Extensible Paper Slit Sheets With High-Density Cushioning Cells
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Solution Overview
Problem
Existing expandable slit sheet papers face limitations in achieving enhanced cushioning characteristics and efficiency due to the conventional understanding of requiring wider slit widths for effective cushioning, which hinders space utilization and increases material thickness.
Innovation Solution
The use of an extensible paper with a novel slit pattern featuring reduced slit lengths and row spacings, along with an alternating row expansion pattern, creates a higher cell density and improved cushioning properties, allowing for thinner and more resilient cushioning products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional wider slit widths are used for effective cushioning, then cushioning characteristics are improved, but material thickness increases and space utilization decreases
Solution Approach 1:
The paper is divided into multiple rows of cells through slitting, creating discrete cushioning units that can expand independently. This segmentation allows for optimized cell dimensions that provide effective cushioning while reducing overall material thickness and improving space utilization.
Solution Approach 2:
The invention changes the geometric parameters of the slit pattern, specifically using narrower slit widths (0.125-0.375 inches) combined with optimized row spacings (0.25-0.50 inches) to create a higher density of smaller cells. This parameter optimization maintains cushioning effectiveness while reducing material thickness.
2Strength
If conventional slit patterns are used, then ease of manufacture is maintained, but cushioning efficiency and resiliency are limited
Solution Approach 1:
The invention optimizes specific parameters of the slit pattern including slit widths of 0.125-0.375 inches and row spacings of 0.25-0.50 inches, which can be achieved with conventional slitting equipment. These parameter changes enhance crush resistance and resiliency without requiring complex manufacturing processes.
Solution Approach 2:
The slit pattern creates localized variations in paper structure with alternating land and leg regions that provide different mechanical properties. The lands provide structural support while the legs provide flexibility, creating local quality variations that enhance overall cushioning performance.
3Strength
If more material is used to improve cushioning, then cushioning characteristics are enhanced, but shipping costs and material requirements increase
Solution Approach 1:
By segmenting the paper into multiple rows of cells, the invention creates a structure that provides enhanced cushioning characteristics through the collective action of many small cells rather than requiring thick layers of material. This segmentation increases cushioning efficiency per unit of material.
Solution Approach 2:
The expanded slit sheet creates a composite structure combining rigid land regions with flexible leg regions, forming a cellular composite material that provides superior cushioning characteristics per unit weight compared to solid paper or conventional cushioning materials.
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 expanded slit sheets with increased crush resistance and resiliency, enabling thinner and lighter cushioning solutions with reduced material requirements, thus optimizing space utilization and reducing shipping costs.
Implementation Method 1
said extensible paper having an extensibility within a range of 3 to 20% in the machine direction
Data Source
Figure 1~2
Figure 3(A)~3(B)
Figure 4(A)
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.