Layered packaging cushion

• US 20060127648A1
• Filed: 10/31/2003
• Published: 06/15/2006
• Est. Priority Date: 09/23/2002
• Status: Active Grant

• Current Assignee: Nicholas P De Luca
• Original Assignee: Nicholas P De Luca
• Inventors: De Luca, Nicholas P.
• Granted Patent: US 8,763,667 B2
• Time in Patent Office: Days
• US Class Current: 428/174
• CPC Class Codes: A61B 2017/00022 Sensing or detecting at the treatment site
• CPC Class Codes: A61B 8/12 in body cavities or body tracts, e.g. by using catheters catheters per se A61M25/00
• CPC Class Codes: A61B 8/445 Details of catheter construction
• CPC Class Codes: B32B 2274/00 Thermoplastic elastomer material thermoplastic elastomer fibres B32B2262/0215, thermoplastic elastomer particles B32B2264/0221, thermoplastic elastomer foam B32B2266/0292
• CPC Class Codes: B32B 2307/31 Heat sealable
• CPC Class Codes: B32B 2307/546 Flexural strength; Flexion stiffness
• CPC Class Codes: B32B 2553/02 Shock absorbing
• CPC Class Codes: B32B 2553/026 Bubble films
• CPC Class Codes: B32B 27/065 of foam
• CPC Class Codes: B32B 27/08 of synthetic resin
• CPC Class Codes: B32B 27/10 of paper or cardboard
• CPC Class Codes: B32B 27/32 comprising polyolefins comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30
• CPC Class Codes: B32B 27/34 comprising polyamides
• CPC Class Codes: B32B 29/007 next to a foam layer
• CPC Class Codes: B32B 29/08 Corrugated paper or cardboard
• CPC Class Codes: B32B 3/12 characterised by a layer of regularly- arranged cells, e.g. a honeycomb structure
• CPC Class Codes: B32B 3/263 characterised by a layer having non-uniform thickness
• CPC Class Codes: B32B 3/266 characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12
• CPC Class Codes: B32B 3/28 characterised by a layer comprising a deformed thin sheet , i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled B32B29/08 takes precedence
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/32 : at least two layers being foamed and next to each other
• CPC Class Codes: B65D 81/113 : of a shape specially adapted to accommodate contents B65D81/053 takes precedence
• CPC Class Codes: G06F 2113/16 : Cables, cable trees or wire harnesses
• CPC Class Codes: G06F 2113/20 : Packaging, e.g. boxes or containers
• CPC Class Codes: G06F 30/00 : Computer-aided design [CAD]
• CPC Class Codes: Y10T 156/1062 : Prior to assembly
• CPC Class Codes: Y10T 156/1075 : of plural laminae from single stock and assembling to each other or to additional lamina
• CPC Class Codes: Y10T 156/1077 : Applying plural cut laminae to single face of additional lamina
• CPC Class Codes: Y10T 156/108 : Flash, trim or excess removal
• CPC Class Codes: Y10T 156/13 : Severing followed by associating with part from same source
• CPC Class Codes: Y10T 156/1304 : Means making hole or aperture in part to be laminated
• CPC Class Codes: Y10T 156/1317 : Means feeding plural workpieces to be joined
• CPC Class Codes: Y10T 156/1322 : Severing before bonding or assembling of parts
• CPC Class Codes: Y10T 156/1348 : Work traversing type
• CPC Class Codes: Y10T 428/24628 : Nonplanar uniform thickness material

Abstract

A packaging cushion insert is useful for cushioning a packaged object. The insert comprises a top sheet, a bottom sheet; and a plurality of interior sheets between the top and bottom sheets. The top sheet, the bottom sheet, and the plurality of interior sheets are in stacked and laminated arrangement. The top sheet, bottom sheet, and plurality of interior sheets each comprise one or more materials selected from an air-cellular cushioning material, cellular foam material, and crumpled paper material.

Claims

1. A packaging cushion insert useful for cushioning a packaged object, the insert comprising:

a top sheet;

a bottom sheet; and

a plurality of interior sheets between the top and bottom sheets, wherein;

the top sheet, the bottom sheet, and the plurality of interior sheets are in stacked arrangement;

the top sheet is attached to a first sheet of the plurality of interior sheets;

the bottom sheet is attached a second sheet of the plurality of interior sheets; and

each of the plurality of interior sheets is attached to at least one other sheet of the plurality of interior sheets;

the top sheet, bottom sheet, and plurality of interior sheets each comprise one or more materials selected from air-cellular cushioning material, cellular foam material, and crumpled paper material.

2. The insert of claim 1 wherein each of the plurality of interior sheets are directly attached to at least one other sheet of the plurality of interior sheets.

3. The insert of claim 1 wherein each of the plurality of interior sheets are adhered by adhesive to at least one other sheet of the plurality of interior sheets.

4. The insert of claim 1 wherein each of the plurality of interior sheets are adhered by heat seal to at least one other sheet of the plurality of interior sheets.

5. The insert of claim 1 wherein at least one of the top and bottom sheets defines an aperture to accommodate insertion of at least a portion of the packaged object within the aperture, whereby the insert surrounds at least a portion of the packaged object.

6. The insert of claim 1 wherein:

at least one of the top and bottom sheets defines a first aperture;

at least one of the plurality of interior sheets defines a second aperture; and

the first and second apertures are aligned to accommodate insertion of at least a portion of the packaged object within the first and second apertures, whereby the insert surrounds at least a portion of the packaged object.

7. The insert of claim 1 wherein at least one of the top sheet, bottom sheet, and plurality of interior sheets comprises an air-cellular cushioning material.

8. The insert of claim 1 wherein the top sheet, bottom sheet, and plurality of interior sheets comprise an air-cellular cushioning material.

9. The insert of claim 1 wherein the air cellular cushioning material comprises a plurality of air cells and the air cells of adjacent sheets comprising air cellular material are in offset arrangement.

10. The insert of claim 1 wherein the air cellular cushioning material comprises a plurality of air cells having diameter of from about 0.25 inches to about 1 inch.

11. The insert of claim 1 wherein at least one of the top sheet, bottom sheet, and plurality of interior sheets comprises a cellular foam materials.

12. The insert of claim 1 wherein the top sheet, bottom sheet, and plurality of interior sheets comprise a cellular foam material.

13. The insert of claim 1 wherein at least one or the top sheet, bottom sheet, and plurality of interior sheets comprises crumpled paper material.

14. The insert of claim 1 wherein the top sheet, bottom sheet, and plurality of interior sheets comprise crumpled paper material.

15. A method of making a package cushioning insert useful for cushioning an object comprising the following steps:

selecting the dimensions of a top sheet, a bottom sheet, and a plurality of interior sheets based on the shape of the object;

cutting the top sheet, bottom sheet, and plurality of interior sheets to the selected dimensions;

placing the top sheet, the bottom sheet, and the plurality of interior sheets in stacked arrangement with the plurality of interior sheets between the top and bottom sheets; and

attaching the top sheet to a first sheet of the plurality of interior sheets;

attaching the bottom sheet to a second sheet of the plurality of interior sheets; and

attaching each of the plurality of interior sheets to at least one other sheet of the plurality of interior sheets, wherein the top sheet, bottom sheet, and plurality of interior sheets comprise one or more materials selected from air-cellular cushioning material, cellular foam material, and crumpled paper material.

16. The method of claim 15 wherein the placing step occurs subsequent to the cutting step.

17. The method of claim 15 wherein each sheet is cut to its selected dimension before placing the sheet in stacked arrangement.

18. The method of claim 15 further comprising the step of digitally modeling the object before the selecting step.

19. The method of claim 15 wherein each attaching step comprises heat sealing.

20. The method of claim 15 wherein each attaching step comprises adhesively attaching.