - axis (substantially 90° or orthogonal to the original plane of the pre - tensioned material 300). Further, some of these embodiments can withstand exposure to greater loads applied to the vertical axis without being crushed compared to other patterned structures. This means that protection can be improved or enhanced for packages during transportation and other applications. Some of these advantages are due to the increased strength of the shape of the folded walls. The folded walls, or accordion - shaped walls, or rotating / folded walls have a large area moment of inertia (also called the moment of inertia or second moment of inertia) in the deployed (deployed by the application of tension or force) article, where the area moment of inertia is in the plane of the original sheet, the relative bending axis is perpendicular to the tensile axis and parallel to the row axis. The second moment of inertia is increased compared to a straight vertical wall without folds.

[0075] When the tension - actuated material 300 is wrapped around the article or disposed directly adjacent to the tension - actuated material 300 itself, the rotated / folded wall regions 330 interconnect with each other and / or with the openings 322, creating an interconnected structure. The interconnection can be measured as defined in the interconnection test specified above.

[0076] 5A is a schematic top view of another exemplary compound slit pattern that is substantially the same as the compound slit pattern of FIG. 3A, except that the slits overlap each other by an overlap distance 535 in the rotating beam 530 region. Specifically, the pattern 500 includes a plurality of slits 510 in a row 512 of slits. Each slit 510 includes a first axial portion 521, a second axial portion 523 spaced from and generally parallel to the first axial portion 521, and a generally transverse portion 525 connecting the first axial portion 521 and the second axial portion 523. Each slit 510 includes four terminal portions 514, 515, 516, 517, and a midpoint 518. The first terminal portions 514, 515 are terminal portions of the first axial portion 521. Ends 516, 517 are ends of second axial portion 523. The space between immediately adjacent slits 510 in row 512 is material forming axial beam 520 between adjacent slits 510 in row 512. When tensioned, axial beam 520 between adjacent slits 510 in row 512 becomes non-rotating beam 532 (shown in FIGS. 5B-5D). The space defined by generally lateral portion 525, excluding non-rotating beam 532, comprises rotating / folding wall 530. Rotating / folding wall 530 can be further described as having two generally rectangular regions 531 and 533, where rectangular region 531 is defined by (1) the generally lateral portions 525 of immediately adjacent slits 510 perpendicular to the tension axis, and (2) adjacent axial portions 521 and 523 of opposing immediately adjacent slits 510. The axial beams 520 are between adjacent slits 510 in a single row 512, more specifically between adjacent axial portions 521 and axial portions 523. Immediately adjacent to the axial beams 520 is a region 533, which is the remaining material of the rotating / folding wall 530 defined in the axial axis by the axial beams 520 and the generally lateral portion 525, and defined in the lateral axis by two generally rectangular regions 531, more specifically the axial extensions of adjacent axial portions 521 and 523. The slits 510 in immediately adjacent rows are phase offset from each other.

[0077] 5A, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 512 of slits 510. The tension axis (T) is the axis along which tension can be applied to the material in which the pattern 500 is formed, resulting in rotation and upward and downward movement of portions of the material.

[0078] 5B-5D are photographic illustrations showing the composite slit pattern of FIG. 5A formed or cut into a material and then tensioned along tension axis T. The material unfolds substantially as described above with respect to FIGS. 3A-4I. The presence of overlap distance 535 contributes at least two improvements to the unfolded material: 1) it allows rotating / folding walls 530 to rotate more than 90 degrees out of the plane of pretensioned material 500, and 2) it increases the plastic deformation at the connection between non-rotating beam 532 and rotating / folding walls 530, allowing the unfolded material to remain more fully unfolded when the external tension is removed.

[0079] 6 is a schematic top view of another exemplary compound slit pattern that is substantially similar to the compound slit pattern of FIG. 3A, except that it illustrates an exemplary variation of the axial symmetry of the non-rotated beam. More specifically, generally lateral portion 625 is not disposed intermediate ends 614 and 615 and ends 616 and 617, respectively. Instead, generally lateral portion 625 is disposed much closer to ends 615, 617 than ends 614, 616.

[0080] More specifically, the pattern 600 includes a plurality of slits 610 in a row 612 of slits. Each slit 610 includes a first axial portion 621, a second axial portion 623 spaced from and generally parallel to the first axial portion 621, and a generally transverse portion 625 connecting the first axial portion 621 and the second axial portion 623. Each slit 610 includes four terminal ends 614, 615, 616, 617, and a midpoint 618. The first terminal ends 614, 615 are terminal ends of the first axial portion 621. The terminal ends 616, 617 are terminal ends of the second axial portion 623. The spaces between immediately adjacent slits 610 in the row 612 form axial beams 620 between adjacent slits 610 in the row 612. When tensioned, the axial beams 620 between adjacent slits 610 in a row 612 become non-rotating beams. The space defined by the generally lateral portions 625, excluding the axial beams 620, includes the rotating / folding wall 630. The rotating / folding wall 630 may be further described as having two generally rectangular regions 631 and 633, where the rectangular region 631 is defined by (1) the generally lateral portions 625 of the immediately adjacent slits 610 perpendicular to the tension axis, and (2) the adjacent axial portions 621 and 623 of the immediately adjacent opposing slits 610. The axial beams 620 are between adjacent slits 610 in a single row 612, more specifically, between adjacent axial portions 621 and 623. Immediately adjacent the axial beam 620 is a region 633, which is the remaining material of the rotating / folding wall 630 defined in the axial axis by the axial beam 620 and the generally lateral portion 625, and defined in the lateral axis by two generally rectangular regions 631, more specifically, by the axial extensions of adjacent axial portions 621 and 623. The slits 610 in directly adjacent rows are phase offset from each other.

[0081] 6A, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 612 of slits 610. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 600 is formed, causing rotation and upward and downward movement of portions of the material.

[0082] The material unfolds substantially as described above with respect to Figures 3A-4I. The change in symmetry of the non-rotating beam with respect to the generally lateral portion 625 causes the non-rotating beam to rotate while remaining parallel to the lateral axis (or a line perpendicular to the tensile axis) as one end connects higher at one rotating / folding wall 630 and lower at an adjacent rotating / folding wall 630.

[0083] 7 is a schematic top view of another exemplary composite slit pattern that is substantially similar to the composite slit pattern of FIG. 3A except that it shows curved terminations. The curved terminations are end regions of the slit that form an end of the slit that has a different radius of curvature than adjacent portions of the slit. The end regions can be less than 10% of the overall length of the slit, the length of the slit extending laterally.

[0084] More specifically, the pattern 700 includes a plurality of slits 710 in a row 712 of slits. Each slit 710 includes a first axial portion 721, a second axial portion 723 spaced from and generally parallel to the first axial portion 721, and a generally transverse portion 725 connecting the first axial portion 721 and the second axial portion 723. Each slit 710 includes four terminal ends 714, 715, 716, 717, and a midpoint 718. Each axial portion 721 and 723 includes a curved portion adjacent the terminal ends. The first terminal ends 714, 715 are terminal ends of the first axial portion 721. The terminal ends 716, 717 are terminal ends of the second axial portion 723. The spaces between immediately adjacent slits 710 in a row 712 form axial beams 720 between adjacent slits 710 in a row 712. When tensioned, the axial beams 720 between adjacent slits 710 in a row 712 become non-rotating beams 732. The spaces defined by the generally lateral portions 725, excluding the non-rotating beams 732, comprise the rotating / folding wall 730. The rotating / folding wall 730 can be further described as having two generally rectangular regions 731 and 733, where the rectangular region 731 is defined by (1) the generally lateral portions 725 of the immediately adjacent slits 710 perpendicular to the tension axis, and (2) the adjacent axial portions 721 and 723 of the directly adjacent opposing slits 710. The axial beams 720 are between adjacent slits 710 in a single row 712, more specifically, between adjacent axial portions 721 and 723. Immediately adjacent the axial beam 720 is a region 733, which is the remaining material of the rotating / folding wall 730 defined in the axial axis by the axial beam 720 and the generally lateral portion 725, and defined in the lateral axis by two generally rectangular regions 731, more specifically, by the axial extensions of the terminal ends 714, 715, 716, and 717 of adjacent axial portions 721 and 723. The slits 710 in directly adjacent rows are phase offset from each other.

[0085] 7A, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 712 of slits 710. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 700 is formed, causing rotation and upward and downward movement of portions of the material.

[0086] The material unfolds substantially as described above with respect to Figures 3A-4I. The addition of curved ends 714, 715, 716, and 717 to axial portions 721 and 723 increases the maximum force the material can withstand before tearing, but does not significantly change the unfolding of the material.

[0087] 8 is a schematic top view of another exemplary compound slit pattern that is substantially the same as the compound slit pattern of FIG. 3A, except that it shows an exemplary variation in which there are two multi-beam slits 880 formed in the material between adjacent slits 810 in a row 812 that are non-rotating beams. A "multi-beam slit" is defined as one or more simple slits (meaning that the slit has no more than two ends) formed between two adjacent slits in a single-slit or multi-slit pattern, where the two adjacent slits are either in the same row or in adjacent rows. The multi-beam slit 880 creates three multi-beams 882 when the patterned material is tension-deployed.

[0088] More specifically, the pattern 800 includes a plurality of slits 810 in a row 812 of slits. Each slit 810 includes a first axial portion 821, a second axial portion 823 spaced from and generally parallel to the first axial portion 821, and a generally transverse portion 825 connecting the first axial portion 821 and the second axial portion 823. Each slit 810 includes four terminal ends 814, 815, 816, 817, and a midpoint 818. The first terminal ends 814, 815 are terminal ends of the first axial portion 821. The terminal ends 816, 817 are terminal ends of the second axial portion 823. The spaces between directly adjacent slits 810 in the row 812 form axial beams 820 between adjacent slits 810 in the row 812. When tensioned, the axial beam 820 between adjacent slits 810 in the row 812 becomes a non-rotating beam 832 that includes three multi-beams 882. In this embodiment, two multi-beam slits 880 are formed in the axial beam 820 between adjacent slits 810 in the row 812. The multi-beam slit 880 is slightly shorter in length than the immediately adjacent generally axial slits 821, 823 of the slit 810 between which the multi-beam slit 880 is disposed. The midpoint of the multi-beam slit 880 is generally aligned with the midpoints of the generally axial slit portions 821, 823 and the generally lateral slit portion 825. The multi-beam slit 880 creates three multi-beams 882 when the patterned material is tensioned.

[0089] The space defined by the generally lateral portions 825, excluding the non-rotating beams 832, comprises the rotating / folding wall 830. The rotating / folding wall 830 may be further described as having two generally rectangular regions 831 and 833, where the rectangular region 831 is defined by (1) the generally lateral portions 825 of the immediately adjacent slits 810 perpendicular to the tensile axis, and (2) adjacent axial portions 821 and 823 of the immediately adjacent opposing slits 810. The axial beams 820 are between adjacent slits 810 in the single row 812, and more specifically, between adjacent axial portions 821 and 823. Immediately adjacent the axial beam 820 is a region 833, which is the remaining material of the rotating / folding wall 830 defined in the axial axis by the axial beam 820 and the generally lateral portion 825, and defined in the lateral axis by two generally rectangular regions 831, more specifically, by the axial extensions of adjacent axial portions 821 and 823. The slits 810 in directly adjacent rows are phase offset from each other.

[0090] 8, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 812 of slits 810. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 800 is formed, causing rotation and upward and downward movement of portions of the material.

[0091] The material unfolds substantially as described above with respect to Figures 3A-4I. The three multi-beams 882 in the non-rotating beam 832 allow the material to take more tension without tearing because the multi-beams 882 create additional paths and corners to distribute the tension load and reduce peak stresses that may initiate tearing.

[0092] Figure 9 is a schematic top view of another exemplary compound slit pattern that is substantially the same as the compound slit pattern of Figure 8, except that it illustrates an exemplary variation in which there is one multi-beam slit 980 formed in an axial beam 920 between adjacent slits 910 in a row 912 that are non-rotating beams. The multi-beam slit 980 creates two multi-beams 982 when the patterned material is deployed in tension.

[0093] More specifically, the pattern 900 includes a plurality of slits 910 in a row 912 of slits. Each slit 910 includes a first axial portion 921, a second axial portion 923 spaced from and generally parallel to the first axial portion 921, and a generally transverse portion 925 connecting the first axial portion 921 and the second axial portion 923. Each slit 910 includes four terminal ends 914, 915, 916, 917, and a midpoint 918. The first terminal ends 914, 915 are terminal ends of the first axial portion 921. The terminal ends 916, 917 are terminal ends of the second axial portion 923. The spaces between immediately adjacent slits 910 in the row 912 form axial beams 920 between adjacent slits 910 in the row 912. When tensioned, the axial beam 920 between adjacent slits 910 in the row 912 becomes a non-rotating beam 932 that includes two multi-beams 982. In this embodiment, a multi-beam slit 980 is formed in the axial beam 920 between adjacent slits 910 in the row 912. The multi-beam slit 980 is slightly longer in length than the generally immediately adjacent axial slits 921, 923 of the slit 910 between which the multi-beam slit 980 is disposed. The midpoint of the multi-beam slit 980 is generally aligned with the midpoints of the generally axial slit portions 921, 923 and the generally lateral slit portion 925. The multi-beam slit 980 creates two multi-beams 982 when the patterned material is tensioned.

[0094] The space defined by the generally lateral portions 925, excluding the non-rotating beams 932, comprises the rotating / folding wall 930. The rotating / folding wall 930 may be further described as having two generally rectangular regions 931 and 933, where the rectangular region 931 is defined by (1) the generally lateral portions 925 of the immediately adjacent slits 910 perpendicular to the tensile axis, and (2) adjacent axial portions 921 and 923 of the immediately adjacent opposing slits 910. The axial beams 920 are between adjacent slits 910 in the single row 912, and more specifically, between adjacent axial portions 921 and 923. Immediately adjacent the axial beam 920 is a region 933, which is the remaining material of the rotating / folding wall 930 defined in the axial axis by the axial beam 920 and a generally lateral portion 925, and defined in the lateral axis by two generally rectangular regions 931, more specifically, by the axial extensions of adjacent axial portions 921 and 923. The slits 910 in directly adjacent rows are phase offset from each other.

[0095] 9, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 912 of slits 910. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 900 is formed, causing rotation and upward and downward movement of portions of the material.

[0096] The material unfolds substantially as described above with respect to Figures 3A-4I. The two multi-beams 982 in the non-rotating beam 932 allow the material to take more tension without tearing because the multi-beams 982 create additional paths and corners to distribute the tension load and reduce peak stresses that may initiate tearing.

[0097] FIG. 10A is a schematic top view of another exemplary compound slit pattern that is substantially similar to the compound slit pattern of FIG. 9, except that the multi-beam slit 1080 is generally the same length as the axial slits 1021, 1023.

[0098] More specifically, the pattern 1000 includes a plurality of slits 1010 in a row 1012 of slits. Each slit 1010 includes a first axial portion 1021, a second axial portion 1023 spaced from and generally parallel to the first axial portion 1021, and a generally transverse portion 1025 connecting the first axial portion 1021 and the second axial portion 1023. Each slit 1010 includes four terminal portions 1014, 1015, 1016, 1017, and a midpoint 1018. The first terminal portions 1014, 1015 are terminal portions of the first axial portion 1021. The terminal portions 1016, 1017 are terminal portions of the second axial portion 1023. The spaces between immediately adjacent slits 1010 in the row 1012 form an axial beam 1020 between the adjacent slits 1010 in the row 1012. When tensioned, the axial beam 1020 between adjacent slits 1010 in the row 1012 becomes a non-rotating beam 1032 that includes two multi-beams 1082 (as shown in Figures 10B-10D). In this embodiment, a multi-beam slit 1080 is formed in the axial beam 1020 between adjacent slits 1010 in the row 1012. The multi-beam slit 1080 is approximately the same length as the immediately adjacent generally axial slits 1021, 1023 of the slit 1010 between which the multi-beam slit 1080 is disposed. Additionally, the midpoint of the multi-beam slit 1080 is approximately aligned with the midpoints of the generally axial slit portions 1021, 1023 and the generally lateral slit portion 1025. The multi-beam slit 1080 creates two multi-beams 1082 when the patterned material is tension deployed.

[0099] The space defined by the generally lateral portions 1025, excluding the non-rotating beams 1032, comprises the rotating / folding wall 1030. The rotating / folding wall 1030 may be further described as having two generally rectangular regions 1031 and 1033, where the rectangular region 1031 is defined by (1) the generally lateral portions 1025 of the immediately adjacent slits 1010 perpendicular to the tensile axis, and (2) adjacent axial portions 1021 and 1023 of the immediately adjacent opposing slits 1010. The material 1020 is between adjacent slits 1010 in the single row 1012, and more specifically, between adjacent axial portions 1021 and 1023. Immediately adjacent the axial beam 1020 is a region 1033, which is the remaining material of the rotating / folding wall 1030 defined in the axial axis by the axial beam 1020 and the generally lateral portion 1025, and defined in the lateral axis by two generally rectangular regions 1031, more specifically, by the axial extensions of adjacent axial portions 1021 and 1023. The slits 1010 in directly adjacent rows are phase offset from each other.

[0100] 10, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 1012 of slits 1010. The tension axis (T) is the axis along which tension can be applied to the material in which the pattern 1000 is formed, causing rotation and upward and downward movement of portions of the material.

[0101] 10B-10E are photographic illustrations showing the composite slit pattern of FIG. 10A formed or cut into the material and then tensioned along the tension axis T. The material unfolds substantially as described above with respect to FIGS. 3A-4I. The two multi-beams 1082 in the non-rotating beam 1032 allow the material to take more tension without tearing because the multi-beams 1082 create additional paths and corners to distribute the tension load and reduce peak stresses that may initiate tearing.

[0102] 11 and 12 are schematic top views of another exemplary compound slit pattern that is substantially similar to the compound slit pattern of FIG. 3A, except that the generally transverse portions 1125, 1225 include interconnecting structures or features. These features can improve the interconnection of the material when placed adjacent to another layer of material and / or wrapped around an item. Additionally, these features can soften the edges of the material. In FIG. 11, the generally transverse portion 1125 has a wavy or v-wave shape. The "v" portions of the waves create the interconnecting features. In FIG. 12, the generally transverse portion 1225 has a cross-slit structure. The cross-slit portions create the interconnecting features.

[0103] In the embodiment of Figures 11 and 12, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the lateral direction and to the direction of the rows of slits. The tension axis (T) is the axis along which tension can be applied to the material in which the patterns 1100, 1200 are formed, causing rotation and upward and downward movement of portions of the material.

[0104] The material unfolds substantially as described above with respect to Figures 3A-4I. When multiple layers of material are in contact, such as when wrapped around an object, the interconnecting features allow the layers to interconnect with each other more strongly and / or in different ways.

[0105] 21A-21B show a compound slit pattern in a sheet of material 2100 that is similar to the pattern in FIG. 11, except that the interconnecting structures or features have a slightly different shape. The lateral portions 2125 of each slit define a curve. Specifically, the lateral portions 2125 of the slits in a row 2112 generally define an undulating wave or sine wave interrupted by axial beams 2120 between each of the slits 2110. FIGs. 21C-21E show a sheet of material having the compound slit pattern of FIGs. 21A-21B when the material is expanded after being subjected to tension in the tensile axis.

[0106] FIG. 13 is a schematic top view of another exemplary composite slit pattern that is substantially the same as the composite slit pattern of FIG. 3A, except that the intersection between the generally transverse slit portion 1325 and the two generally axial slit portions 1321, 1323 is rounded or has rounded corners. These features can soften the edges of the material by removing sharp corners that a user may come into contact with during use of the material. In this embodiment, the tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and to the direction of the rows of slits. The tension axis (T) is the axis along which tension can be applied to the material formed with the pattern 1300, causing rotation and upward and downward movement of portions of the material. The material unfolds substantially as described above with respect to FIGS. 3A-4I.

[0107] 14 is a schematic top view of another exemplary composite slit pattern. The pattern 1400 includes a plurality of slits 1410 in a row of slits 1412. Each slit 1410 includes a generally transverse portion 1425 that terminates in four ends 1414, 1415, 1416, and 1417 and has a midpoint 1418. Each of the ends 1414, 1415, 1416, and 1417 curves slightly away from the transverse portion 1425. The spaces between directly adjacent slits 1410 in the row 1412 form axial beams 1420 between adjacent slits 1410 in the row 1412. When tensioned, the axial beams 1420 between adjacent slits 1410 in the row 1412 become non-rotating beams 1432.

[0108] The space defined by the generally lateral portions 1425, excluding the non-rotating beams 1432, comprises the rotating / folding wall 1430. The rotating / folding wall 1430 may be further described as having two generally rectangular regions 1431 and 1433, where the rectangular region 1431 is defined by (1) the generally lateral portions 1425 of the immediately adjacent slits 1410 perpendicular to the pulling axis, and (2) the adjacent axial portions (which are imaginary axial lines passing through the ends 1414, 1415 and ends 1416, 1417, respectively) of the immediately adjacent opposing slits 1410. The axial beams 1420 are between adjacent slits 1410 in the single row 1412, and more specifically, between adjacent axial portions 1421 and 1423. Immediately adjacent the axial beam 1420 is a region 1433, which is the remaining material of the rotating / folding wall 1430 defined in the axial axis by the axial beam 1420 and the generally lateral portion 1425, and defined in the lateral axis by two generally rectangular regions 1431, more specifically, by the axial extensions of adjacent axial portions 1421 and 1423. The slits 1410 in directly adjacent rows are phase offset from each other.

[0109] The tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 1412 of slits 1410. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 1400 is formed, causing rotation and upward and downward movement of portions of the material.

[0110] Because the axial portions 1421 and 1423 do not extend axially far enough to align or overlap, the material unfolds differently than in Figures 3A-4I. Because the axial portions 1421 and 1423 do not align or overlap, the rotating / folding wall 1430 cannot rotate 90 degrees relative to the original plane of the pretensioned sheet 1400. Instead, the rotating / folding wall will buckle and rotate slightly. If the axial portions 1421 and 1423 were very short relative to the axial pitch, the material would unfold more similar to the simple slit pattern of Figures 1A-1C. The curved ends of the axial portions 1421 and 1423 would increase the maximum tension the material can withstand without tearing. A test method for measuring the maximum tension is described in U.S. Provisional Patent Application No. 62 / 953,042, which is assigned to the present assignee and is incorporated herein by reference in its entirety. The maximum tensile (e.g., tear force) is the maximum force measured by the load frame when the sample is stretched. This is typically just before the material begins to tear.

[0111] FIG. 15 is a schematic top view of another exemplary composite slit pattern. The pattern 1500 includes a plurality of slits 1510 within a row 1512 of slits. Each slit 1510 includes a generally transverse portion 1525 that terminates at two ends 1514, 1516, has a midpoint 1518, and includes a plurality of cross slits 1590 that are cut through and intersect the generally transverse portion 1525 and are generally parallel to the tensile axis T. Each cross slit 1590 can be interpreted as creating two additional ends. Thus, the embodiment of FIG. 15 can be interpreted as having 30 ends (14×2=28 ends from the 14 cross slits+2 ends of the generally transverse portion 1525). The cross hatch slits further provide an enhanced interconnecting feature. Material 1520 is between adjacent slits 1510 in a row 1512. The slits 1510 in immediately adjacent rows are phase offset from each other.

[0112] The tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 1512 of slits 1510. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 1500 is formed, causing rotation and upward and downward movement of portions of the material.

[0113] The material unfolds substantially as described above with respect to Figures 1A-1C. When multiple layers of material are in contact, such as when wrapped around an object, the cross slits allow the layers to interconnect with each other while the straight slits (such as Figures 1A-1C) do not interconnect.

[0114] FIG. 16 is a schematic top view of another exemplary composite slit pattern substantially similar to the composite slit pattern of FIG. 15, except that the slit is a double slit. As used herein, the term "double slit pattern" refers to a pattern consisting of a plurality of individual slits. The pattern includes a plurality of rows of slits, where the individual slits in a first row are substantially aligned with the individual slits in a directly adjacent second row. The double slit is composed of a slit in a first row that is substantially aligned with a slit in a second row. These two substantially aligned slits together form a double slit. The double slits in the directly adjacent (axially directly adjacent) rows are phase offset from each other. More information regarding double slit patterns can be found, for example, in U.S. Provisional Patent Application No. 62 / 952806, the contents of which are incorporated herein in their entirety.

[0115] The tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 1612 of slits 1610. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 1600 is formed, causing rotation and upward and downward movement of portions of the material.

[0116] When the material 1600 is tensioned or deployed along the tension axis T, a portion of the material 1600 is subjected to tension and / or compression that moves the material 1600 out of plane from the original plane of the material 1600 in an untensioned state. When tensioned along the tension axis, the ends 1614, 1616 are compressed and drawn toward each other, causing the flap region 1650 of the material 1600 to move upward or buckle relative to the plane of the material 1600 in the pretensioned state, creating a flap. The flap region 1650 includes a portion of the cross slit that includes a portion of the cross slit end. A portion of the transverse beam 1630 ripples out of plane from the original plane of the material 1600 in the pretensioned state, forming a loop while remaining nominally parallel to the tension axis. The rippled portion of the transverse beam 1630 includes a portion of the cross slit that includes a portion of the cross slit end. The axial beams 1620 between adjacent slits 1610 in a row 1612 remain substantially parallel to the original plane of the pretensioned material 1600. The overlapping beams 1636 buckle and rotate out of plane from the plane of the original material or sheet. The movement of the flap regions 1650 combines with the corrugation of the lateral beams 1630 to create the openings 1622. This deployment process is substantially similar to that described with respect to Figures 5A-5C of U.S. Provisional Patent Application No. 62 / 952,806, which is incorporated herein in its entirety.

[0117] Figure 17A is a schematic top view of another exemplary compound slit pattern that is substantially similar to the compound slit pattern of Figure 3A, except that generally transverse slit portions 1725 have a wavy configuration or structure. Such a slit pattern creates major and minor wall sections (accordion-like walls have high and low sections).

[0118] The tension axis (T) is substantially parallel to the axial direction and substantially perpendicular to the transverse direction and the direction of the rows 1712 of slits 1710. The tension axis (T) is the axis along which tension can be applied to the material in which pattern 1700 is formed, causing rotation and upward and downward movement of portions of the material.

[0119] 17B-17D are photographic illustrations showing the composite slit pattern of FIG. 17A formed or cut into the material and then tensioned along the tension axis T. The material unfolds substantially as described above with respect to FIGS. 3A-4I. When multiple layers of material are in contact, such as when wrapped around an object, the different heights of the rotating / folding walls 1730 allow the layers to interconnect with each other more strongly and / or in different ways.

[0120] FIG. 18A is a schematic top view of another exemplary compound slit pattern that is substantially similar to the compound slit pattern of FIG. 17A, except that the amplitude of the waves in the lateral slit portion 1725 is varied.

[0121] Figures 18B-18E are photographs and diagrams created from photographs showing the composite slit pattern of Figure 18A formed or cut into a material and then tensioned along a tension axis T. The material expands substantially as described above with respect to Figures 17A-17D and 3A-4I.

[0122] 19 is a schematic top view of another exemplary compound slit pattern. Pattern 1900 includes a plurality of slits 1910 in a row of slits 1912. Slits 1910 have three terminal portions 1914, 1915, 1916 at the end of three straight portions 1921, 1922, 1923. All straight portions 1921, 1922, 1923 intersect at a point 1918. The spaces between directly adjacent slits 1910 in row 1912 form axial beams 1920 between adjacent slits 1910 in row 1912. The slits 1910 in directly adjacent rows are phase offset from each other.

[0123] The unique geometry of the slits 1910 allows the material to be subjected to more than one tension axis. Specifically, the material can expand when tension is applied substantially perpendicular to any of the three linear portions, as represented by the three primary tension axes (T1, T2, T3). The primary tension axes (T1, T2, T3) are the primary axes along which tension can be applied to the material formed with the pattern 1900, causing rotation of a portion of the material as well as upward and downward movement. The primary axes have components at all planar angles, so tension in any direction will cause some expansion of the material.

[0124] FIG. 20 is a schematic top view of another exemplary composite slit pattern similar to the pattern shown in FIG. 19. Pattern 2000 includes a plurality of slits 2010 in a row of slits 2012. Slits 2010 have three terminal portions 2014, 2015, 2016 at the end of three straight portions 2021, 2022, 2023. Straight portions 2021 and 2022 are collinear. All straight portions 2021, 2022, 2023 intersect at point 2018. Spaces between directly adjacent slits 2010 in row 2012 form axial beams 2020 between adjacent slits 2010 in row 2012. Slits 2010 in directly adjacent rows are phase offset from each other.

[0125] The unique geometry of the slit 2010 allows the material to be subjected to more than one tension axis. Specifically, the material can expand when tension is applied substantially perpendicular to either of the two linear portions, as represented by the two tension axes (T1, T2). The tension axes (T1, T2) are the primary tension axes. Because the primary tension axes are orthogonal, tension in any axis can cause some unfolding of the material in which the pattern 2000 is formed, resulting in rotation of portions of the material as well as upward and downward movement.

[0126] Any of the embodiments shown or described herein may be combined with other embodiments shown or described herein, including any specific feature, shape, structure, or concept shown or described herein may be combined with any of the other specific features, shapes, structures, or concepts shown or described herein. Those skilled in the art will recognize that many variations may be made to the compound slit patterns, the formation of patterns in materials, and the deployment of those materials while still falling within the scope of the present disclosure. For example, in an embodiment showing a double slit pattern, the pattern may be a triple slit, quadruple slit, or other multi-slit pattern rather than a double slit pattern. Alternatively, the length of the slits, the size of the slits, the thickness of the slits, the shape of the slits, the size or shape of the rows, the size or shape of the transverse beams, and / or the size or shape of the overlapping beams may vary. Additionally, the degree of offset or phase offset may differ from that shown. The pitch of the slits, rows, or beams may vary. The angle between the pulling axis and the slits may vary. The alignment of the pattern with respect to the pulling axis and / or the side of the material may vary. Some of these changes may alter deployment patterns.

[0127] Most of the slit patterns shown herein have areas that are described as either moving or buckling upwards or downwards relative to the original plane of the sheet when tension is applied. The distinction between upward and downward movement is an arbitrary description used for clarity to substantially conform to the accompanying drawings. All samples can be flipped over to change the downward movement to an upward movement (and vice versa). Additionally, where those areas of the sample flip, it is normal and expected that inversions will occur from time to time, and similar features that were moving upwards in previous areas will now move downwards, and vice versa. These inversions can occur in small areas such as a single slit, or over large sections of material. These inversions are random and natural, and are the result of natural variations in materials, manufacturing, and applied forces. Efforts were made to photograph areas of material without inversions, but all samples tested have these natural variations and performance is not significantly affected by the number or location of inversions.

[0128] All of the slit patterns shown herein are shown as being approximately perpendicular to the pull axis. In many embodiments, this can provide superior performance, but any of the slit patterns shown or described herein can be rotated at an angle to the pull axis. An angle of less than 45 degrees from the pull axis is preferred.

[0129] Additionally, all of the slit patterns shown herein include slits that are out of phase with each other by approximately one-half the lateral spacing between immediately adjacent slits (or 50% of the lateral spacing). However, the patterns may be out of phase by any desired amount including, for example, one-third the lateral spacing, one-quarter the lateral spacing, one-sixth the lateral spacing, one-eighth the lateral spacing, etc. In some embodiments, the phase offset is less than one or less than three-quarters, or less than one-half the lateral spacing between immediately adjacent slits in a row. In some embodiments, the phase offset is more than one-fiftieth, or more than one-twentieth, or more than one-tenth the lateral spacing between immediately adjacent slits in a row.

[0130] In some embodiments, the minimum phase offset is such that the ends of the slits in alternating rows intersect a line parallel to the tensile axis that passes through the ends of the slits in adjacent rows. In some embodiments, the maximum phase offset is similarly limited by creating a continuous path of material. If the width of the slits perpendicular to the tensile axis is constant for all slits and has a value w, and the gap between the slits perpendicular to the tensile axis is constant and has a value g, then the minimum and maximum phase offsets are:

number

[0131] Article. The present disclosure also relates to one or more articles or materials that include any of the slit patterns described herein. Some exemplary materials that can form the slit patterns described herein include, for example, paper (including cardboard, corrugated paper, coated or uncoated paper, kraft paper, cotton bond, recycled paper); plastic; woven and nonwoven materials and / or fabrics; elastic materials (including rubber such as natural rubber, synthetic rubber, nitrile rubber, silicone rubber, urethane rubber, chloroprene rubber, ethylene vinyl acetate, or EVA rubber); non-elastic materials (including polyethylene and polycarbonate); polyester; acrylic; and polysulfone. The article can be, for example, a material, a sheet, a film, or any similar structure.

[0132] Examples of thermoplastic materials that can be used include one or more of polyolefins (e.g., polyethylene (high density polyethylene (HDPE), medium density polyethylene (MDPE), low density polyethylene (LDPE), linear low density polyethylene (LLDPE)), metallocene polyethylene, and the like, and combinations thereof), polypropylene (e.g., atactic and syndiotactic polypropylene), polyamides (e.g., nylons), polyurethanes, polyacetals (e.g., Delrin), polyacrylates, and polyesters (e.g., aliphatic polyesters such as polyethylene terephthalate (PET), polyethylene terephthalate glycol (PETG), and the like, and polylactic acid), fluoroplastics (e.g., THV from 3M Company, St. Paul, Minn.), and combinations thereof. Examples of thermosetting materials can include one or more of polyurethanes, silicones, epoxies, melamine, phenol-formaldehyde resins, and combinations thereof. Examples of biodegradable polymers can include one or more of polylactic acid (PLA), polyglycolic acid (PGA), poly(caprolactone), copolymers of lactide and glycolide, poly(ethylene succinate), polyhydroxybutyrate, and combinations thereof.

[0133] As used herein, "paper" refers to a woven or nonwoven sheet-like product or fabric (which can be folded and of various thicknesses) made from cellulose (specifically, fibers of cellulose (natural or artificial)) or otherwise producible from pulp of plant sources such as wood, corn, grass, rice, etc. Paper includes products made from both conventional and non-conventional papermaking processes, as well as materials of the above types in which the sheet has other types of fibers embedded therein, such as reinforcing fibers. Paper may have a coating on the sheet or on the fibers themselves. Examples of non-conventional products that are "paper" within the context of this disclosure include sheet forms of materials available under the trade name TRINGA from PAPTIC (Espoo, Finland) and under the trade name SULAPAC from SULAPAC (Helsinki, Finland).

[0134] The material from which the single slit pattern is formed can be of any desired thickness. In some embodiments, the material has a thickness of about 0.001 inch (0.025 mm) to about 5 inches (127 mm). In some embodiments, the material has a thickness of about 0.01 inch (0.25 mm) to about 2 inches (51 mm). In some embodiments, the material has a thickness of about 0.1 inch (2.5 mm) to about 1 inch (25.4 mm). In some embodiments, the thickness is greater than 0.001 inch (0.025 mm), greater than 0.01 inch (0.25 mm), greater than 0.05 inch (1.3 mm), greater than 0.1 inch (2.5 mm), greater than 0.5 inch (13 mm), greater than 1 inch (25 mm), greater than 1.5 inch (38 mm), greater than 2 inches (51 mm), greater than 2.5 inches (64 mm), or greater than 3 inches (76 mm). In some embodiments, the thickness is less than 5 inches (127 mm), less than 4 inches (101 mm), less than 3 inches (76 mm), less than 2 inches (51 mm), less than 1 inch (25 mm), less than 0.5 inches (13 mm), less than 0.25 inches (6.3 mm), or less than 0.1 inches (2.5 mm).

[0135] In some embodiments where the material is paper, the thickness is from about 0.003 inches (0.076 mm) to about 0.010 inches (0.25 mm). In some embodiments where the material is plastic, the thickness is from about 0.005 inches (0.13 mm) to about 0.125 inches (3.2 mm).

[0136] In some embodiments, the slit or cut pattern extends substantially to one or more of the edges of the sheet, film, or material. In some embodiments, this allows the material to be of unlimited length and also to be unfolded by tension, especially if made of a non-stretchable material. A "non-stretchable" material is generally defined as a material that has an ultimate elongation value of less than 25%, 10% or less, or in some embodiments, 5% or less when in an integrally complete (no slits) configuration. The amount of edge material is the area of ​​the material that surrounds but does not include the single slit pattern. In some embodiments, the edge material amount or downweb boundary can be defined as the width of a rectangle whose major axis is parallel to the tensile axis and of infinite length, and can be provided on the substrate without overlapping or contacting any of the slits. In some embodiments, the edge material amount is less than 0.010 inches (0.25 mm), or less than 0.001 inches (0.025 mm). In some embodiments, the width of the downweb border is less than 0.010 inches (0.25 mm), or less than 0.001 inches (0.025 mm). In some embodiments, the amount of edge material is less than 5 times the thickness of the substrate. In some embodiments, the width of the downweb border is less than 5 times the thickness of the substrate.

[0137] A cross-web slab can be defined as a rectangular region having a rectangle with a long axis perpendicular to the tensile axis and infinite length and a finite width, and can be provided on the substrate without overlapping or contacting any slits or cuts. In some embodiments, a cross-web slab of any width may already be present in the article as an integral part of the pattern. In some embodiments, a cross-web slab of any width may be added to the end of an article of finite length to facilitate unfolding the article. In some embodiments, a cross-web slab of any width may be added intermittently to an article with a continuous pattern.

[0138] In some embodiments, the distance between the longest spaced ends of a single slit (also referred to as the slit length) is from about 0.25 inches (0.001 mm) to about 3 inches (76 mm) long, from about 0.5 inches (13 mm) to about 2 inches (51 mm), or from about 1 inch (25 mm) to about 1.5 inches (38 mm). In some embodiments, the longest distance between the ends of a single slit (also referred to as the slit length) is from 50 times the substrate thickness to 1000 times the substrate thickness, or from 100 to 500 times the substrate thickness. In some embodiments, the slit length is less than 1000 times the substrate thickness, less than 900 times, less than 800 times, less than 700 times, less than 600 times, less than 500 times, less than 400 times, less than 300 times, less than 200 times, or less than 100 times the substrate thickness. In some embodiments, the slit length is more than 50 times, more than 100 times, more than 200 times, more than 300 times, more than 400 times, more than 500 times, more than 600 times, more than 700 times, more than 800 times, or more than 900 times the substrate thickness.

[0139] Methods of Manufacture. The slit patterns and articles described herein can be manufactured in a number of different ways. For example, the slit patterns can be formed by extrusion, molding, laser cutting, water jet machining, machining, stereolithography or other 3D printing techniques, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, other suitable negative or positive processing techniques, or combinations thereof. Specifically, with reference to FIG. 22, paper or other sheet material 30 can be fed into a nip consisting of a rotary die 20 and anvil 10. In this example, the material 30 is stored in a roll configuration in which the material is wound around a central axis that may or may not include a central core. The rotary die 20 has a cut surface 22 thereon that corresponds to the pattern desired to be cut into the sheet material 30. The die 20 cuts through the material 30 at the desired locations to form the slit patterns described herein. The same process can be used with a flat die and flat anvil.

[0140] Method of Use. The articles and materials of the present disclosure can be used in a variety of ways. In one embodiment, a two-dimensional sheet, material, or article is tensioned along a tension axis, which causes slits to form and / or move openings and / or flaps as described herein. In some embodiments, tension is applied by hand or machine.

[0141] Applications. The present disclosure describes articles that start as flat sheets, but upon application of force / tension, expand into three-dimensional structures. In some embodiments, such structures form energy absorbing structures. The patterns, articles, and structures described herein have many possible applications, at least some of which are described herein.

[0142] One exemplary application is to protect objects for transportation or storage. As mentioned above, existing shipping materials have various drawbacks, such as taking up too much space when stored before use (e.g., bubble wrap, packing peanuts), resulting in high shipping costs; requiring special equipment to manufacture (e.g., inflatable airbags); not always being effective (e.g., crinkle paper); and / or not being widely recyclable (e.g., bubble wrap, packing peanuts, inflatable airbags). The tension-activated expansion films, sheets, and articles described herein can be used to protect objects during transportation without any of the drawbacks mentioned above. When manufactured from sustainable materials, the articles described herein are effective and sustainable. Because the articles described herein are flat when manufactured, shipped, sold, and stored, and only become three-dimensional when activated by a user with tension / force, these articles are more effective and efficient in maximizing storage space and minimizing shipping / carrying / packaging costs. Retailers and users can use a relatively small space to accommodate products that expand to 10, 20, 30, or 40 times or more of their original size. Moreover, the articles described herein are simple and very easy to use. The user simply pulls the product off the roll or takes a flat sheet of the product, applies tension to the entire article along the pull axis (this can be done by hand or machine), and then wraps the product around the item to be shipped. In many embodiments, no tape is required because the interconnecting features allow the product to interconnect with another layer of itself.

[0143] In some embodiments, the slit patterns described herein create packaging materials and / or buffer films that provide advantages over existing offerings. For example, in some embodiments, the packaging materials and / or buffer films of the present disclosure provide enhanced buffering capacity or product protection. In some embodiments, the packaging materials and / or buffer films of the present disclosure provide similar or enhanced buffering capacity or product protection compared to existing offerings, but are recyclable and / or more sustainable or environmentally friendly than existing offerings. In some embodiments, the packaging materials and / or buffer films of the present disclosure provide similar or enhanced buffering capacity or product protection compared to existing offerings, but can be expanded and wrapped around the item to be shipped. Structures that retain their shape when tension is applied may be preferred because they can eliminate the need for tape to hold the material in place in many applications.

[0144] In this document, the terms "a" or "an" are used to include one or more, as is common in patent documents, regardless of any other examples or the use of "at least one" or "one or more." In this document, the term "or" refers to a non-exclusive "or," so that "A or B" includes "A but not B," "B but not A," and "A and B," unless otherwise indicated. In this document, the terms "including" and "in which" are used as the plain English equivalents of the corresponding terms "comprising" and "wherein." Also, in the appended claims, the terms "including" and "comprising" are open-ended; that is, a system, apparatus, article, composition, formulation, or process that includes another element in addition to the elements recited after such a term in a claim is still deemed to be within the scope of that claim. Moreover, in the appended claims, the terms "first," "second," and "third," etc., are used merely as labels and are not intended to impose numerical requirements on their objects.

[0145] The above description is intended to be illustrative, and not limiting. For example, the above-described embodiments (or one or more aspects thereof) can be used in combination with each other. An Abstract is provided to comply with 37 CFR §1.72(b) to enable the reader to quickly grasp the nature of the technical disclosure. The Abstract is provided with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. In addition, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as intending that an unclaimed disclosed feature is essential to any claim. Rather, the inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the appended claims are incorporated herein in the Detailed Description as examples or embodiments, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the present invention can be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0146] All recitations of value ranges by endpoints are intended to include all numbers subsumed within that range (ie, the range 1 to 10 includes, for example, 1, 1.5, 3.33, and 10).

[0147] The terms first, second, third, etc. in the detailed description and claims are used to distinguish between similar elements and do not necessarily describe an order or chronology. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of functioning in orders other than those described or illustrated herein.

[0148] Moreover, terms such as top, bottom, upper, lower, etc. in the detailed description and claims are used for descriptive purposes and do not necessarily describe relative positions, with it being understood that the terms so used are interchangeable under appropriate circumstances, and that the embodiments of the invention described herein are capable of functioning in orientations other than those described or illustrated herein.

[0149] Those skilled in the art will appreciate that many changes may be made to the details of the above-described embodiments and implementations without departing from the principles underlying them. Moreover, various modifications and variations to the present disclosure will be apparent to those skilled in the art that do not depart from the spirit and scope of the present disclosure. Thus, the scope of the present application should be determined solely by the following claims and their equivalents. In addition to the respective embodiments, the following aspects are noted. (Appendix 1) a sheet of material having a plurality of slits arranged in a plurality of rows of slits, each of the slits in a row being laterally spaced from an immediately adjacent slit in the row to form an axial beam, the axial beam extending between slits in adjacent rows, the plurality of slits including a repeating pattern of compound slits; Includes expansion materials. (Appendix 2) 2. The expandable material of claim 1, wherein the material defines a plane in a pretensioned configuration and defines a tension axis, and wherein at least a portion of the material rotates from the plane by 45 degrees or more when tension is applied along the tension axis. (Appendix 3) 3. The expandable material of claim 1 or 2, wherein the compound slit includes three or more end portions, and at least one of the end portions is curved. (Appendix 4) 4. The expandable material of any one of claims 1 to 3, wherein at least some of the compound slits include at least one of a hook, a loop, a sine wave, a square wave, a triangle wave, and a cross slit. (Appendix 5) The expandable material of any one of claims 1 to 4, wherein the plurality of compound slits define a slit pattern that extends through one or more of the edges of the material. (Appendix 6) 6. The expandable material of any one of claims 1 to 5, wherein the material comprises at least one of paper, cardboard, plastic, elastic material, non-elastic material, polyester, acrylic, polysulfone, thermosetting polymer, thermoplastic polymer, biodegradable polymer, woven material, non-woven material, and combinations thereof. (Appendix 7) The expanding material of any one of claims 1 to 6, wherein the material is paper and has a thickness of about 0.003 inches (0.076 mm) to about 0.010 inches (0.25 mm). (Appendix 8) The expanding material of any one of claims 1 to 6, wherein the material is plastic and has a thickness of about 0.005 inches (0.13 mm) to about 0.125 inches (3.2 mm). (Appendix 9) 9. The expanded material of any one of claims 1 to 8, wherein the material passes the interconnection test described herein. (Appendix 10) The expandable material of any one of claims 1 to 9, wherein each of the slits has a lateral length that is perpendicular to the tensile axis. (Appendix 11) 11. The expandable material of any one of claims 1 to 10, wherein each slit has a horizontal length, and the slits in a first row of slits are offset from slits in an adjacent row of slits by no more than 75% of the horizontal length of each slit in the first row of slits. (Appendix 12) The expansion material of any one of claims 1 to 11, wherein each of the slits has a slit shape and a slit orientation, and the slit shape, the slit orientation, or both the slit shape and the slit orientation are different within a row of slits. (Appendix 13) The expansion material of any one of claims 1 to 12, wherein the slits have a slit shape and a slit orientation, and the slit shape, the slit orientation, or both the slit shape and the slit orientation are different in adjacent rows. (Appendix 14) 14. The expanding material of any one of claims 1 to 13, wherein the material has a thickness of about 0.001 inches (0.025 mm) to about 5 inches (127 mm). (Appendix 15) The expandable material of any one of claims 1 to 14, wherein each of the plurality of slits has a slit length of about 0.25 inches (6.35 mm) to about 3 inches (76.2 mm). (Appendix 16) 16. The expanding material of any one of claims 1 to 15, wherein each slit of the plurality of slits has a slit length, the material has a material thickness, and the ratio of slit length to material thickness is from about 50 to about 1000. (Appendix 17) A die capable of forming the composite pattern according to any one of claims 1 to 16. (Appendix 18) A packaging material formed from any of the expandable materials described in any one of appendixes 1-16. (Appendix 19) 19. The packaging material of claim 18, wherein the expandable material is stored in a rolled configuration. (Appendix 20) 19. The packaging material of claim 18, wherein the expanding material is one or more individual sheets. (Appendix 21) 21. The packaging material of claim 20, further comprising an envelope having the expanding material disposed within the envelope. (Appendix 22) A method for producing any of the expansion materials described in any one of appendixes 1 to 16, comprising: forming the compound slit pattern in the material by at least one of extrusion, molding, laser cutting, water jet machining, machining, stereolithography, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, or combinations thereof; A manufacturing method comprising: (Appendix 23) A method of using any of the expansion materials described in any one of appendixes 1 to 16, comprising: expanding the material by applying tension to the material along a tension axis; Including, how to use. (Appendix 24) 24. The method of claim 23, wherein the application of tension causes one or more of: (1) the slits to form openings; and / or (2) the material adjacent the slits to form corrugations. (Appendix 25) 25. The method of claim 23 or 24, wherein the tension is applied by hand or by machine. (Appendix 26) 26. The method of any one of claims 23 to 25, wherein applying tension to the expansive material along the tension axis causes the material to change from a two-dimensional structure to a three-dimensional structure.

Claims

1. A sheet of material having a plurality of slits arranged in a plurality of rows of slits defining a plane in a pretensioned configuration, the plurality of slits having an axial direction and a lateral direction that is perpendicular to the axial direction and each slit having a curved lateral length that is perpendicular to a tensile axis parallel to the axial direction, each of the slits in a row being spaced in the lateral direction from an immediately adjacent slit in the row to form an axial beam, the axial beam extending between slits in adjacent rows, the plurality of slits including a repeating pattern of compound slits each having more than two termini; Includes expansion materials.

2. The expanding material of claim 1, wherein at least a portion of the material rotates out of the plane by more than 45 degrees when tension is applied along the tensile axis.

3. The expanded material of claim 1, wherein the slits in a first row of slits are offset from slits in an adjacent row of slits by no more than 75% of the lateral length of each slit in the first row of slits.

4. The expanding material of claim 1 , wherein the material has a thickness of about 0.001 inch (0.025 mm) to about 5 inches (127 mm).

5. A die capable of forming a plurality of slits according to any one of claims 1 to 4.

6. A packaging material comprising any of the expanding materials according to any one of claims 1 to 4.

7. The packaging material of claim 6 , wherein the expanding material is in a roll configuration.

8. A method for producing any of the expanding materials according to any one of claims 1 to 4, comprising the steps of: forming the plurality of slits in the material by at least one of extrusion, molding, laser cutting, water jet machining, machining, stereolithography, laser ablation, photolithography, chemical etching, rotary die cutting, stamping, or combinations thereof; A manufacturing method comprising:

9. A method of using any of the expansion materials according to any one of claims 1 to 4, comprising the steps of: expanding the material by applying tension to the material along a tension axis; Including, how to use.

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