Alternating Expansion Pattern Slit Sheet Cushioning

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Solution Overview

Problem

Existing slit sheet expandable paper products face limitations in achieving optimal cushioning characteristics due to constraints in slit pattern design, leading to suboptimal expansion and resilience, particularly in terms of cell density and thickness.

Innovation Solution

The development of novel slit sheet paper with an alternating row expansion pattern and the use of extensible paper that expands into unique patterns, featuring slits and land regions with specific angles of inclination, allowing for increased cell density and improved cushioning properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Quantity of substance

If traditional slit patterns are used, then the paper can be expanded, but the cell density is insufficient and thickness is too large

Engineering Contradiction:

Improvecell densityVSAvoidthickness

Core Design Contradiction:

Quantity of substanceVSLength of stationary object

Solution Approach 1:

The paper is divided into multiple rows of slits creating numerous small cells instead of fewer large cells. The slit pattern includes first rows and second rows of slits with land regions between them, segmenting the paper into a high-density cellular structure that increases cell concentration while reducing overall thickness.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the paper have different properties: land regions have specific angles of inclination (different from 45 degrees) while other regions have standard properties. This local variation in land region angles creates alternating expansion patterns that optimize both cell density and thickness reduction in different areas of the expanded paper.

Inventive Principle:

Principle #3Local quality

2Ease of operation

If expansion force is applied, then the slit sheet expands into cushioning form, but too much force is required making it difficult to use

Engineering Contradiction:

Improveease of expansionVSAvoidexpansion force

Core Design Contradiction:

Ease of operationVSForce

Solution Approach 1:

The land regions are designed with specific angles of inclination that differ from the traditional 45 degrees. This parameter change in the land region geometry reduces the mechanical resistance during expansion, allowing the slit sheet to expand more easily with less applied force while still achieving the desired cushioning form.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If slit pattern is optimized for cell density, then cushioning characteristics improve, but the complexity of slit pattern design increases

Engineering Contradiction:

Improvecushioning characteristicsVSAvoidslit pattern design

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The slit pattern employs asymmetric land regions with specific angles of inclination that are different from standard angles (different from 45 degrees). This asymmetric design creates alternating expansion patterns between first and second rows of slits, optimizing cushioning characteristics through controlled directional expansion while maintaining a manageable pattern structure.

Inventive Principle:

Principle #4Asymmetry

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The solution results in a more resilient and thinner cushioning product with enhanced cushioning characteristics, achieving greater cell concentration and reduced thickness, while also reducing the force required for expansion, making it easier to use and more cost-effective.

Implementation Method 1

an extensible paper that expands into unique patterns, featuring slits and land regions with specific angles of inclination, allowing for increased cell density

Methodology Applied

Scientific EffectElastic deformation: Elasticity

Implementation Method 2

a more resilient and thinner cushioning product with enhanced cushioning characteristics, achieving greater cell concentration and reduced thickness

Methodology Applied

Scientific EffectGeometric expansion pattern: Geometry

Data Source

PatentUS11834240B2Expanded slit sheet cushioning products with novel alternating expansion patterns

Publication Date: 2023.12.05 HEXCELPACK LLC

AI summary

In the preferred embodiments, a paper cushioning product is provided that includes: a sheet of slit paper having a slit pattern, the slit pattern upon expansion forming cells that include land regions that are inclined with respect to a plane of an unexpanded sheet; the sheet of slit paper being configured such that expanding the sheet of slit paper with said slits produces land regions that have angles of inclination from the plane of the unexpanded sheet, with said land regions alternating on a row by row basis in forward and backward directions such that the slit pattern upon expansion includes an alternating cell opening pattern wherein each row opens in an opposite direction from an adjacent row. In preferred embodiments, the product further includes at least one of a) said sheet of slit paper is extensible paper that is extensible in a machine direction in a range of at least 3% and/or b) said sheet of slit paper includes slits configured such that upon expansion the slit sheet paper expands into an alternating row expansion pattern.