Expanded Slit Sheet Cushioning With Novel Slit Pattern
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Solution Overview
Problem
Existing slit sheet paper products face limitations in achieving optimal cushioning characteristics due to the need for increased width in the expanded state, which is counterintuitive to enhancing cushioning properties, and previous technologies struggled with achieving smaller slit patterns that could provide enhanced cushioning despite reduced width.
Innovation Solution
The use of an extensible paper with a novel slit pattern featuring slits between 0.30 to 0.45 inches in length and spaces between rows ranging from 0.1125 to 0.1688 inches, resulting in a higher number of legs per square foot and an alternating row expansion pattern, allowing for greater crush resistance and resiliency while maintaining a thinner profile.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the slit width is reduced to increase the number of legs per square foot, then cushioning properties are enhanced, but the expanded width decreases
Solution Approach 1:
The patent applies parameter changes by precisely controlling the slit width within the range of 0.30 to 0.45 inches and the space between rows within 0.1125 to 0.1688 inches. This optimization creates a higher number of legs per square foot, enhancing cushioning properties while managing the expanded width through controlled geometric parameters.
Solution Approach 2:
The patent segments the paper into a pattern of slits and spaces, creating multiple small cells that form legs when expanded. This segmentation increases the number of legs per square foot, which enhances cushioning properties by distributing impact forces across more contact points, even though the overall expanded width is reduced.
2Strength
If the slit pattern is made smaller to increase cell density, then crush resistance is improved, but the thickness profile increases
Solution Approach 1:
The patent optimizes the parameters of the slit pattern by controlling slit width (0.30 to 0.45 inches) and space between rows (0.1125 to 0.1688 inches) to achieve high cell density. This creates superior crush resistance through increased leg count, while the alternating row expansion pattern helps manage the thickness profile by controlling how cells orient during expansion.
Solution Approach 2:
The patent employs an alternating row expansion pattern where adjacent rows of cells expand in opposite directions. This asymmetric expansion behavior controls the three-dimensional shape of the expanded material, allowing high cell density for crush resistance while managing the overall thickness profile through directional control of cell orientation.
3Strength
If more paper material is used to increase cushioning effectiveness, then protection is improved, but shipping costs increase
Solution Approach 1:
The patent segments the paper into a high-density pattern of slits and spaces, creating numerous small cells that form legs when expanded. This segmentation allows the material to achieve superior cushioning effectiveness through increased leg count per square foot, providing better protection with the same amount of paper material, thereby reducing shipping costs.
Solution Approach 2:
The patent changes the geometric parameters of the slit pattern to optimize the number of legs per square foot. By controlling slit width and spacing, the material achieves enhanced cushioning effectiveness without increasing the amount of paper used, maintaining cost-effectiveness while improving protection.
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
This approach enables the creation of more resilient and crush-resistant cushioning products with improved cell density and reduced thickness, allowing for lighter weight and more efficient packaging solutions with reduced shipping costs.
Implementation Method 1
said slit sheet paper being formed from an extensible paper made to be extensible in the machine direction and the cross direction without said slit pattern
Data Source
AI summary
In the preferred embodiments, the present invention provides substantially improved slit sheet cushioning products by advantageously combining novel paper properties with novel slit patterns for improved features and characteristics. In some illustrative and non-limiting example embodiments, cushioning products of the present invention can include, e.g., a novel slit sheet material in combination with extensible paper employed as, e.g., a cushioning pad or as cushioning within an envelope product, wherein the cushioning product can be substantially more resilient, but, yet, e.g., thinner for better utilization of space.