U.S. patent application number 17/638575 was filed with the patent office on 2022-09-22 for packaging assembly comprising an interior bond.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Irinia Hass, Lisa M. Miller.
Application Number | 20220297915 17/638575 |
Document ID | / |
Family ID | 1000006447137 |
Filed Date | 2022-09-22 |
United States Patent
Application |
20220297915 |
Kind Code |
A1 |
Miller; Lisa M. ; et
al. |
September 22, 2022 |
PACKAGING ASSEMBLY COMPRISING AN INTERIOR BOND
Abstract
A packaging assembly including a flexible outer shell layer and
a flexible inner cushioning layer in overlapping relation with each
other and comprising at least one interior bond that bonds an
interior area of the outer shell layer to an interior area of the
inner cushioning layer.
Inventors: |
Miller; Lisa M.; (Spring
Valley, WI) ; Hass; Irinia; (Woodbury, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
1000006447137 |
Appl. No.: |
17/638575 |
Filed: |
September 23, 2020 |
PCT Filed: |
September 23, 2020 |
PCT NO: |
PCT/IB2020/058905 |
371 Date: |
February 25, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62904842 |
Sep 24, 2019 |
|
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|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 81/03 20130101;
B65D 65/10 20130101; B65B 55/20 20130101; B65D 65/44 20130101 |
International
Class: |
B65D 81/03 20060101
B65D081/03; B65D 81/02 20060101 B65D081/02; B65D 65/10 20060101
B65D065/10; B65B 55/20 20060101 B65B055/20 |
Claims
1. A packaging assembly comprising a flexible outer shell layer and
a flexible inner cushioning layer in overlapping relation with each
other and comprising at least one interior bond that bonds an
interior area of the outer shell layer to an interior area of the
inner cushioning layer.
2. The packaging assembly of claim 1, wherein the inner cushioning
layer comprises bubble wrap that includes a film portion and a
bubble portion that includes air or gas-filled bubbles, wherein the
film portion of the bubble wrap is adjacent to the outer shell
layer, and wherein the interior bond bonds a discrete area of the
film portion of the bubble warp to the discrete portion of the
outer shell layer.
3. The packaging assembly of claim 1 wherein the at least one
interior bond occupies less than 20% of the total area of the outer
shell layer and less than 20% of the total area of the inner
cushioning layer.
4. The packaging assembly of claim 1 wherein the inner cushioning
layer has a thickness of between about 1/32 inch and about 1
inch.
5. The packaging assembly of claim 1 wherein the outer shell layer
is a multilayer structure.
6. The packaging assembly of claim 1 wherein the outer shell layer
comprises at least one of paper, plastic, a nonwoven, or
combinations thereof.
7. The packaging assembly of claim 1 wherein the outer shell layer
comprises at least one of polypropylene, polyethylene,
polyurethane, polyester, and/or a copolymer of any of these.
8. The packaging assembly of claim 1 wherein the outer shell layer
comprises an oriented or biaxially oriented organic polymeric
material.
9. The packaging assembly of claim 1 wherein the outer shell layer
comprises an outward major surface that is a writable surface.
10. The packaging assembly of claim 1 wherein the at least one
interior bond between the outer shell layer and the inner
cushioning layer is a melt bond.
11. The packaging assembly of claim 1 wherein the at least one
interior bond between the outer shell layer and the inner
cushioning layer is provided by at least one piece of double-faced
pressure-sensitive adhesive.
12. The packaging assembly of claim 1 wherein the at least one
interior bond between the outer shell layer and the inner
cushioning layer is a single interior bond that overlaps with a
geometric center of the outer shell layer and a geometric center of
the inner cushioning layer.
13. The packaging assembly of claim 1 wherein the at least one
interior bond between the outer shell layer and the inner
cushioning layer occupies less than 10% of the total area of the
outer shell layer and less than 10% of the total area of the inner
cushioning layer.
14. The packaging assembly of claim 1 wherein the outer shell layer
and the inner cushioning layer are at least substantially
co-extensive.
15. The packaging assembly of claim 1 further comprising at least
one area of pressure-sensitive adhesive that is provided on a major
surface of the inner cushioning layer that faces away from the
outer shell layer, and wherein the pressure-sensitive adhesive
comprises a major adhesive surface that faces away from the outer
shell layer.
16. The packaging assembly of claim 15 wherein the
pressure-sensitive adhesive comprises a release liner that is
releasably disposed on the entirety of the major adhesive surface
of the pressure-sensitive adhesive.
17. The packaging assembly of claim 1 wherein the packaging
assembly is provided as a roll good comprising the outer shell
layer and the inner cushioning layer, co-rolled with each
other.
18. A method of packaging an item using a packaging assembly
comprising a flexible outer shell layer and a flexible inner
cushioning layer in overlapping relation with each other and
comprising at least one interior bond therebetween, the method
comprising: positioning the packaging assembly with the inner
cushioning layer facing upward; placing the item to be packaged on
the inner cushioning layer so that the item overlaps a geometric
center of the of the outer shell layer and the inner cushioning
layer; wrapping the inner cushioning layer around the item into a
protective configuration while the outer shell layer remains
unmoving; optionally securing the inner cushioning layer in the
protective configuration; wrapping the outer shell layer around the
inner cushioning layer that is in the protective configuration so
that the outer shell layer is in an encapsulating configuration in
which the outer shell layer completely envelopes the inner
cushioning layer and in which the inner cushioning layer is
retained in the protective configuration; and, securing the outer
shell layer in the encapsulating configuration.
Description
BACKGROUND
[0001] Packaging assemblies, e.g., shipping containers, padded
mailers, and the like, have found increasing use as more and more
items are purchased online and are shipped to the end-user.
SUMMARY
[0002] In broad summary, herein is disclosed a packaging assembly
including a flexible outer shell layer and a flexible inner
cushioning layer in overlapping relation with each other and
comprising at least one interior bond that bonds an interior area
of the outer shell layer to an interior area of the inner
cushioning layer. These and other aspects will be apparent from the
detailed description below. In no event, however, should this broad
summary be construed to limit the claimable subject matter, whether
such subject matter is presented in claims in the application as
initially filed or in claims that are amended or otherwise
presented in prosecution.
BRIEF DESCRIPTION OF THE DRAWINGS
[0003] FIG. 1 is a perspective view of an exemplary packaging
assembly with an item disposed in a ready-for-packaging
condition.
[0004] FIG. 2 is a side view of an exemplary packaging assembly
with an item disposed in a ready-for-packaging condition.
[0005] FIG. 3 is a side view of an exemplary packaging assembly as
disclosed herein.
[0006] FIG. 4 is a side view of an exemplary packaging assembly and
illustrating methods of packaging an item within the
construction.
[0007] FIG. 5 is a side view of another exemplary packaging
assembly as disclosed herein.
[0008] Like reference numbers in the various figures indicate like
elements. Some elements may be present in identical or equivalent
multiples; in such cases only one or more representative elements
may be designated by a reference number but it will be understood
that such reference numbers apply to all such identical elements.
All figures and drawings in this document are not to scale and are
chosen for the purpose of illustrating different embodiments of the
invention. In particular the dimensions of the various components
are depicted in illustrative terms only, and no relationship
between the dimensions of the various components should be inferred
from the drawings, unless so indicated. Although terms such as
first and second may be used in this disclosure, it should be
understood that those terms are used in their relative sense only
unless otherwise noted.
[0009] Terms such as outward and inward are defined in relation to
the packaging assembly as packaged (e.g., wrapped) around an item,
with inward denoting toward the item and with outward denoting away
from the item. For clarity of description, these terms are retained
even in descriptions of the packaging assembly and components
thereof, prior to the assembly being packaged around an item.
[0010] As used herein as a modifier to a property or attribute, the
term "generally", unless otherwise specifically defined, means that
the property or attribute would be readily recognizable by a person
of ordinary skill but without requiring a high degree of
approximation (e.g., within +/-20% for quantifiable properties).
The term "substantially", unless otherwise specifically defined,
means to a high degree of approximation (e.g., within +/-10% for
quantifiable properties). The term "essentially" means to a very
high degree of approximation (e.g., within plus or minus 2% for
quantifiable properties; it will be understood that the phrase "at
least essentially" subsumes the specific case of an "exact" match.
However, even an "exact" match, or any other characterization using
terms such as, e.g., same, equal, identical, uniform, constant, and
the like, will be understood to be within the usual tolerances or
measuring error applicable to the particular circumstance rather
than requiring absolute precision or a perfect match.
DETAILED DESCRIPTION
[0011] Disclosed herein is a packaging assembly 1. Packaging
assembly 1 comprises a flexible outer shell layer 20 and a flexible
inner cushioning layer 10, as shown in exemplary embodiment in
perspective view in FIG. 1 and in side view in FIG. 2. By flexible
is meant that layers 10 and 20, when manipulated individually
and/or if manipulated simultaneously as a stacked pair of layers,
can be easily bent, folded, and so on, by hand by a human user,
without the use of any special tools or the like.
[0012] Flexible layers 10 and 20 are in overlapping relation with
each other, as shown in exemplary embodiment in FIGS. 1 and 2. By
overlapping relation is meant that, when layers 10 and 20 are in a
ready-for-packaging condition (e.g., flat on a suitable horizontal
surface, as in FIGS. 1 and 2) at least 40% of the total area of
layer 10 overlaps layer 20, and vice versa. In various embodiments,
at least 60, 80, 90 or 95% of the total area of layer 10 overlaps
layer 20, and vice versa. In some convenient embodiments, layers 10
and 20 are coextensive, meaning that they share the same shape and
size with essentially 100% of their area in overlapping relation
with each other, as in the exemplary arrangement of FIG. 1. In many
convenient embodiments, packaging assembly 1 and layers 10 and 20
thereof may be at least generally rectangular and may exhibit four
major terminal edges. In some specific embodiments, layers 10 and
20 may be at least generally square, as shown in exemplary
embodiment in FIG. 1.
[0013] Packaging assembly 1 comprises at least one interior bond 30
that is located between inner cushioning layer 10 and outer shell
layer 20, as shown in exemplary embodiment in FIGS. 1 and 2. As
shown in further detail in FIG. 3, interior bond 30 bonds an
interior area 21 of outer shell layer 20 to an interior area 11 of
inner cushioning layer 10. Other area(s) 22 of outer shell layer 20
and area(s) 12 of inner cushioning layer 10 remain unbonded as
evident in FIG. 3. The provision of at least one interior bond 30
in this manner allows shell layer 20 and cushioning layer 10 to be
provided to an end user and handled by the end user as a multilayer
stack that is held together by the at least one interior bond 30.
However, the unbonded areas 22 and 12 of the shell layer 20 and the
cushioning layer 10 can be manipulated separately and individually,
which is advantageous as discussed later herein.
[0014] By at least one interior bond is meant a bond (i.e., one or
more bonds, whether direct or indirect) between the shell layer 20
and the cushioning layer 10, that is located in an interior area of
each layer. In other words, no portion of bond 30 will extend to a
terminal edge of layer 10 or layer 20. Rather, each layer will
include a "picture-frame" border of unbonded material (areas 12 and
22, in FIG. 3). Left, right, fore and aft unbonded areas, that are
not bonded by interior bond 30 and that collectively comprise an
unbonded picture-frame border, are also indicated (as 1, r, f and
a) in FIG. 1.
[0015] In some embodiments, an interior bond will occupy (in terms
of total actual bonded area) less than 40% of the total area of
each layer. In various embodiments, an interior bond 30 may occupy
less than 35, 30, 25, 20, 15, 10, 8, 6, 4 or 2% of the total area
of each layer. In further embodiments, an interior bond 30 may
occupy at least 0.5, 1.0, 1.5, 3.0, 5.0, 7.0, 13, 18, 23, or 28% of
the total area of each layer. By way of a specific example, the
exemplary interior bond 30 depicted in FIG. 1 occupies
approximately 3% of the total area of each layer.
[0016] In some embodiments the at least one interior bond 30 will
overlap with the geometric center of shell layer 20 and/or the
geometric center of cushioning layer 10 (in either case, this means
that with the packaging assembly 1 in a ready-for-packaging
configuration, the geometric center of the layer will pass through
some portion of interior bond 30). In some such embodiments, the at
least one interior bond will overlap with the geometric center 5 of
packaging assembly 1 as indicated in exemplary manner in FIG. 2. In
some such embodiments, the geometric center of layer 10, layer 20,
and/or packaging assembly 1 will pass through (i.e., will coincide
with) the geometric center of interior bond 30, again as in FIG. 2.
In instances in which the at least one interior bond 30 is provided
by multiple individual bonds with unbonded areas in between (as
discussed below), for purposes of establishing a condition of the
geometric center of bond 30, the geometric center of the total area
occupied by the multiple bonded areas that collectively make up
bond 30 will be used. Thus, in some instances the geometric center
of interior bond 30 may, e.g., pass through an unbonded area, e.g.,
in between two adjacent bonded areas. An interior bond 30 may have
any suitable shape; e.g., generally rectangular (e.g., square) as
in the exemplary embodiment of FIG. 1.
[0017] In some embodiments, an at least one interior bond may take
the form of a single, continuous bond (e.g., as shown in exemplary
embodiments in FIGS. 1 and 2). In other embodiments, an at least
one interior bond may take the form of multiple discrete bonds that
are provided in a desired pattern along selected areas of layers 10
and 20, with the multiple discrete bonds serving as the at least
one interior bond 30 and collectively exhibiting a total bonded
area that meets the requirements listed above.
[0018] In some embodiments an at least one interior bond may take
the form of a melt-bond between the shell layer 20 and the
cushioning layer 10. A melt bond may be achieved, e.g., by way of
temperature, ultrasonic energy, or any suitable means, combined,
e.g., with appropriate pressure as needed. Thus in some embodiments
an at least one interior bond 30 may take the form of a pattern of
ultrasonic welds between layers 10 and 20.
[0019] In some embodiments an adhesive may be used to provide
interior bond 30, e.g., a liquid adhesive, a glue, a hot melt
adhesive, or the like, applied, e.g., as a strip, as a set of dots,
and so on. In some convenient embodiments an at least one interior
bond 30 may be provided by a double-faced pressure-sensitive
adhesive, e.g., a piece, patch or strip of such an adhesive, as
indicated in FIGS. 1-3. In such embodiments a major inward surface
33 of adhesive 30 may face toward, and be bonded to, a major
outward surface 14 of cushioning layer 10; a major outward surface
34 of adhesive 30 may face toward, and be bonded to, major inward
surface 24 of shell layer 20.
[0020] A packaging assembly 1 as disclosed herein may be used
according to the general method depicted in generic, exemplary
embodiment in FIG. 4. As a preliminary step, packaging assembly 1
can be positioned generally flat (e.g., on any suitable horizontal
surface) with cushioning layer 10 facing up, and an item 100 to be
packaged may be positioned as desired (typically, centered over the
geometric center 5 of packaging assembly 1) atop cushioning layer
10 as shown in FIGS. 2 and 4. With reference to the side view of
FIG. 4, as a first ("A") step of packaging item 100 within
packaging assembly 1, areas 12 of cushioning layer 10, which are
not bonded to shell layer 20 and are thus free to be moved
independently of shell layer 20, are folded over the top surface of
item 100 in the general manner indicated by block arrows A of FIG.
4. At this point, the folded-over areas of cushioning layer 10 may
be secured (e.g., with pressure-sensitive tape or the like) to each
other, and/or to item 100, if desired.
[0021] An additional A step can then be performed with the
remaining unbonded areas of cushioning layer 10. It will be
understood that FIG. 4 is a cross-sectional view that can only show
the folding of certain areas of the layers. Thus, with reference to
the top, perspective view of FIG. 1, the above-described first A
step may involve folding over the left (l) and right (r) areas of
cushion layer 10. The additional A step will then involve folding
over the fore (f) and aft (a) areas of cushion layer 10, noting
that folded-over portions of the left and right areas may be
present atop the fore and aft areas as the result of the first A
step, and will accordingly be folded along with the fore and aft
areas in the second A step.
[0022] The result of performing these steps is that cushioning
layer 10 becomes wrapped around the item 100 in a protective
configuration, by which is meant that layer 10 surrounds item 100
on all sides so that no portion of item 100 is reachable from the
outside along a line that does not pass through at least a portion
of cushioning layer 10. (Depending on, e.g., the size of the item
relative to cushioning layer 10, there may be multiple layers of
cushioning layer 10 on at least one side of the item 100).
[0023] In some embodiments, the cushioning layer can be secured
(e.g., with pressure-sensitive adhesive tape, or with mechanical
means such as string or staples) in the protective configuration.
However, in some embodiments the cushioning layer may merely be
held in this configuration while subsequent manipulations are
performed with shell layer 20, so that shell layer 20, when in its
final configuration as described below, holds and maintains
cushioning layer 10 in its protective configuration.
[0024] After inner cushioning layer 10 has been wrapped around item
100 into a protective configuration as described above, a "B"
packaging step can be performed in which areas 22 of outer shell
layer 20 that are not bonded to inner cushioning layer 10 (and that
thus remained undisturbed during the above-described steps of
folding the cushioning layer), can be folded over the outward
surface of the portions of cushioning layer 10 that are atop item
100, in the general manner indicated by block arrows B of FIG. 4.
An additional B step can then be performed with any remaining
unbonded areas of outer shell layer 20, in similar manner as
discussed above for remaining unbonded areas of cushioning layer
10.
[0025] The result of the above-described steps of wrapping outer
shell layer 20 around inner cushioning layer 10 will be that outer
shell layer 20 is now in an encapsulating configuration. By this is
meant that the outer shell layer 20 completely surrounds the inner
cushioning layer on all sides so that no portion of inner
cushioning layer 10 (or item 100) is reachable from the outside
along a line that does not pass through at least a portion of shell
layer 20. After the outer shell layer has been folded into an
encapsulating configuration, outer shell layer 20 can be secured
(e.g., with pressure-sensitive adhesive tape) in the protective
configuration.
[0026] It will be understood that the above arrangements may be
modified in any suitable manner. For example, in some embodiments
the edges of the cushioning layer and/or the shell layer may be cut
by an end user, e.g., with scissors, to reduce the total area of
the layer(s) and/or or to modify the shape of the layer(s) in view
of the size and/or shape of the item to be packaged. In some
embodiments, multiple items 100, rather than a single item 100, may
be packaged in a single packaging assembly of the general type
described herein.
[0027] In some embodiments packaging assembly 1 may optionally
comprise at least one area of pressure sensitive adhesive 40 that
is provided on a major inward surface 13 of cushioning layer 10
that faces away from outer shell layer 20, as shown in exemplary
embodiment in FIG. 5. Pressure-sensitive adhesive 40 can comprise a
major adhesive surface that faces away from outer shell layer 20;
an item 100 to be packaged can be contacted with (e.g., disposed
on) the major adhesive surface of adhesive 40. Adhesive 40 thus can
hold item 100 so that item 100 has less tendency to shift or slide
during the above-described packaging process. Any such adhesive 40
need not necessarily be extremely strong, or need to hold item 100
permanently; rather, the adhesive may only serve to momentarily
tack down item 100 until item 100 is secured within packaging
assembly 1 as described above. If desired, adhesive 40 may be a
pressure-sensitive adhesive of the type typically described as
repositionable, so that item 100 can be separated from adhesive 40
when desired, without damaging or marring the surface of item
100.
[0028] An adhesive 40 may be provided by, for example, a piece of
double-faced adhesive tape or the like. Such an adhesive can have
any suitable size or shape, and/or can be provided by a single
piece of adhesive tape or by several pieces working in combination.
If desired, packaging assembly 1 may be provided to an end user
with a release liner in place over the major adhesive surface of
adhesive 40 (i.e., the "top" surface as shown in FIG. 5); such a
release liner can be removed by the end user when an item is ready
to be contacted with the adhesive.
[0029] In some embodiments, any such adhesive 40 will occupy (in
terms of total actual bonded area) less than 40% of the total area
of outer shell layer 20. In various embodiments, any such adhesive
40 may occupy less than 35, 30, 25, 20, 15, 10, 8, 6, 4 or 2% of
the total area of each layer. In further embodiments, any such
adhesive may occupy at least 0.5, 1.0, 1.5, 3.0, 5.0, 7.0, 13, 18,
23, or 28% of the total area of each layer.
[0030] A packaging assembly 1 as disclosed herein may be provided
in any suitable format. In some embodiments, multiple packaging
assemblies 1 can be provided, e.g., stacked into a batch, e.g., in
a box or other suitable container, from which successive packaging
assemblies 1 can be removed for use. In some embodiments, multiple
packaging assemblies 1 may be provided as a roll good in which
outer shell layer 20 and inner cushioning layer 10 are co-rolled
with each other. The presence of the at least one interior bond
between these two layers will retain the layers in their proper
configuration (e.g., minimizing any tendency of the layers to slip,
shift, telescope or the like) relative to each other. An end user
can merely cut off a desired section of the roll good for use in
packaging any particular item. In various embodiments, packaging
assembly 1 may exhibit a total thickness of between about 1/32 inch
and about 2 inches, or between about 7/64 inch and about 2 inches,
or between about 1/4 inch and about 1 inch.
[0031] Flexible outer shell layer 20 can be any desired layer that
provides at least some of the features described herein. In some
embodiments, the outer layer is a single layer. In some
embodiments, the outer layer includes multiple layers. As is
described in greater detail below, in some embodiments, the outer
layer is at least one of single-ply, double-ply, or triple-ply
and/or single layer or multi-layer. The multi-layer constructions
can include any desired number of layers.
[0032] In embodiments where the outer layer is single ply, the
outer layer material may be a heavy weight paper (such as, for
example, kraft paper or the like), a plastic film (such as, for
example, MYLAR.TM.), a nonwoven material (such as, for example,
TYVEK.TM.), or a treated paper (such as, for example, aluminized
paper).
[0033] In some embodiments, the outer layer includes a paper layer,
which can be coated paper, Kraft paper, or higher quality paper
such as Bond or white paper. In some embodiments, the paper may be
printable and/or metallized to obtain a decorative packaging
material. In some embodiments, the metallized paper layer may also
be provided with graphics thereon.
[0034] In some embodiments, the outer layer includes a plastic. In
some embodiments, the plastic is printed, embossed, structured, or
reinforced. In some embodiments, the plastic includes at least one
of polypropylene, polyethylene, polyurethane, polyester, and/or a
copolymer of any of these. In some embodiments, the polyethylene is
at least one of a low density polyethylene, a metallocene linear
low density polyethylene, linear low density polyethylene, a low
density polyethylene, polypropylene, olefinic block copolymer(s), a
high density polyethylene, and/or copolymers and/or blends of any
of these.
[0035] In some embodiments, the plastic is a thermoplastic and/or
olefin material. The plastic may be oriented uniaxially or
biaxially to impart high-strength thereto. A biaxial orientation
may be preferred for greatest strength. One or more of the surfaces
of the plastic layer may be corona discharge treated to render one
or more of them receptive to inks and printing. Further, if a
decorative package is desired, the plastic may be metallized as by
vacuum deposition.
[0036] In some embodiments, the outer layer is a multilayer plastic
film. In some embodiments, the multilayer film includes one to
seven layers. In some embodiments, the multilayer film includes
more than seven layers. In some embodiments, the multilayer
assembly includes at least one of polypropylene, polyethylene,
cyclic olefin copolymers, polyurethane, polyester, polyamide,
and/or a copolymer of any of these. In some embodiments, at least
the layer of shell layer 20 that provides the inward major surface
24 of shell layer 20 may contain a polymer that enables
melt-bonding to the material of cushioning layer 10. Some exemplary
layers capable of providing melt-bonding include, for example,
those comprising low density polyethylene, linear low density
polyethylene, metallocene linear low density polyethylene,
polypropylene, olefinic block copolymers, and/or copolymers and/or
blends of any of these. One or more of the layers of a multilayer
outer layer may impart to the overall outer layer assembly a low
gas permeability that enables air retention in the cushioning layer
(e.g., bubble wrap). One or more of the layers in the multilayer
assembly may provide tear resistance properties. Some exemplary
layers capable of providing tear resistance include, for example,
those comprising low density polyethylene, linear low density
polyethylene, metallocene linear low density polyethylene,
polypropylene, olefinic block copolymers, polyamide, polyester,
polyurethane, and/or copolymers and/or blends of any of these.
[0037] In some embodiments, the outer layer is a two-ply or
two-layer assembly or laminate. In some embodiments, the two-ply or
two-layer assembly or laminate is a paper/plastic assembly or
laminate. In some such embodiments, a paper layer is laminated to a
plastic film layer. Another exemplary two-ply or two-layer outer
layer or assembly is a laminate that includes a water impermeable
plastic film having a first corona discharge treated surface that
is adhesively cold laminated to the paper layer.
[0038] In some embodiments, the outer layer is three-ply. In some
embodiments, the two-ply material(s) described above may further
include an additional paper layer to form a paper-plastic-paper,
three-ply laminate sheeting. The extra paper layer may be desirable
for packaging objects with pointed edges or simply when a packaging
material with more strength is desired. As the paper layers form
the inner and outer sides of the packaging material, they can
easily be printed with graphics or other indicia prior to
application of the cushioning and/or cohesive material(s). This
enables the packaging material to have one appearance on the
outside of the package and another, different appearance on the
side of the material that faces the item being shipped. Another
exemplary outer layer is a three-ply laminate that includes a water
impermeable plastic film, e.g., having first and second corona
discharge treated surfaces that are adhesively cold laminated to
first and second paper layers. In some embodiments, the outer layer
is more than three layers.
[0039] It may also be desirable that outer shell layer 20 may have
an outer major surface 23 (or a portion thereof) that is a
printable major surface so that logos, messages, advertisements,
emblems, trademarks or addressee information (or a location, e.g.,
rectangular box, that is designated for putting address information
thereinto) etc., may be printed, e.g., on outward surface 23 of
outer shell layer 20. In some embodiments, the outer layer may
include one or more corona discharge treated surface to render it
receptive to inks.
[0040] Thus in at least some embodiments, the outer surface 23 of
shell layer 20 should be able to be provided with indicia or other
printed information. If the material itself is not inherently
receptive to such printed information, it can be treated to be
receptive. For example, a plastic film of polyethylene that has the
outer surface treated by a corona discharge can then be printed or
provided with printed indicia. It is also possible, although less
preferred, that the indicia be applied to the packaging material by
an adhesive-backed sticker, label or the like.
[0041] In some embodiments, the outer shell layer 20 has a
thickness of greater than about 0.5 mils, or greater than 0.75
mils, or greater than 1 mil, or greater than 1.25 mils, or greater
than 1.5 mils, or greater than 1.75 mils, or greater than 2 mils.
In some embodiments, the outer layer has a thickness of less than 5
mils, or less than 4.5 mils, or less than 4.0 mils, or less than
3.5 mils, or less than 3 mils. In some embodiments, the outer layer
has a thickness of between about 0.5 mils and about 5 mils, or
between about 1 mil and about 4 mils, or between about 2 mils and
about 3 mils. In some embodiments where the outer layer is paper,
the outer layer has a thickness of greater than about 3 mils.
[0042] In some embodiments, at least a portion, and in some
instances, substantially the entire, outer major surface 23 of
outer layer 20 is writable (e.g., can be written on with
conventional writing instruments such as pens, pencils, and/or
markers). In some embodiments, this can be achieved by selecting
materials for the outer layer that inherently provide that
characteristic. In some embodiments, this can be achieved by
treating at least a portion of the surface of the selected outer
layer to impart desired writability and/or adhesion (e.g., applying
an adhesive-backed paper sheet or label). In some embodiments, one
or more varnishes are applied to or included in the outer layer
construction. Applying or including a varnish layer to a treated
surface may impart writability by, for example, changing surface
roughness and, thus, the surface coefficient of friction. In some
embodiments, the varnish chemistry may be tailored to achieve
compatibility with an ink and/or cohesive formulation. In addition,
if desired a decorative package is provided in an embodiment
wherein the exterior surface of the outer layer is metallized or
aluminized. If a silver finish is desired, an aluminized surface
may be preferred. Other metallizing treatments, e.g., with copper,
iron, or alloys, can be used when other colors are desired.
[0043] In some embodiments, the outer shell layer 20 is water
impermeable. In some embodiments, the outer layer is sufficiently
tear and scuff resistant such that a wrapped item remains secure
and protected during shipping and handling. In some embodiments,
the outer layer includes one or more materials providing at least
one of insulation from thermal or acoustic shock and/or radiation
protection.
[0044] It is desired that the packaging assembly 1 should provide
some degree of shock and/or impact resistance to prevent damage to
an item being shipped. The herein-described inner cushioning layer
10 can be any suitable layer that provides cushioning of an item
100 that is packaged in (e.g., wrapped in) a packaging assembly 1.
In some embodiments, it is desired that the cushioning layer have a
relatively low profile to avoid undesirable bulk which could make
packaging more complicated and/or storage more challenging. In some
embodiments, the cushioning layer has a thickness of between about
1/32 inch and about 2 inches. In some embodiments, the cushioning
portion has a thickness of greater than about 1/32, or about 7/64
inch, or about 1/4 inch, or about 1/2 inch, or about 3/4 inch, or
about 1 inch. In some embodiments, the cushioning portion has a
thickness of less than about 2 inches, or less than about 1 inch,
or less than about 3/4 inch, or less than about 1/2 inch.
[0045] In some embodiments, the inner cushioning layer 10 is a
single layer. In some embodiments, the cushioning layer or portion
includes multiple layers. In some embodiments, the cushioning layer
10 includes bubble wrap. As used herein, the term "bubble wrap" is
meant to include all pliable, polymeric materials that include
spaced, protruding air or gas-filled bubbles that are capable of
providing cushioning. The term is meant to include those items
referred to as bubble wrap, bubble pack, bubble paper, bubble film,
air or gas bubble packing, bubble wrapping, and aeroplast. Some
embodiments of bubble wrap include a first thin flexible layer 15
of plastic or polymeric material having a plurality of spaced apart
recesses in one surface (so that layer 15 is significantly
non-planar) and a second thin flexible, relatively flat "film"
layer 16 of plastic material. The second "film" layer 16 is bonded
to the one surface of the first layer 15 to seal air or gas into
the recesses to form "bubbles", as shown in detail in FIG. 3 and as
will be readily understood by artisans in the field. The bubble
wrap can include, for example, polyethylene as the plastic material
for example, a linear low density polyethylene, a low density
polyethylene and/or a high density polyethylene. However, other
suitable plastics or polymers may also be used, such as, for
example, polypropylene. Some commercially available bubble wraps
include, for example, Scotch.TM. Cushion Wrap. Bubble wraps that
may be particularly suitable are described in U.S. Provisional
Patent Application No. 62/786,592, which is incorporated herein in
its entirety. As noted above, in some embodiments, an inner
cushioning layer 10 can include a bubble portion 15 and a film
portion 16 that combine to form a bubble wrap. In some embodiments,
the bubble wrap has a thickness of between about 1/32 inch and
about 1/2 inch. In some embodiments, the bubble wrap has a
thickness of greater than about 1/32, or about 7/64 inch, or about
1/4 inch. In some embodiments, the bubble wrap has a thickness of
less than about 1/2 inch, or less than about 1/4 inch, or less than
about 1/3 inch.
[0046] Further details of materials (e.g., bubble wraps) that can
be used as an inner cushioning layer, and of materials that can be
used as an outer shell layer, are described in U.S. Provisional
Patent Applications Nos. 62/620,031 and 62/794,617 and in the
resulting International (PCT) Patent Application Publication No. WO
2019/142172, all of which are incorporated by reference herein in
their entirety.
[0047] In some embodiments, the inner cushioning layer 10 may
include at least one layer of flexible foam. Exemplary flexible
foams can include, for example, polyethylene, polyester, acrylic,
polyurethane, or polypropylene. Regardless of the specific
composition and/or geometric format (e.g., whether comprising
bubble wrap, flexible foam, or both), an inner cushioning layer 10
as described herein will be distinguished from a so-called
"cohesive" layer that is purposefully configured to adhere to
itself in the manner described, e.g., in U.S. Provisional Patent
Applications Nos. 62/620,031 and 62/794,617 and in the resulting
International (PCT) Patent Application Publication No. WO
2019/142172. In particular, inner major surface 13 of inner
cushioning layer 10 as disclosed herein, will not exhibit any
property of being "cohesive", self-adhering, self-bonding, or any
like term or property.
[0048] It will be apparent to those skilled in the art that the
specific exemplary elements, structures, features, details,
configurations, etc., that are disclosed herein can be modified
and/or combined in numerous embodiments. All such variations and
combinations are contemplated by the inventor as being within the
bounds of the conceived invention, not merely those representative
designs that were chosen to serve as exemplary illustrations. Thus,
the scope of the present invention should not be limited to the
specific illustrative structures described herein, but rather
extends at least to the structures described by the language of the
claims, and the equivalents of those structures. Any of the
elements that are positively recited in this specification as
alternatives may be explicitly included in the claims or excluded
from the claims, in any combination as desired. Any of the elements
or combinations of elements that are recited in this specification
in open-ended language (e.g., comprise and derivatives thereof),
are considered to additionally be recited in closed-ended language
(e.g., consist and derivatives thereof) and in partially
closed-ended language (e.g., consist essentially, and derivatives
thereof). To the extent that there is any conflict or discrepancy
between this specification as written and the disclosure in any
document that is incorporated by reference herein but to which no
priority is claimed, this specification as written will
control.
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